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Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

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Turbo Compounding
A Technology Whos Time Has Come

25 Aug, 2005
Carl T. Vuk
John Deere Moline Technical Center
25 August, 2005

BA

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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

OUTLINE

History
Rate Limiters
Environmental Factors
Electric Turbo Compounding
System Architecture
Drivers
Analysis
Testing
Summary
25 August, 2005

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BA

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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

Turbo Compounding History

1953
1954
1968
1981
1983
1986
1988
1990
1991
1998
2002
2002

25 August, 2005

Douglas DC-7 (Wright 3350 TC)

Napier Nomad (12 Cyl Diesel 2-stroke)
Mitsubishi 10ZF (V10 2-stroke Diesel)
Cummins NH
Cummins V903 (Military Application)
Cat 3406 & 11.3L
Hino 8.82L
DAF
Scania 11L (Current Production)
Cat 15L (21st Century Truck)
Isuzu Ceramic IDI (Experimental)
Volvo (Current Production)

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BA

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OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
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HE

UTUR E

Napier Nomad
Circa 1955

25 August, 2005

Technology Delivery Process

P

D
D

BA

D
D

OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Two-Stage Mechanically
Coupled System

Technology Delivery Process

P

D
D

BA

D
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OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
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HE

UTUR E

Technology Limiters

Technology Delivery Process

P

System Complexity

High Ratio Gear Trains

Torsional Couplers
Impact on Turbocharger and Engine
Machine Placement

Control Issues
Costs

25 August, 2005

D
D

BA

D
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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

UTUR E

D
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Factors Favoring TC
Increasing Fuel Costs
Availability of Low Cost Controls
Availability of Cost Effective Power
Electronics (Automotive Hybridization)
EGR Requirements for NOx Control
High Pressure Ratio VG Turbos

25 August, 2005

BA

D
D

OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
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HE

UTUR E

Electric Turbo
Compounding

Simple Architectures Possible

Flexible Placement
Isolated Coupling

Integrated Electronic Control

High Efficiency
Modest Cost

25 August, 2005

Technology Delivery Process

P

D
D

BA

D
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OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
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TurboCompounding
Drivers

Technology Delivery Process

P

D
D

BA

D
D

Improved Fuel Economy - 10+%

Increased Power Density - 20+%
Emissions & After Treatment Benefits
High Exhaust Pressure Requirement EGR
Maturation of Electrification Technology

25 August, 2005

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

UTUR E

Emissions Impact

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Increased Output Directly Impacts

Specific Emissions
Power Turbine Reduces Net Impact of
Retarded Injection Timing
Improved Transient Response Lowers
Emissions
Electrical Output Can Power Emissions
Control Devices

25 August, 2005

BA

D
D

OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
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UTUR E

Power Density Growth

Enablers

Technology Delivery Process

P

D
D

Turbo Chargers (1970 1990)

After Cooling (1975 2005)
High Performance Pistons (1985 2005)
Turbo Compounding (2008 - .)

25 August, 2005

BA

D
D

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

UTUR E

TC System Schematic
Electrically Coupled Deere System

25 August, 2005

D
D

BA

D
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OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Turbo Generator
on Gas Stand

Technology Delivery Process

P

D
D

BA

D
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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Analysis

D
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BA

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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Turbocharger Assembly

D
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BA

D
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OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Advanced
TurboCharger

Technology Delivery Process

P

D
D

BA

D
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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Power Electronics

D
D

BA

D
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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Engine Testing

D
D

BA

D
D

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

25 August, 2005

UTUR E

Engine Testing

D
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BA

D
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OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
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UTUR E

System
Parameters

Technology Delivery Process

P

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BA

D
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50 kW Turbo Generator
340V DC Output
Wastegate Control For Overspeed Protection
50 kW Motor/Generator
No Energy Storage
Integrated Control Engine/Turbo Generator
Advanced High Pressure Ratio Turbocharger

25 August, 2005

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

UTUR E

Efficiency Targets

Power Turbine
Turbo Generator w/Controller
Turbocharger Compressor
Turbocharger Turbine
Motor/Generator w/Controller
Engine w/TurboCompounding

25 August, 2005

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BA

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OFP
PDP
CSP
CAP

85%
95%
78%
85%
95%
46%

Technology Delivery Process

John Deere

dvanced CEngineering
T F
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HE

UTUR E

D
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WAVE Performance Predictions

12

Efficiency Improvement [%]

11

AFR = 23
AFR = 26

7
AFR = 30
6
0

10

15

20

25

Power Turbine Power As A Percentage Of Total System Power [%]

25 August, 2005

BA

D
D

CSP
CAP

Turbocompound Effect On Performance

10

OFP
PDP

30

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

Engine Test Data

UTUR E

D
D

60

2300 RPM
2100 RPM

50

1900 RPM
45

TG Power - kWe

40
35
30
25
20
15
10
5
0
0

20

40

60
Engine Load (%)

25 August, 2005

BA

D
D

CSP
CAP

TurboGenerator Power vs. Engine Speed and Load

55

OFP
PDP

80

100

John Deere

dvanced CEngineering
T F
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HE

UTUR E

Application
Selection Criteria

Technology Delivery Process

P

D
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Steady-State High-Duty Cycle Operation

High Annual Usage
Power Growth Requirement
Vehicle Electrification Benefits

25 August, 2005

BA

D
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OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

Potential Applications

9000 Tractor

25 August, 2005

Combine

D
D

8000 Tractor

Truck

BA

D
D

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

DoE Program Focus

D
D

BA

Define Application Scope

Develop and Evaluate Second Generation
Hardware
Integrate Turbo Compounding With
Engine for Optimal Performance and
Emissions

25 August, 2005

D
D

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

D
D

Summary
Proven Technology
Significant, Economy, Power, and
Emissions Benefits
Must be Integrated With Emissions
Strategies and Vehicle Electrification
Benefits in Specific Applications to be
Defined

25 August, 2005

BA

D
D

OFP
PDP
CSP
CAP

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

Acknowledgments

Funding
John Deere Tech Council
DOE

Engine Performance Testing

Todd Whiting

25 August, 2005

Technology Delivery Process

P

D
D

BA

D
D

OFP
PDP
CSP
CAP

Technology Delivery Process

John Deere

dvanced CEngineering
T F
RE ATING

HE

UTUR E

D
D

BA

D
D

OFP
PDP
CSP
CAP

Questions ?

25 August, 2005