Waste heat recovery apparatus

• US 7,950,230 B2
• Filed: 09/09/2008
• Issued: 05/31/2011
• Est. Priority Date: 09/14/2007
• Status: Expired due to Fees

• Current Assignee: DENSO Corporation, Nippon Soken, Inc. (DENSO Corporation)
• Original Assignee: DENSO Corporation, Nippon Soken, Inc. (DENSO Corporation)
• Inventors: Yamashita, Kouji, Nishikawa, Michio, Uno, Keiichi, Kishita, Hiroshi
• Primary Examiner(s): Nguyen; Hoang M
• Application Number:
  US12/232,010
• Publication Number:
  US 20090071156A1
• Time in Patent Office: 994 Days
• Field of Search: 606/16, 606/18, 60660-667
• US Class Current: 60/618
• CPC Class Codes: F01K 13/02 Controlling, e.g. stopping or starting
• CPC Class Codes: F02G 5/02 Profiting from waste heat of exhaust gases
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A waste heat recovery apparatus including a Rankine cycle which includes a heater for heating an operation fluid by waste heat from a heat-generating device, an expansion unit for converting energy of expansion of the operation fluid flowing out from the heater into mechanical energy, and a condenser for condensing and liquefying the expanded operation fluid, a temperature detector for detecting the temperature of the operation fluid on the inlet side of the expansion unit, a pressure detector for detecting inlet-side pressure of the expansion unit, a pressure detector for detecting outlet-side pressure of the expansion unit, and a control unit. The control unit controls a command rotational speed of the expansion unit based on superheated degree information at the inlet of the expansion unit obtained from the operation fluid temperature and the inlet-side pressure, and pressure information in which the outlet-side pressure is considered.

Claims

1. A waste heat recovery apparatus which utilizes waste heat from a heat generating device, comprising:

a Rankine cycle which includes a pump for circulating an operation fluid, a heater for heating the operation fluid by the waste heat, an expansion unit for converting energy of expansion of the heated operation fluid into mechanical energy, and a condenser for condensing and liquefying the expanded operation fluid;

a temperature detector which detects a temperature of the operation fluid flowing into the expansion unit;

an inlet-side pressure detector which detects pressure on an inlet side of the expansion unit;

an outlet-side pressure detector which detects pressure on an outlet side of the expansion unit; and

Rankine operation control means for controlling an command rotational speed of the expansion unit based on superheated degree information on the inlet side of the expansion unit and pressure information, the superheated degree information being obtained from the temperature of the operation fluid detected by the temperature detector and the inlet-side pressure detected by the inlet-side pressure detector, and the pressure information being obtained by considering the outlet-side pressure detected by the outlet-side pressure detector.

2. The waste heat recovery apparatus according to claim 1, wherein the Rankine operation control means includes maximum/minimum rotational speed setting means for setting a maximum rotational speed and a minimum rotational speed based on the superheated degree information and the pressure information to obtain the command rotational speed.

3. The waste heat recovery apparatus according to claim 2, wherein

the pressure information is one of the outlet-side pressure and a pressure differential between the inlet-side pressure and the outlet-side pressure;

and

the maximum/minimum rotational speed setting means calculates a first maximum rotational speed and a first minimum rotational speed of the expansion unit based on the superheated degree information, calculates a second maximum rotational speed and a second minimum rotational speed of the expansion unit based on the pressure information, sets one of the first maximum rotational speed and the second maximum rotational speed, whichever is smaller, as the maximum rotational speed, and sets one of the first minimum rotational speed and the second minimum rotational speed, whichever is smaller, as the minimum rotational speed.

4. The waste heat recovery apparatus according to claim 2, wherein

the pressure information is a pressure ratio of the inlet-side pressure to the outlet-side pressure, and

the maximum/minimum rotational speed setting means sets the minimum rotational speed to a predetermined value, and sets the maximum rotational speed by adding thereto an increment and decrement determined in advance based on the superheated degree information of the expansion unit and the pressure ratio.

5. The waste heat recovery apparatus according to claim 4, wherein the increment and decrement are set to be large when the superheated degree information and the pressure ratio are both large, as compared to when the superheated degree information and the pressure ratio are both small.

6. The waste heat recovery apparatus according claim 2, wherein the Rankine operation control means includes command rotational speed determining means for determining the command rotational speed based on a battery voltage of a battery that stores the electric energy converted from the mechanical energy.

7. The waste heat recovery apparatus according to claim 1, wherein the Rankine operation control means includes stop-delaying means which, when the command rotational speed of the expansion unit is zero, shifts to a control for stopping the expansion unit only when the command rotational speed is still zero even after a predetermined period of time elapses.

8. The waste heat recovery apparatus according to claim 1, further comprising Rankine operation determination control means for determining whether there is an operation command that is output when the operating conditions are satisfied in an initial period of operation of the Rankine cycle.

9. The waste heat recovery apparatus according to claim 1, further comprising Rankine start control means and Rankine start determination control means for determining if the Rankine cycle is normally started before the Rankine operation control means controls the command rotational speed of the expansion unit.

10. The waste heat recovery apparatus according to claim 1, further comprising Rankine stop control means for commanding the command rotational speed of the expansion unit to be zero after the rotational speed of the expansion unit is decreased to a predetermined rotational speed.

