Hybrid opposed-piston engine system

Abstract

An opposed-piston engine system equipped for full hybrid compressed-air/combustion includes capacity for storing air compressed by the engine during a combustion mode of operation. The hybrid opposed-piston engine system includes a control mechanization for operating the opposed-piston engine in a combustion mode by provision of fuel, in a compressed-air mode by provision of stored compressed air, and in a combustion mode supplemented by provision of stored compressed air. A method of operating a hybrid vehicle equipped with an opposed-piston engine includes storing air compressed by the engine during a combustion mode of operation and operating in the vehicle a compressed-air mode by provision of stored compressed air.

Claims

1. A hybrid engine system; comprising: an opposed-piston engine with at least one cylinder having piston-controlled exhaust and intake ports, a charge air channel to provide air to at least one intake port, an exhaust channel to remove exhaust gas from at least one exhaust port, a fuel system to deliver fuel for combustion in the cylinder; and a compression-release port in fluid communication with the cylinder bore; an air storage device; a bidirectional air transport channel connecting the air storage device with the compression release port, the bidirectional air transport channel comprising a braking valve connected to the bidirectional air transport channel; and, an engine control unit programmed to cause the bidirectional air transport channel to transport compressed air between the air storage device and the compression release port and further programmed to cause the braking valve to couple the bidirectional air transport channel to the exhaust channel to either store compressed air in the air storage device or inject compressed air between the pistons.

2. The hybrid engine system of claim 1; in which the bidirectional air transport channel comprises a compression-release valve mounted in the compression release port, a transport channel in fluid communication with the compression-release valve, and a storage valve in fluid communication with the transport channel and connected to the air storage device.

3. The hybrid engine system of claim 2, in which the storage valve is further connected to the charge air channel and the engine control unit is further programmed to cause the storage valve to couple the air storage device to the charge air channel.

4. The hybrid engine system of claim 1, in which the opposed-piston engine is a two-stroke, fuel-injected opposed-piston engine.

5. The hybrid engine system of claim 1, in which the opposed-piston engine includes one, two, or three or more crankshafts.

6. The hybrid engine system of claim 1, in which the opposed-piston engine includes one, two, or three or more ported cylinders.

7. The hybrid engine system of claim 6, in which the opposed-piston engine is a two-stroke, fuel-injected opposed-piston engine.

8. The hybrid engine system of claim 7, in which the opposed-piston engine includes one, two, or three or more crankshafts.

9. A hybrid engine system, comprising: an opposed-piston engine with at least one cylinder having piston-controlled exhaust and intake ports, a charge air channel to provide air to at least one intake port, an exhaust channel to remove exhaust gas from at least one exhaust port, a fuel system to deliver fuel for combustion in the cylinder, and a compression-release port in fluid communication with the cylinder bore; an air storage device; a bidirectional air transport channel connecting the air storage device with the compression release port; and, an engine control unit programmed to cause the bidirectional air transport channel to transport compressed air between the air storage device and the compression release port to either store compressed air in the air storage device or inject compressed air between the pistons, wherein the bidirectional air transport channel comprises a compression-release valve mounted in the compression release port, a transport channel in fluid communication with the compression-release valve, and a storage valve in fluid communication with the transport channel and connected to the air storage device.

10. The hybrid engine system of claim 9, in which the storage valve is further connected to the charge air channel and the engine control unit is further programmed to cause the storage valve to couple the air storage device to the charge air channel.

11. The hybrid engine system of claim 9, in which the opposed-piston engine is a two-stroke, fuel-injected opposed-piston engine.

12. The hybrid engine system of claim 9, in which the opposed-piston engine includes one, two, or three or more crankshafts.

13. The hybrid engine system of claim 9, in which the opposed-piston engine includes one, two, or three or more ported cylinders.

14. The hybrid engine system of claim 13, in which the opposed-piston engine is a two-stroke, fuel-injected opposed-piston engine.

15. The hybrid engine system of claim 14, in which the opposed-piston engine includes one, two, or three or more crankshafts.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic illustration of an opposed-piston engine of the prior art.

(2) FIG. 2 is a schematic illustration of a hybrid opposed-piston engine system according to this disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(3) The hybrid opposed-piston engine system described in this specification is presented in an explanatory context that includes a two-stroke, fuel-injected opposed-piston engine having at least one cylinder with a bore in which a pair of pistons is disposed with their end surfaces in opposition. This example is not intended to limit the opposed-piston engine in any way. Thus, a hybrid opposed-piston engine system is not limited to any specific number of crankshafts. For example, the engine may comprise one crankshaft, two crankshafts, or three or more crankshafts. In other aspects, the hybrid opposed-piston engine may comprise one, two, three, or more ported cylinders, each with a bore, piston-controlled exhaust and intake ports, and a pair of opposed pistons disposed in the bore.

