Electric Turbo Compounding...A Technology Who’s Time Has Come•Carl T. Vuk•John DeereTechnical CenterOUTLINE•System Architecture•Review of Hardware Elements•System Analysis•Test Results•Application Recommendations•Conclusions•Future Work•Questions24 Aug, 2006Electric Turbo Compounding:•A System That Converts Waste Exhaust Energyto Shaft Work, using a Turbine, and Couples itBack to the Engine, ElectricallyWhy Turbo Compounding ?•Today’s Engines Reject 40% of the Fuel’s Energy in theExhaust Gas Stream.The Exhaust is an Excellent Source ofHigh Grade Heat, And it’s Free!•Turbo Compounding Technology is Available and ProvenWith Mature System Costs in the Order of $50/kW.•The Technology Provides Power Growth, Improved FuelEconomy, and Reduced Emissions.24 Aug, 200624 Aug, 2006System ArchitectureTurbo Generator•Converts Exhaust Energy into Shaft Work•Converts Shaft Work into Electrical Power•Simple Architecture•Very High Efficiency•Known Technology•Cost Effective Design24 Aug, 2006Motor Generator•Generates When Turbo GenCan Not (Generating Mode)•Couples Turbo Gen Power Back to Engine (Motoring Mode)•Flywheel Mounted forCompact Packaging•Simple Low Cost Machine Using Known Technology•High Efficiency BPM Technology24 Aug, 2006Power Electronics•Controls Turbo Gen Speed and Delivers DC Power•Manages Motor Gen to Regulate BUS Voltage•Very High Efficiency Over Operating Envelope•Cost Effective Components•Liquid Cooled24 Aug, 2006Advanced TurboCharger•High Pressure Turbine•Significantly Upgraded Efficiency•Fixed Geometry Turbine Nozzle Vanes•Vaned Diffuser (Compressor)24 Aug, 200624 Aug, 2006DynoTest SetupAdvanced TurbochargerPower turbineGeneratorTwo Stage Architecture•Independent Control of Turbo Machinery Elements•Modest Pressure Ratios•Interstage After Treatment•Allows for Simple Turbo Machinery•Improved Transient Response24 Aug, 2006Electric Coupling•Power Turbine Speed Control Optimization•Efficient Power Recirculation w/o Fluid Coupling•Packaging Flexibility•Motor Generator Supports Vehicle Electrification24 Aug, 2006Variable Geometry Turbines•VG TurboCharger Not Needed to Drive EGR•VG Power Turbine -Option•Provides Direct Control of Turbo Compounding Output•Increases Part Load& PartSpeed Output•Potential Control of Engine Air Flow & Transient Response•Fixed Geometry Power Turbine –Option•Better Efficiency at Full Load•Reduced System Complexity•Lower Cost24 Aug, 200624 Aug, 2006Variable Vane Mechanism(Power Turbine)24 Aug, 2006Variable Vane Mechanism(Power Turbine)Motor Generator Optimization•Efficiency Must be High (95%) in Operating Envelope•Packaging is Critical For Common Design and MinimalVehicle Disruption•Every Application is Different.Assuming Will Not ProduceOptimal Results24 Aug, 2006Engine Test Data(Output Characteristics)TGPowervs.LoadandSpeed:TG3 w/-20% &-39% NGV,BWVTG,PCU1 -7Sep050200400600800100012001400EngineLoad -Nmw/Tier3EmissionsInjection Timing and EGRSchedules051015202530354045505560

TG P o w e r - k W e2300RPM-TG3 w/-39%NGV-BWVTG2300RPM-TG3 w/-20%NGV-BWVTG2300RPM-TG3 w/NomNGV-BWVTG2100RPM-TG3 w/-39%NGV-BWVTG2100RPM-TG3 w/-20%NGV-BWVTG2100RPM-TG3 w/NomNGV-BWVTG24 Aug, 2006Engine Performance Data(Fuel Economy)FuelEconomy:Combined EngineShaft+ElectricPowerOutputs30050070090011001300EngineLoad-Nm190195200205210215220225230235240245250255260

Co m b i n e d S F C - g / k W hNon-Turbocompound BaselineEngineTurbocompound Engine24 Aug, 2006Application Targets –Turbo Compounding•High-Duty Cycle Steady StateOperation MaximizesBenefit•High Annual Usage Improves Payback•Vehicle Electrification Helps Justify Added Cost•Motor/Gen Needed Even w/o TurboCompounding•More Efficient to Use Electrical Power in Vehicle•Power Growth•Valuable in Some Applications•Allows Smaller Higher Duty Cycle Engines inApplications Not Needing Power Growth24 Aug, 200624 Aug, 2006Ideal ApplicationsCombinesLarge TractorsRow CropTractorsTrucks24 Aug, 2006Tractor Mounted Turbo Generator24 Aug, 2006Hardware Integrated in Tractor24 Aug, 2006Deere 9L Engine in International TruckConclusions:•20% Power Growth Has Been Demonstrated With LittleAdverse Impact On The Engine.Higher Output is Possible.•Fuel Economy Improvements of 10% Have BeenDemonstrated at Tier 3 Conditions•Turbo Compounding is Compatible With Emissions andAppears to Provide Benefit•An Electrically Coupled Two Stage Architecture offersControl, Efficiency, Emissions, and Packaging Benefits.ItAlso Supports Electrification.•System Costs Suggest Commercialization Potential24 Aug, 2006Future Work•Evaluate Benefits of the Variable Geometry Power Turbine•Characterize Performance Benefits in Vehicles•Deere Tractor•On-Highway Truck•Expand Scope to Include Larger Engines•Develop Next Generation Hardware•Optimize for Tier 424 Aug, 2006Acknowledgements•I would like to thank John Deere, US Department of Energy,International Truck, and Eaton for support of this program,and for allowing us to share a high level overview of thiswork.24 Aug, 200624 Aug, 2006Questions ?