11. The waste heat recovery apparatus according to claim 1, further comprising Rankine stop determination control means for determining if the Rankine cycle is normally stopped.

12. The waste heat recovery apparatus according to claim 1, further comprising:

a rotary electric machine which has functions of an electric motor and a generator, and is connected to the pump and to the expansion unit through the same shaft;

a bypass passage which bypasses the expansion unit;

an opening/closing part which opens and closes the bypass passage; and

Rankine start control means, wherein, at the time of starting the Rankine cycle, the Rankine start control means controls the opening/closing part to open the bypass passage and controls the rotary electric machine to operate as the electric motor at a predetermined rotational speed, if the temperature of the gaseous phase operation fluid detected by the temperature detector becomes equal to or higher than a predetermined temperature, the Rankine start control means controls the opening/closing part to close the bypass passage and controls the opening/closing part such that an operation rotational speed increases relative to the predetermined rotational speed until a pressure differential between the inlet-side pressure detected by the pressure detector and the outlet-side pressure detected by the pressure detector reaches a predetermined pressure differential.

13. The waste heat recovery apparatus according to claim 12, wherein the Rankine start control means controls the rotary electric machine such that the operation rotational speed continuously and monotonously increases relative to the predetermined rotational speed.

14. The waste heat recovery apparatus according to claim 12, wherein the Rankine start control means controls the rotary electric machine such that the operation rotational speed increases stepwise relative to the predetermined rotational speed.

15. The waste heat recovery apparatus according to claim 12, further comprising a supercooled degree detector which detects a supercooled degree of the operation fluid on an inlet side of the pump, wherein

when the rotary electric machine is to be operated as the electric motor, the Rankine start control means controls the rotary electric machine first to operate at a first predetermined rotational speed as the predetermined rotational speed, and if the supercooled degree detected by the supercooled degree detector becomes equal to or higher than a predetermined supercooled degree, the Rankine start control means controls the rotary electric machine to operate at a second predetermined rotational speed lower than the first predetermined rotational speed.

16. The waste heat recovery apparatus according to claim 15, wherein, when the rotary electric machine is to be operated at the second predetermined rotational speed, the Rankine start control means controls the rotary electric machine such that the operation rotational speed decreases from the first predetermined rotational speed to the second predetermined rotational speed in one of a continuous and monotonous manner and a stepwise manner.

17. A waste heat recovery apparatus comprising:

a Rankine cycle which includes a pump for pressure-feeding a liquid phase operation fluid, a heater for transforming the liquid phase operation fluid fed from the pump into a gaseous phase operation fluid by heating with waste heat from a heat-generating device, an expansion unit for converting energy of expansion of the gaseous phase operation fluid flowing out from the heater into mechanical energy, and a condenser for condensing and liquefying the expanded gaseous phase operation fluid flowing out from the expansion unit and introducing the liquefied operation fluid into the pump;

a rotary electric machine which has both functions of an electric motor and a generator, and is connected to the pump and the expansion unit through the same shaft;

a control unit which controls the operation of the rotary electric machine;

a bypass passage which bypasses the expansion unit;

an opening/closing part which is controlled by the control unit to open and close the bypass passage;

a temperature detector which detects the temperature of the gaseous phase operation fluid on an inlet side of the expansion unit; and

pressure differential detecting means for detecting a pressure differential between an inlet and an outlet of the expansion unit;

wherein, at the start of the Rankine cycle, the control unit controls the opening/closing part to open the bypass passage and controls the rotary electric machine to operate as the electric motor at a predetermined rotational speed, and if the temperature of the gaseous phase operation fluid detected by the temperature detector becomes equal to or higher than a predetermined temperature, the control unit controls the opening/closing part to close the bypass passage, and controls the rotary electric machine such that an operation rotational speed of the rotary electric machine increases relative to the predetermined rotational speed until a pressure differential detected by the pressure differential detector means reaches a predetermined pressure differential.

18. The waste heat recovery apparatus according to claim 17, wherein the control unit continuously and monotonously increases the operation rotational speed of the rotary electric machine relative to the predetermined rotational speed.

19. The waste heat recovery apparatus according to claim 17, wherein the control unit increases the operation rotational speed of the rotary electric machine stepwise relative to the predetermined rotational speed.

20. The waste heat recovery apparatus according to claim 17, further comprising a supercooled degree detector which detects the supercooled degree of the operation fluid on the inlet side of the pump, wherein, when the rotary electric machine is to be operated as the electric motor, the control unit controls the rotary electric machine first to operate at a first predetermined rotational speed as the predetermined rotational speed, and if the supercooled degree detected by the supercooled degree detector becomes equal to or higher than a predetermined supercooled degree, the control unit controls the rotary electric machine to operate at a second predetermined rotational speed lower than the first predetermined rotational speed.

21. The waste heat recovery apparatus according to claim 20, wherein, when the rotary electric machine is to be operated at the second predetermined rotational speed, the control unit controls the rotary electric machine such that the operation rotational speed decreases from the first predetermined rotational speed to the second predetermined rotational speed in one of a continuous and monotonous manner and a stepwise manner.