JohnDeere

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25 August, 2005

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Technology Delivery Process

Turbo CompoundingA Technology Who’s Time Has Come

Turbo CompoundingA Technology Who’s Time Has Come

25 Aug, 2005 Carl T. Vuk

John Deere Moline Technical Center

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Technology Delivery Process

OUTLINEOUTLINEHistoryRate LimitersEnvironmental FactorsElectric Turbo CompoundingSystem ArchitectureDrivers AnalysisTestingSummary

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Technology Delivery Process

Turbo Compounding HistoryTurbo Compounding History1953 Douglas DC-7 (Wright 3350 TC)1954 Napier Nomad (12 Cyl Diesel 2-stroke)1968 Mitsubishi 10ZF (V10 2-stroke Diesel)1981 Cummins NH1983 Cummins V903 (Military Application)1986 Cat 3406 & 11.3L1988 Hino 8.82L1990 DAF1991 Scania 11L (Current Production)1998 Cat 15L (21st Century Truck)2002 Isuzu Ceramic IDI (Experimental)2002 Volvo (Current Production)

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Technology Delivery ProcessNapier NomadCirca 1955

Napier NomadCirca 1955

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Technology Delivery ProcessTwo-Stage Mechanically Coupled System

Two-Stage Mechanically Coupled System

JohnDeere

CREATING THE FUTUREAdvanced Engineering

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Technology LimitersTechnology Limiters

System ComplexityHigh Ratio Gear TrainsTorsional CouplersImpact on Turbocharger and EngineMachine Placement

Control IssuesCosts

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Factors Favoring TCFactors Favoring TC

Increasing Fuel CostsAvailability of Low Cost ControlsAvailability of Cost Effective Power Electronics (Automotive Hybridization)EGR Requirements for NOx ControlHigh Pressure Ratio VG Turbos

JohnDeere

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Technology Delivery ProcessElectric Turbo CompoundingElectric Turbo Compounding

Simple Architectures PossibleFlexible PlacementIsolated Coupling

Integrated Electronic ControlHigh EfficiencyModest Cost

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Technology Delivery ProcessTurboCompounding Drivers

TurboCompounding Drivers

Improved Fuel Economy - 10+%Increased Power Density - 20+%Emissions & After Treatment BenefitsHigh Exhaust Pressure Requirement – EGRMaturation of Electrification Technology

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Emissions ImpactEmissions Impact

Increased Output Directly Impacts Specific EmissionsPower Turbine Reduces Net Impact of Retarded Injection TimingImproved Transient Response Lowers EmissionsElectrical Output Can Power Emissions Control Devices

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Technology Delivery ProcessPower Density Growth Enablers

Power Density Growth Enablers

Turbo Chargers (1970 – 1990)After Cooling (1975 – 2005)High Performance Pistons (1985 – 2005)Turbo Compounding (2008 - ….)

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TC System SchematicElectrically Coupled Deere System

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Technology Delivery ProcessTurbo Generatoron Gas Stand

Turbo Generatoron Gas Stand

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Technology Delivery Process

AnalysisAnalysis

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Technology Delivery Process

Turbocharger AssemblyTurbocharger Assembly

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Technology Delivery ProcessAdvanced TurboCharger

Advanced TurboCharger

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Power ElectronicsPower Electronics

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Engine TestingEngine Testing

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Technology Delivery Process

Engine TestingEngine Testing

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Technology Delivery ProcessSystem Parameters

System Parameters

50 kW Turbo Generator340V DC OutputWastegate Control For Overspeed Protection50 kW Motor/GeneratorNo Energy StorageIntegrated Control Engine/Turbo GeneratorAdvanced High Pressure Ratio Turbocharger

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Efficiency TargetsEfficiency Targets

Power Turbine 85%Turbo Generator w/Controller 95%Turbocharger Compressor 78%Turbocharger Turbine 85%Motor/Generator w/Controller 95%Engine w/TurboCompounding 46%

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Turbocompound Effect On Performance

6

7

8

9

10

11

12

0 5 10 15 20 25 30Power Turbine Power As A Percentage Of Total System Power [%]

Effic

ienc

y Im

prov

emen

t [%

]

AFR = 30

AFR = 26

AFR = 23

WAVE Performance PredictionsWAVE Performance Predictions

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Engine Test DataEngine Test Data

TurboGenerator Power vs. Engine Speed and Load

0

5

10

15

20

25

30

35

40

45

50

55

60

0 20 40 60 80 100Engine Load (%)

TG P

ower

- kW

e

2300 RPM2100 RPM1900 RPM

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Technology Delivery ProcessApplication Selection Criteria

Application Selection Criteria

Steady-State High-Duty Cycle OperationHigh Annual UsagePower Growth RequirementVehicle Electrification Benefits

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Potential Applications

Combine

9000 Tractor 8000 Tractor

Truck

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Technology Delivery Process

DoE Program FocusDoE Program Focus

Define Application ScopeDevelop and Evaluate Second Generation HardwareIntegrate Turbo Compounding With Engine for Optimal Performance and Emissions

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Technology Delivery Process

SummarySummary

Proven TechnologySignificant, Economy, Power, and Emissions BenefitsMust be Integrated With Emissions Strategies and Vehicle ElectrificationBenefits in Specific Applications to be Defined

JohnDeere

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25 August, 2005

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Technology Delivery Process

AcknowledgmentsAcknowledgments

FundingJohn Deere Tech CouncilDOE

Engine Performance TestingTodd Whiting

JohnDeere

CREATING THE FUTUREAdvanced Engineering

25 August, 2005

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Technology Delivery Process

Questions ?Questions ?