driving clean technology with e-Superchargers, turbine generators

driving clean technology with
e-Superchargers, turbine generators,
and
turbocharger technology
CONFIDENTIAL
Key Topics
The Company and the Technology
The Market, Aeristech’s Portfolio and Route to Commercialisation
Case Studies –
• E-Supercharger for Super-compact Range Extender
• Benefits of FullElectric Turbocharger (FETT) on a 1.2L Petrol engine
CONFIDENTIAL
Company Overview
•
Who are we? UK based advanced engineering, design and development company with patented
technologies for electric boosting
•
Aeristech Ltd formally founded in 2006 but operations started in 2008
•
Capital investment from Private Investors and VCs group – More than 30 different investors
•
Transition from Research / early Proof of Concept to application engineering (up to prototype and
demonstration level)
•
Why Aeristech? The most powerful and efficient electric boosting devices and exhaust waste energy
recovery systems
•
Automotive Applications include:
 FullElectric Turbocharger Technology
 Electrically driven supercharger (e-Booster) technology
 E-Compressors (Fuel Cell applications)
 Turbine Generators for energy recovery
•
Business model based on technology licensing with Tier1 Suppliers
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History
2006
2007
2008
2009
2010
2011
First OEM
collaboration
Feasibility
2013
2014
Engine test with
booster and turbine
14kW eBooster test
Bench Test
High-speed PM Motor
Rapid Acceleration
2012
Performance
FullElectric turbo test
with energy storage
Vehicle Applications
Engine test with 48V supercharger
Range extender
supercharged for
50% more power
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Electric Machine as the Core of Technology
Very low electrical switching frequency
delivering higher efficiency and torque
density. This allows exceptionally accurate
high-transient motor control.
Aeristech’s 10kW eSupercharger






Fastest Accelerating
Most Power Dense
Control by the millisecond
Compact, low mass, low inertia
Cheaper IGBT/MOSFET components
High efficiency
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Market Trends and the Role of Electric Boosting
Market Drivers
•
Main driver is legislative (global trend)
•
Customers expect economical cars with better performance!
 Industry trend towards engine “downsizing”
Source: ICCT, Global Passenger Vehicle Standards, 2011
Conventional (Mechanical) Systems
Conventional turbochargers and superchargers can provide boost, but they have
inherent drawbacks.
•
For extreme downsizing, single-turbo systems will not be capable of producing
enough boost pressure whilst maintaining acceptable transient response.
•
One adopted solution is multi-stage boosting systems
 Electric Superchargers (eSuperchargers)
With very fast response time, eSuperchargers are very effective in addressing the
low-speed turbo lag issues associated with downsized engines.
 Electric Turbochargers (FETT)
A “old” concept made possible only by Aeristech’s motor and control technology
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Products – Electric Supercharger
What is it?
•
An electric compressor to feed the engine and remove turbo
lag.
•
Supplements the existing (larger) turbocharger.
•
Cheaper and simpler than a conventional supercharger.
Why?
•
More power from smaller engines – less CO2
•
Less revolutionary than Full Electric – near-term market
•
Installed on a 1L range extender engine for Mahle
•
•
increased power 40%
Installed on a conventional 2L engine for Tier1
•
reduced turbo lag 50% and enables extreme
downsizing greater than 60%
•
Very compact
•
Minimal changes to engine and vehicle
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Products – Full Electric Turbocharger
What is it?
• An electric compressor to feed the engine and increase
its power
•
An electric turbine to harvest exhaust gas energy
•
Cheaper and simpler than a conventional turbocharger.
Why?
•
More power from smaller engines – less CO2
•
Replaces complex multi-stage systems like this
•
Easier to package
•
Lower mass
•
Fewer moving parts
•
Lower cost
•
Better performance
CONFIDENTIAL
Above: Aeristech’s full electric turbocharger
Below: Multi-stage mechanical turbocharger
Aeristech’s Portfolio and Timing
CONFIDENTIAL
Routes to Market
Technology Licensing
OEMs
Tier1s – OEM
Supply Chain
Licensing for
Volume
Manufacturing
Automotive
Consultancies
Alternative Revenue
Streams
Niche Markets &
Low/medium Vol
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Joint Venture
for High Value
Manufacturing
E-Supercharger Applications
(“eSupercharger”)
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eSupercharger Applications
Application
General
Target engine
Air compressor type
Motor type
Max speed
Bearings
Input voltage
Performance Nominal rated flow (Engine at
1750rpm boosted to 2bar)
Pressure ratio (at nom. flow)
Minimum rated flow (Engine idle
speed of 750rpm)
Max boost pressure
Range of max boost pressure
Flow range at max boost (Engine
Speed 1000–1750rpm)
Max Flow
Transient
Idle to max flow, 1.8bar boost
Packaging
Motor / Compressor Mass
Motor / Compressor Volume
2.0L Petrol or Diesel (or less)
Centrifugal (bespoke design)
High Speed Permanent Magnet
