Turbocharger for an internal combustion engine

• US 8,495,875 B2
• Filed: 08/06/2010
• Issued: 07/30/2013
• Est. Priority Date: 08/06/2009
• Status: Expired due to Fees

• Current Assignee: Schaeffler Technologies AG & Co.KG (INA-Holding Schaeffler GmbH & Co. KG)
• Original Assignee: Schaeffler Technologies AG & Co.KG (INA-Holding Schaeffler GmbH & Co. KG)
• Inventors: Triller, Andreas, Englisch, Andreas
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): Nguyen, Ngoc T
• Application Number:
  US12/806,234
• Publication Number:
  US 20110036089A1
• Time in Patent Office: 1,089 Days
• Field of Search: 60607-609
• US Class Current: 60/608
• CPC Class Codes: F02B 37/10 at least one pump being alternatively or simultaneously driven by exhaust and other drive, e.g. by pressurised fluid from a reservoir or an engine-driven pump
• CPC Class Codes: F02B 39/02 Drives of pumps exhaust drives or combined exhaust and other drives F02B37/00; Varying pump drive gear ratio
• CPC Class Codes: F02B 39/10 electric
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A turbocharger for an internal combustion engine, in which a mechanical energy flow can be generated from an exhaust gas flow of the internal combustion engine for providing engine intake airfow under pressure. The turbocharger includes a mechanical energy converter connected between the exhaust gas flow and the intake airflow, by which converter the mechanical energy flow can be transferred and transmitted. The turbocharger also includes an electrical energy converter associated with the mechanical energy flow for converting mechanical energy into electrical energy, or vice versa, to enable improved intake airflow charging of an internal combustion engine. By means of the electrical energy converter, an electrical energy flow can be selectively branched off to a battery or fed into the mechanical energy flow.

Claims

1. A turbocharger for an internal combustion engine, in which mechanical energy flow is generated from engine exhaust gas flow and is fed to provide intake airflow to the internal combustion engine, said turbocharger comprising:

an exhaust gas turbine positioned for receiving engine exhaust gas from an externally-positioned internal combustion engine, wherein the exhaust gas turbine is operative for providing mechanical energy from the engine exhaust gas;

an intake airflow compressor positioned at an engine intake airflow conduit of the externally-positioned internal combustion engine for providing air under pressure to the externally-positioned internal combustion engine;

a mechanical energy converter connected between the exhaust gas turbine and the intake airflow compressor for receiving mechanical energy provided by the exhaust gas turbine and for providing mechanical energy to the intake airflow compressor; and

a rotatable electrical energy converter operatively connected with the mechanical energy converter for receiving mechanical energy from the exhaust gas turbine and for converting received mechanical energy output into electrical energy, wherein the electrical energy converter is operative for converting received electrical energy from an electrical energy accumulator into mechanical energy for supply to the mechanical energy converter and to the intake airflow compressor, whereby a flow of electrical energy from the electrical energy converter can be selectively branched to the electrical energy accumulator from a received flow of mechanical energy by the electric energy converter, and whereby a flow of electrical energy can be provided to the electrical energy converter from the electrical energy accumulator to drive the intake airflow compressor.

2. A turbocharger in accordance with claim 1, wherein the mechanical energy converter includes a variable speed planetary transmission having a continuously variable transmission ratio.

3. A turbocharger in accordance with claim 2, wherein the variable speed planetary transmission includes a first transmission stage and a second transmission stage, and wherein the electrical energy converter is disposed between the first and second transmission stages.

11. An internal combustion engine including a turbocharger in accordance with claim 1.

12. An internal combustion engine in accordance with claim 11, wherein the turbocharger is operated from engine exhaust gas to drive the exhaust gas turbine to generate mechanical energy;

wherein mechanical energy generated by the exhaust gas turbine is supplied to the electrical energy converter for generating electrical energy by the electrical energy converter;

wherein a flow of electrical energy is selectively branched off from the electrical energy converter to an electrical energy accumulator during a first operating condition of the internal combustion engine; and

wherein electrical energy is selectively supplied from the electrical energy accumulator to the electrical energy converter for providing mechanical energy to supplement mechanical energy generated by the exhaust gas turbine during a second operating condition of the internal combustion engine.

