Engine Downsizing Potential of Electric Turbochargers

e-boosters, turbine generators,
and
turbocharger technology
About Aeristech
• High-performance electric machines
• Electric/aero integration and optimisation
• Power electronics design and prototyping
• Rotordynamics and damping systems
• Thermal management in turbine generator
• Turbomachine testing
Aeristech’s Core Technology
Unique control architecture and machine
• High efficiency (reduced switching losses)
• More than 100 kW per kg of magnet
material (based on typical Neodymium)
• Capable of high power (1-50 kW)
Aeristech’s Core Technology
Unique control architecture and machine
2.8
• High efficiency (reduced switching losses)
• More than 100 kW per kg of magnet
material (based on typical Neodymium)
• Capable of high power (1-50 kW)
• Capable of high voltage (>12V)
cost
12V
120V
power
Aeristech e-Booster
•
Boost 2.1bar
•
14kw Shaft Power
•
Speed 120krpm
•
Aerodynamic, ŋ = 76%
•
Inverter to Shaft Power
efficiency of 76 – 88%
Compressor Test Rig Details
•Mass flow is measured using a pre-calibrated bell-mouth
flow meter
•Measured inlet and outlet absolute pressures and
temperatures used to map corrected mass flow and
efficiency in line with published data.
•Standard-SAE J1723 (Non-Positive Displacement
Supercharger) was used as a guideline in the test rig
construction.
Inlet Section
Outlet Section
Test Procedure
•The AM3 Supercharger is mounted to the Cold Air Test Rig.
•Water cooling used to remove heat from the stator and bearings.
•Filtered oil-mist lubrication supply is attached to each bearing cap.
•Data acquisition from the air path is provided by a single unit recording temperature,
pressure, and mass air flow.
•Coolant supplies are monitored by a second DAQ unit and rotor-dynamics DAQ 3
Methodology:
1. Ambient temperature and pressure recorded.
2. Shaft speed (supercharger speed) set by the control system
3. The mass flow rate is set by adjusting the valve.
4. Results ensured to converge to meet the steady state standard stabilisation criteria.
5. Converged temperature and absolute pressure readings taken at the suction and discharge
sections.
6. The valve position (mass flow) is readjusted whilst keeping the shaft speed constant
and more data sets are recorded as required.
7. Reset the speed and the data recording process is repeated.
e-Booster Acceleration (1)
Speed Range (krpm)
60 - 100
Boost (bar)
0.51
Time (s)
0.38
e-Booster Acceleration (2)
Data Set Speed Range (krpm)
1
75 - 115
2
90 - 115
3
75 - 115
Boost (bar)
0.62
0.43
0.65
Time (s)
0.50
0.40
0.60
e-Booster Acceleration (3)
Data Set Speed Range (krpm)
1
50 - 80
2
50 - 95
3
75 - 100
Boost (bar)
0.30
0.51
0.35
Time (s)
0.45
0.40
0.45
Compressor Test Rig
Turbine Test Rig
Control Architecture
Controller
Motor
Control Architecture
Controller
Conventional
Motor
Motor
360 000
3 000 Hz
switches
per second
180 000 RPM
Control Architecture
Controller
Conventional
Motor
Aeristech
Motor
Motor
360 000
3 000 Hz
switches
per second
180 000 RPM
38 000
6 000 Hz
switches
per second
180 000 RPM
Control Architecture
Controller
Conventional
Motor
Aeristech
Motor
Motor
360 000
3 000 Hz
switches
per second
180 000 RPM
38 000
6 000 Hz
switches
per second
180 000 RPM
Generally, Loss = (Amps) * (Switches per second) * k
Aeristech’s Costs Compared to
Conventional Control
Cost Driver
Sensitivity
Magnets
Less Sensitive
Aeristech makes better use of
magnet material
Stator material
Equal
Aeristech uses less stator
material but is more sensitive
to its quality
IGBT substrate material
Less Sensitive
Aeristech uses fewer switching
events, so requires less
footprint
• Fully decoupled architecture
• Compressor(s) optimised for surge
• Turbine(s) optimised for efficiency
• Simpler packaging and pipework
• Fewer losses in pipes and valves
• Greater control of EGR
• Lower cost than a multi-stage turbo
• Aeristech is a technology licensing company
to work with OEs and Tier-1s
• Aeristech have the capability to build
prototypes for customer evaluation
– specific and optimised to their requirements
• Aeristech’s independence allows us to work
with any nominated manufacturing partner
• Aeristech develop bespoke system solutions
for arduous motorsport applications
• Aeristech maximises standard materials and
manufacturing processes, for volume
production
Thank You
Bryn Richards
Chief Executive Officer
Mobile: +44 7906 517686
Email: [email protected]
Unit G
Princes Drive Industrial Estate
Coventry Road
Kenilworth
Warwickshire CV8 2FD
United Kingdom
Telephone: +44 1926 258422
Email: [email protected]
Web: www.aeristech.co.uk