120 000 RPM
High Precision Ceramic Hybrid
Rolling Element
46V – 50V (48V nominal)
0.0715 kg/s
2.0 bar
0.0153 kg/s
2.0 bar
1000-1750 RPM
0.0408 – 0.0715 kg/s
0.0797 kg/s
< 0.5s
4.7kg
< 1.4ltr
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eSupercharger Applications
Compressor map
- Existing design
- Tested to 120 000 rpm
Projects include:- 2 litre engine “e-Supercharger”
- 900cc range extender
- 1.2 litre downsized engine
“e-Booster” (simulation only)
CONFIDENTIAL
Case Study
sSupercharger for Super-compact
Range Extender
E-Supercharger for Super-compact Range Extender
Project Objectives
• Increase power output of MAHLE Powertrain’s Range Extender (Rex)
engine from 30kW to 50kW with minimal changes to the base engine design
• By implementing Aeristech’s E-Supercharger technology as an optional
power upgrade
• Develop and validate the concept with a proof-of-concept demonstrator
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E-Supercharger for Super-compact Range Extender
Range Extender Engine Family Concept - Increasing power required with
increased vehicle weight
Source: Mahle Powertrain Ltd
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E-Supercharger for Super-compact Range Extender
Power Upgrade Paths
Power increase
• Increased speed
• Increased torque
40 kW can be achieved
through increasing
engine speed or
increased torque
50+ kW requires
30 kW
4000
rev/min
72 Nm
increased speed
and increased torque
Source: Mahle Powertrain Ltd
CONFIDENTIAL
Results - Pressure Charging + Increased Speed
• Initial testing
achieved 56 kW at
5500 rev/min
• E-supercharger
power requirement
is 4.5 kW
(unoptimised)
• 51 kW net power
Source: MAHLE Powertrain Ltd
CONFIDENTIAL
Full Electric Turbocharger Technology (FETT)
Fully decoupled architecture:
Turbine Generator
Electric Compressor
Turbine-Generator
Power Electronics
and Control
Large turbine and
independent impeller
speeds
improve efficiency
•
•
•
Fully electric
Highly efficient
Power on demand
E-Supercharger
Optimised combustion due
to precise control of air
flow
CONFIDENTIAL
Aeristech’s FETT Potential
•
fullElectricTT a single stage electric turbocharger covering the
full range of engine operation.
•
A self-contained system no external source of power
•
No significant cost barrier conventional materials
•
High boost levels from a power dense compressor with full
ECU control
•
Turbo lag mitigation with a compressor motor sized according
to needs
•
High efficiency from independent speed control of turbine and
compressor, combined with very high electrical efficiency
•
A compact system fewer pipes and valves, high-density
electric machines
•
Fewer switching events in the controller and fewer losses,
compared to any equivalent operating speed, power level, and
component price
CONFIDENTIAL
FETT Case Study
Comparative Analysis
(Simulation)
1.2 L Petrol Engine
WLTC, ARTEMIS drive
cycle
WLTC and ARTEMIS Simulation
Simulation procedure
WLTC
ARTEMIS
Duration
WLTC
Low
Medium
High
Extra High
s
589
433
455
323
1800
Stop
Distance
Duration
s
m
156
3095
48
4756
31
7158
7
8254
242
23262
Duration
ARTEMIS S
Urban
993
Rural
1082
Motorway
1068
3143
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Stop
Duration Distance
s
m
302
4870
37
17272
19
28736
358
50878
Replaced the Turbocharger with FETT
Assumptions
•
No engine downsizing
•
No change to steady-state boost
•
No change to gear selection
•
Decouple turbine from compressor
•
No change to transmission
•
Add an electric wastegate
•
No change to vehicle mass
•
Add electrical losses
Results
Baseline (0%) = conventional turbocharger
•
The turbocharger achieved an energy balance
across the drive cycles
•
FETT CO2 improvement by Back Pressure Drop
 0.8% on WLTC (entire cycle)
 1.6% on ARTEMIS (entire cycle)
 1.1% on WLTC extra high speed
 1.7% on ARTEMIS motorway
•
FETT CO2 improvement by Turbo-Compounding
 1.9% on WLTC (entire cycle)
 2.9% on ARTEMIS (entire cycle)
 2.4% on WLTC extra high speed
 3.3% on ARTEMIS motorway
CONFIDENTIAL
Energy Storage Requirement
 Applications:
 Energy storage simulation: WLTC, ARTEMIS, 0-100km/h
Max
Cycle
acceleration Energy Storage
m/s^2
kJ
WLTC
1.75
1
ARTEMIS
2.86
1.87
0-100km/h
3.08
2.42
 Results:
 Maximum 10kW power required from energy storage
 Select 2.7kJ energy storage capacity
 Assume Maxwel BCAP0005 ultracapcitors
 2.7kg
 12cm x 12cm x 12cm
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0-100km/h Simulation
 Assumptions:
 No change to engine and transmission
 Decouple compressor from turbine
 0.5s compressor response with FETT,
2.5s compressor response with conventional turbo.
 Results:
0-100km/h simulation
Conventional
Turbo
100
Full Electric
Turbo
100
10
9
Vehicle speed (km/h)
Vehicle speed Duration
km/h
s
100
90
80
70
60
50
40
30
20
10
0
Full Electric Turbo
Conventional Turbo
0
CONFIDENTIAL
2
4
Time (s)
6
8
10
1.2L engine in a 2,000kg kerb weight car
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1.2L engine in a 2,000kg kerb weight car
Overall cycle
Road
Motorway
BSFC reduction - ARTEMIS
Back pressure drop
Turbocompounding
%
%
3.79
6.00
2.76
4.38
4.52
7.12
CONFIDENTIAL
Thank You
Julien Servant
Commercial Director
Mobile: +44 7825 304959
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
CONFIDENTIAL