Double-ended electric supercharger

• US 10,280,850 B1
• Filed: 01/23/2018
• Issued: 05/07/2019
• Est. Priority Date: 01/23/2018
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Zeng, Tao, Kantrow, Daniel William, Hu, Liangjun
• Primary Examiner(s): Moulis, Thomas
• Application Number:
  US15/878,212
• Time in Patent Office: 469 Days
• CPC Class Codes: F02B 2037/125 Control for avoiding pump stall or surge
• CPC Class Codes: F02B 37/001 using exhaust drives arranged in parallel
• CPC Class Codes: F02B 37/04 Engines with exhaust drive and other drive of pumps, e.g. with exhaust-driven pump and mechanically-driven second pump
• CPC Class Codes: F02B 37/16 by bypassing charging air
• CPC Class Codes: F02B 37/18 by bypassing exhaust from the inlet to the outlet of turbine or to the atmosphere
• CPC Class Codes: F02B 37/24 by using pumps or turbines with adjustable guide vanes
• CPC Class Codes: F02B 39/10 electric
• CPC Class Codes: F02D 41/0007 for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02D 41/005 according to engine operating conditions
• CPC Class Codes: F02D 41/0052 Feedback control of engine parameters, e.g. for control of air/fuel ratio or intake air amount
• CPC Class Codes: F02D 41/0065 Specific aspects of external EGR control constructional details of EGR system F02M26/00
• CPC Class Codes: F02D 41/26 using computer, e.g. microprocessor
• CPC Class Codes: F02M 26/08 for engines having two or more intake charge compressors or exhaust gas turbines, e.g. a turbocharger combined with an additional compressor
• CPC Class Codes: F04D 17/105 with double suction
• CPC Class Codes: F04D 25/06 the pump being electrically driven F04D25/08 takes precedence
• CPC Class Codes: F04D 29/056 Bearings
• CPC Class Codes: F05D 2220/40 in turbochargers
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

Methods and systems are provided for compound boosted engine comprising an electric supercharger. In one example, the electric supercharger may be double-ended with a compressor arranged on either side of an electric motor and rotationally coupled to the electric motor via shafts. The electric supercharger may be configured to provide boost assist to a twin turbocharger system via a bypass channel adapted with a bypass valve.

Claims

1. A system for a supercharger, comprising:

an electric motor of the supercharger including a first output shaft and a second output shaft positioned on opposing sides of the electric motor and sharing a common rotational axis;

a first compressor of the supercharger rotationally coupled to the first output shaft;

a second compressor of the supercharger rotationally coupled to the second output shaft; and

a bypass passage including a valve, the bypass passage configured to divert air flow in an air conduit to both the first compressor and the second compressor.

2. The system of claim 1, wherein the first compressor and the second compressor are coupled parallel relative to one another and symmetrically coupled to opposite ends of the electric motor and driven by a common output shaft comprising the first output shaft and the second output shaft.

3. The system of claim 1, further comprising a first journal bearing coupled to the first output shaft and a second journal bearing coupled to the second output shaft.

4. The system of claim 3, wherein the first compressor and the second compressor are symmetric to one another, and wherein the first journal bearing and the second journal bearing are symmetric to one another.

5. The system of claim 1, wherein rotation of the electric motor rotates both the first compressor and the second compressor at a common speed.

6. The system of claim 1, wherein the supercharger is positioned within the air conduit and wherein a first portion of air received in the air conduit is directed through the first compressor and a second, remaining portion of the air received in the air conduit is directed through the second compressor, the first portion substantially equal to the second portion.

7. The system of claim 1, wherein the supercharger is coupled in a vehicle, the supercharger further comprising a controller with computer-readable instructions for adjusting an output of the electric motor based on vehicle operator torque demand.

8. An engine system, comprising:

an engine;

a first compressor driven by an exhaust turbine;

an intake passage including the first compressor and a bypass valve;

a second compressor including two symmetric impellers coupled via an output shaft to opposing ends of an electric motor; and

a bypass passage including the second compressor, an inlet of the bypass passage coupled to the intake passage upstream of the bypass valve and downstream of the first compressor, and an outlet of the bypass passage coupled to the intake passage downstream of the bypass valve.