(4) In this specification the oxygen-bearing gas mixture provided to mix with fuel in order to enable combustion in an opposed-piston engine is referred to as air, and this term is intended to include fresh air and/or charge air. In some instances, the air may include an admixture of exhaust products; otherwise, it may not.

(5) In FIG. 2, a hybrid opposed-piston engine system which may be used for powering a vehicle includes an opposed-piston engine 49 having one or more cylinders 50. Each cylinder 50 has a bore 52 and intake and exhaust ports 54 and 56 formed or machined in respective ends of the cylinder. Intake and exhaust pistons 60 and 62 are slidably disposed in the bore 52 with their end surfaces 60e and 62e opposing one another. When the pistons 60 and 62 are at or near their TC positions, a combustion chamber is defined by the bore 52 and the end surfaces of the pistons. The intake piston 60 and all other intake pistons are coupled to a crankshaft 70 disposed along one side of the engine 49, and the exhaust piston 62 and all other exhaust pistons are coupled to a crankshaft 72 disposed along the opposite side of the engine. Fuel is injected directly into the combustion chamber, between the piston end surfaces 60e and 62e, through at least one fuel injector nozzle 74 mounted in an opening through the side of the cylinder 50; preferably, a second fuel injector (not seen) is mounted to an opening in the cylinder opposite the opening in which the injector 74 is mounted. A fuel supply 76 comprising a reservoir, a pump or pumps, and a common rail or rails supplies fuel to the injectors of the engine.

(6) The engine 49 operates in a combustion mode as per the description of the engine illustrated in FIG. 1. In this regard, air is transported through a charge air channel 88 of the engine to the intake port 54 when the pistons 60 and 62 are near BC. The air flows through the intake port 54 into the bore 52 of the cylinder. As rotation of the crankshafts 70 and 72 drives the pistons into the bore, the air is compressed into the space of the combustion chamber and mixed with fuel injected into the combustion chamber. The air/fuel mixture combusts, which forces the pistons apart and thereby delivers mechanical energy to the crankshafts. When the pistons are near BC, products of combustion (exhaust) flow out of the exhaust port into and through an exhaust channel 78 of the engine.

(7) For full hybrid capability, the opposed-piston engine system of FIG. 2 is also equipped to operate the engine 49 in one or more compressed-air modes. In this regard, the engine system has a bidirectional air transport channel for transporting compressed air through a compression-release port 81 that opens through the sidewall of the cylinder 50 at a position intermediate the intake and exhaust ports; preferably, but not necessarily, the port 81 is located in a portion of the cylinder between the TC locations of the pistons 60 and 62. The bidirectional air transport channel includes a compression-release valve 80 mounted in the compression release port 81, a transport channel 82 in fluid communication with the compression-release valve 80, and a storage valve 84 in fluid communication with the transport channel 82. A channel 85 transports compressed air between the storage valve 84 and a compressed air storage device 86. Alternatively, the storage valve may be mounted on the device 86. A channel 87 transports compressed air from the storage valve 84 to an intake valve assembly 90. Pressurized air is provided as an input to the intake valve assembly 90. The intake valve assembly 90 has an output that is transported to the engine intake ports via channel 88.

(8) The valves 80, 84, and 90 are preferably high-speed, computer-controlled devices actuated by any one or more of mechanical, electrical, hydraulic, and pneumatic means. Control of these devices and of the fuel supply 76 is implemented by a programmed engine control unit (ECU) 100. The ECU 100 receives input data relative to the operating state of the engine (Engine OP State) and also receives sensed engine parameters including, without limitation, a crank angle (CA) indicative of engine speed and operating condition, Air Storage Pressure (P1) indicative of the air pressure in the air storage device 86, and cylinder Pressure (P2) indicative of the gas pressure in the cylinder, between the end surfaces of the pistons 60 and 62. In instances when the system of FIG. 2 provides motive power in a vehicle, the ECU 100 receives input data relative to the positions of Accelerator and Brake Pedals. The sensors by which the ECU 100 receives these parameter values are not shown in the figures; however, for purposes of this specification these and other sensors may comprise physical measurement devices and/or virtual systems, Using these and possibly other parameters, the ECU may be programmed to cause the valve setting configurations set out in Table I.

(9) TABLE-US-00001 TABLE I Valve Setting 1 Setting 2 Setting 3 80 Shut bore 52 to shut channel 82 84 Shut air storage 86 air storage 86 to channel 82 to channel 87 90 Shut shut channel 87 to channel 88

(10) Responsive to sensed parameter values and an indicated engine state, the hybrid opposed-piston engine system of FIG. 2 may be configured for open bi-directional fluid communication between the air storage device 86 and the cylinder bore 52 when the valves 80, 84, and 90 are set to setting 2. Depending on the difference in air storage and cylinder pressure, the bidirectional configuration supports either replenishment of stored compressed air by flow of compressed air from the cylinder 50 into the air storage device 86 or air-only operation of the engine 49 by movement of the pistons 60 and 62 in response to flow of stored compressed air from the air storage device 86 into the cylinder 50.