13. A turbocharger in accordance with claim 1, wherein the mechanical energy converter is a two-stage planetary gear transmission.

14. A turbocharger in accordance with claim 1, including a tandem turbocharger including two exhaust gas turbines and two intake airflow compressors, each connected to provide a pair of parallel flow turbochargers, including a unitary mechanical energy converter positioned between and connected with each of the turbochargers.

15. A turbocharger in accordance with claim 14, including two respective planetary gear transmissions, wherein the intake airflow compressors are each non-rotatably connected with a common sun gear of the respective planetary gear transmissions.

16. A turbocharger in accordance with claim 14, wherein respective exhaust gas turbines are operatively connected with respective intake airflow compressors through respective freewheels.

4. A method for operating a turbocharger for an internal combustion engine, the turbocharger including an exhaust gas turbine, an intake airflow compressor, a rotatable mechanical energy converter connected between the exhaust gas turbine and the intake airflow compressor, and an electrical energy converter operatively connected with the mechanical energy converter, said method comprising the steps of:

operating the turbocharger from engine exhaust gas to rotate the exhaust gas turbine to generate mechanical energy;

supplying mechanical energy generated by the exhaust gas turbine to the rotatable electrical energy converter for generating electrical energy by rotating the electrical energy converter;

selectively branching off a flow of electrical energy from the electrical energy converter to an electrical energy accumulator during a first operating condition of the internal combustion engine; and

selectively supplying electrical energy from the electrical energy accumulator to the rotatable electrical energy converter for rotating the electrical energy converter to provide to the intake airflow compressor mechanical energy to supplement mechanical energy generated by the exhaust gas turbine and for supplying supplemental rotational power input to the intake airfow compressor during a second operating condition of the internal combustion engine.

5. A method in accordance with claim 4, including the step of:

steplessly transmitting mechanical energy flow to the intake airflow compressor through a variable planetary gear transmission having a continuously variable transmission ratio.

6. A method in accordance with claim 4, including the steps of:

transmitting additional mechanical energy to the intake airflow compressor to supplement mechanical energy provided to the intake air compressor by the exhaust gas turbine when the rotational speed of the internal combustion engine falls below a threshold engine rotational speed by feeding a flow of electrical energy to the electrical energy converter to operate the electrical energy converter as a motor for driving the intake air compressor; and

transmitting mechanical energy not needed for driving the intake air compressor to the electrical energy accumulator when engine rotational speed of the internal combustion engine exceeds the threshold speed by branching off electrical energy flow from the electrical energy converter to the electrical energy accumulator.

7. A method in accordance with claim 4, including the step of:

steplessly transmitting mechanical energy to the intake airflow compressor so that the speed of the intake airflow compressor associated with an engine intake airflow volume over an increasing speed characteristic of the internal combustion engine, relative to the speed of the exhaust gas turbine associated with the exhaust gas flow, first increases disproportionately, then increases again under-proportionately, and thereafter decreases slightly.

8. A method in accordance with claim 7, including the step of:

controlling a flow of electrical energy from the electrical energy converter and transmitting resulting additional mechanical energy to the exhaust gas turbine so that the exhaust gas turbine speed increases proportionally to internal combustion engine speed.

9. A method in accordance with claim 4, including at least one of the following steps:

selectively branching a flow of electrical energy from the electrical energy converter to an electrical energy source;

selectively branching a flow of electrical energy from the electrical energy converter to an electrical energy sink and

selectively branching a flow of electrical energy from the electrical energy converter to a rechargeable battery.

10. A method in accordance with claim 4, including the steps of:

controlling flow of electrical energy by an electrical energy control component; and

controlling operation of the electrical energy converter by the electrical energy control component.