9. The system of claim 8, wherein the inlet of the bypass passage is positioned upstream of a confluence of a first inlet of a first of the two impellers of the second compressor and a second inlet of a second of the two impellers of the second compressor, and wherein the outlet of the bypass passage is positioned downstream of another confluence of a first outlet of the first of the two impellers and a second outlet of the second of the two impellers.

10. The system of claim 8, further comprising a controller with computer-readable instructions stored on non-transitory memory for adjusting a position of the bypass valve based on operator torque demand and turbine speed.

11. The system of claim 10, wherein the adjusting includes:

responsive to an increase in the operator torque demand,

opening the bypass valve to provide compressed air to the engine via the first compressor when the turbine speed is higher than a threshold speed; and

closing the bypass valve to provide compressed air to the engine via each of the two impellers of the second compressor when the turbine speed is lower than the threshold speed.

12. The system of claim 11, wherein the controller includes further instructions for, after closing the bypass valve, adjusting an output of the electric motor based on the increase in operator torque demand, wherein the output of the electric motor simultaneously rotates each of the two impellers of the second compressor at a common speed.

13. The system of claim 12, wherein the controller includes further instructions for selectively closing the bypass valve and increasing the output of the electric motor while flowing compressed air to the engine via the first compressor responsive to a pressure ratio across the first compressor being within a threshold of a surge limit or a choke limit of the first compressor.

14. The system of claim 13, wherein the exhaust turbine is a variable geometry turbine positioned in an exhaust passage of the engine, wherein the system further comprises a high pressure exhaust gas recirculation (HP-EGR) passage for recirculating exhaust gas from the exhaust passage, upstream of the turbine, to the intake passage, downstream of the outlet of the bypass passage, and wherein the controller includes further instructions for adjusting a nozzle flow area of the variable geometry turbine to vary EGR flow through the HP-EGR passage.

15. The system of claim 14, wherein the controller includes further instructions for:

responsive to the pressure ratio across the first compressor being within the threshold of the surge limit, decreasing the nozzle flow area by a first amount; and

responsive to the pressure ratio across the first compressor being within the threshold of the choke limit, increasing the nozzle flow area by a second amount, each of the first amount and the second amount based on the increased output of the electric motor.

16. The system of claim 8, wherein the first compressor and the exhaust turbine are included in a twin turbocharger system.

17. A method for a boosted engine system, comprising:

responsive to an increase in operator torque demand,

closing a waste-gate to spool up a turbocharger;

closing a bypass valve coupled in an air intake passage to divert air into a bypass; and

operating an electric motor of a double-ended electric supercharger positioned in the bypass to direct compressed air to an engine via each of a pair of compressors of the supercharger.

18. The method of claim 17, further comprising:

after spooling up the turbocharger, opening the bypass valve and disabling the electric motor to direct compressed air to the engine via a compressor of the turbocharger; and

while flowing air via the turbocharger compressor, selectively closing the bypass valve and operating the electric motor responsive to a pressure ratio across the turbocharger compressor being within a threshold of a choke margin or a surge margin.

19. The method of claim 18, wherein the turbocharger compressor is driven by a variable geometry turbine, the method further comprising increasing a nozzle flow area of the turbine responsive to the pressure ratio across the turbocharger compressor being within the threshold of the choke margin and decreasing the nozzle flow area of the turbine responsive to the pressure ratio across the turbocharger compressor being within the threshold of the surge margin, a degree of the increasing and decreasing of the nozzle flow area based on an output of the electric motor.

20. The method of claim 19, further comprising decreasing opening of an EGR valve to increase recirculation of exhaust gas from upstream of the turbine to downstream of the supercharger responsive to the pressure ratio across the turbocharger compressor being within the threshold of the surge margin and increasing the opening of the EGR valve to decrease the recirculation of exhaust gas from upstream of the turbine to downstream of the supercharger responsive to the pressure ratio across the turbocharger compressor being within the threshold of the choke margin, a degree of the increasing and decreasing of the opening of the EGR valve based on the output of the electric motor.