(11) Responsive to sensed parameter values and an indicated engine state, the hybrid opposed-piston engine of FIG. 2 may be configured for supplementing combustion operation of the engine when the valves 80, 84, and 90 are set to setting 3, which enables flow of stored compressed air from the air storage device 86 into the charge air channel via the flow path 86, 85, 84, 90.

(12) In some aspects, the engine system of FIG. 2 may further be equipped for compression-release engine braking by provision of a braking valve 92, also under control of the ECU 100. The braking valve 92 is connected to the transport channel 82 so as to release compressed air from the cylinder 50 for the purpose of engine braking. Preferably, but not necessarily, the compressed air released for engine braking is transported by the braking valve 92 to the exhaust channel 78. Accordingly, responsive to sensed parameter values and a sensed engine state, the ECU 100 may be programmed to configure the engine for engine braking by opening the compression-release valve 80, shutting the storage valve 84, and opening the braking valve 92 so that compressed air is released from the cylinder 50 via the flow path 82, 92.

(13) As will be appreciated when FIG. 2 is considered, a full hybrid compressed-air/combustion capability of an opposed-piston engine system is realized by provision of a bidirectional air flow path between a compressed-air storage device and the bore of at least one ported cylinder.

(14) A method of operating a wheeled vehicle such as an automobile, truck, or motorcycle, or a tracked vehicle such as a tank or snowmobile, equipped with a hybrid compressed-air/combustion opposed-piston engine system according to FIG. 2 (hereinafter, a hybrid vehicle) may include a process for storing compressed air for later use and a process for operating the engine using compressed air alone. In either or both cases, the ECU 100 is programmed to execute processes in which air compressed between the pistons is stored in the air storage device and in which the opposed-piston engine is driven by compressed air, alone or to supplement combustion. In some aspects, the ECU 100 is further programmed to execute a process for braking the engine by release of compressed air.

(15) Energy may be stored as compressed air in the air storage device 86 during a braking or deceleration event of the hybrid vehicle by way of a process in which: 1. The ECU 100 detects from brake and/or throttle pedal position signals that the vehicle is decelerating; 2. The ECU 100 shuts off fuel at one or more injectors 70 and lowers rail pressure; 3. When the cylinder pressure P.sub.2 exceeds the air storage pressure P.sub.1, the ECU 100 opens the decompression valve 80 and uses the storage valve 84 to connect the released air directly into the air storage device 86; 4. When the cylinder pressure P.sub.2 drops below the air storage P.sub.1, the ECU 100 closes the compression-release valve 80 to prevent loss of compressed air from the air storage device 86. 5. When the air storage device 86 is filled to its capacity, the ECU 100 again opens the compression release valve 80 but uses the braking valve 92 to output the released air. 6. Comment: //If the air intake pressure is controlled by a supercharger with a typical compression ratio of 16 to 17, it is possible to reach the air storage device capacity limit// 7. At the end of the braking or deceleration event, fuel injection is resumed. The storage valve 84 can be closed to prevent leakage from the air storage device 86.

(16) On a subsequent launch event (acceleration, for example), compressed air stored in the device 86 may be used to convert this stored energy into mechanical energy for propelling the hybrid vehicle by way of a process in which: 1. The ECU 100 detects from brake and throttle pedal positions that the vehicle is accelerating; 2. When the ECU recognizes from the crank angle CA that the two pistons 60 and 62 are at their minimum volume positions, it ceases delivery of fuel to one or more injectors 70 and sets the storage valve 84 to directly connect the air storage device 86 to the compression-release valve 80; 3. The compression-release valve 80 is then opened, thereby releasing stored compressed air from the air storage device 86 and injecting the released compressed air into the cylinder bore 52 through the compression-release port 81 to force the pistons apart thereby providing positive torque at the output shaft of the engine; 4. When the cylinder pressure P.sub.2 drops below the air storage pressure P.sub.1, the ECU 100 closes the compression-release valve 80; and 5. When the ECU 100 determines based on cylinder and tank pressures P.sub.2 and P.sub.1 that the remaining energy is insufficient to provide the desired launch acceleration rate, it can then begin normal fueled operation.

(17) In addition, if desired for a quicker launch transient, the storage valve 84 can be set to directly connect to the air storage tank through the normally closed intake valve 90, and the intake valve 90 can be opened, thereby supplementing the intake air with compressed air released from the air storage device 86.

(18) Although principles of compressed-air/combustion hybridization of opposed-piston engines have been described with reference to presently preferred embodiments, it should be understood that various modifications can be made without departing from the spirit of the described principles. Accordingly, the scope of patent protection accorded to these principles is limited only by the following claims.