Sliding vane rotary expander for waste heat recovery system

This application claims priority to U.S. Provisional Application No. 61/144,248, which was filed on Jan. 13, 2009.

This disclosure relates to a rotary expander for a waste heat recovery system, and in particular, to a sliding vane rotary expander.

Fuel economy can be improved for internal combustion engines by utilizing a waste heat recovery system. One type of waste heat recovery system utilizes a Rankin cycle loop where a working fluid receives heat rejected by an EGR cooler. The recovered waste heat is converted into useful work through an expander and compounded with the engine output through a compounding device, such as an alternator. Typically, the expander greatly influences the overall efficiency of the waste heat recovery system, the power compounding method and system cost.

One type of expander is a rotary expander, which includes sliding vane expanders. The performance of sliding vane expander is typically not very good due to a low pressure expansion ratio relating to its low volumetric efficiency resulting from internal leakage. Increasing rotational speed of a sliding vane expander improves the volumetric efficiency, however, the siding friction of the vanes against its housing also increases leading to deterioration in the mechanical efficiency of the expander.

An engine waste heat recovery system is disclosed that includes an engine configured to reject heat to a working fluid. A heat exchanger is configured to receive the working fluid. First and second stages respectively include first and second vane assemblies, each having a hub supporting vanes that are radially movable relative to its hub. The first stage includes a high pressure chamber and a first intermediate pressure chamber, and the second stage includes a second intermediate pressure chamber and a low pressure chamber. The high pressure chamber is configured to receive the working fluid from the heat exchanger. The first and second intermediate pressure chambers are fluidly coupled to one another. The first vane assembly is configured to rotate from the high pressure chamber to the first intermediate pressure chamber with the second vane assembly configured to rotate from the second intermediate pressure chamber to the low pressure chamber.

One example rotary expander includes a housing having a cavity. A vane assembly has a hub supporting vanes that are radially movable relative to the hub and in engagement with the cavity. The vane assembly is disposed within the cavity and provides first and second sides, each of the first and second sides providing the first and second chambers. The first chambers are fluidly coupled to one another, and the second chambers are fluidly coupled to one another.

Another example rotary expander includes a housing having a cavity with first and second chambers. A ring is supported within the cavity by a bearing. A vane assembly has a hub supporting vanes that are radially movable relative to the hub and in engagement with the cavity. The vane assembly is disposed within the ring, and the ring is configured to rotate relative to the vanes and the housing.

The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 illustrates an example power plant utilizing an engine waste heat recovery system having a sliding vane expander.

FIG. 2 is one example sliding vane expander according to the disclosure.

FIG. 3 schematically illustrates a multi-stage expander assembly utilizing the expander illustrated in FIG. 2 .

FIG. 4 illustrates the multi-stage expander shown in FIG. 3 in more detail.

FIG. 5 is another example sliding vane expander according to the disclosure.

FIG. 6 schematically illustrates a multi-stage expander assembly utilizing the expander illustrated in FIG. 5 .

FIG. 7 illustrates the multi-stage expander shown in FIG. 6 in more detail.

FIG. 1 schematically illustrates an example power plant 10 including an example engine waste heat recovery (WHR) system 11 . The power plant 10 includes an engine 12 , such as an internal combustion engine, which may be diesel or gasoline. The engine 12 includes an intake system 14 and an exhaust system 16 . In the example illustrated, exhaust gases from the exhaust system 16 drive a turbine 18 , which in turn rotates a compressor 20 that provides charge air 24 to the intake 14 . Compressed air from the compressor 20 may pass through a charge air cooler 22 before entering an EGR mixer 30 . The EGR mixer 30 also receives EGR gases 28 cooled by a heat exchanger 26 .

A liquid coolant loop 32 receives heat rejected from the engine 12 . The example liquid coolant loop 32 includes a pump 34 that circulates the liquid coolant from the engine 12 through a radiator 36 that is cooled by a fan 38 .

A working fluid loop 40 circulates a working fluid, such as a water and ethanol mixture, to receive rejected heat from the engine 12 , which may be provided through the EGR cooler 26 and/or other sources. The working fluid loop 40 includes a sliding vane expander 42 fluidly coupled to the heat exchanger 26 . The working fluid rotationally drives the sliding vane expander 42 , which in turn rotates a compounding device 44 , such as an alternator, which is operationally coupled to a drive member 46 connected to the engine 12 . The drive member may be an electric motor, for example. In this manner, waste heat gathered by the engine heat recovery system 11 supplements the power provided by the engine 12 .

In the example illustrated, the working fluid loop 40 includes a condenser 48 that receives the expanded working fluid from the sliding vane expander 42 . Condensed working fluid is collected in a reservoir 50 , which is circulated by a low pressure pump 52 . The pressure of the working fluid from the low pressure pump 52 is regulated by a flow control device 54 . A high pressure pump 56 receives the working fluid, a portion of which may pass through the charge air cooler 22 , and supplies the working fluid to the heat exchanger 26 through a pressure regulator 58 .

In one example, the sliding vane expander 42 is provided by an expander assembly 60 , as illustrated in FIG. 2 . The expander assembly 60 includes a housing 62 receiving a ring 64 supported by a bearing 66 . In one example, the bearing 66 is a needle bearing. The ring 64 provides a cavity 68 within which a hub 70 is disposed. Multiple vanes 72 are received in slots 74 circumferentially arranged about the hub 70 . The vanes 72 slidably move radially inwardly and outwardly to maintain engagement with an inner surface of the ring 64 as the hub 70 is rotated about its axis A. Biasing members may be provided in the slots 74 to urge the vanes 72 outward. The hub 70 is disposed to one side of the cavity 68 to provide a pumping chamber with which first and second chambers 76 , 78 are in fluid communication. The high pressure working fluid from the heat exchanger 26 enters the first chamber 76 and expands, rotationally driving the hub 70 and its shaft 71 in a counterclockwise direction, before being expelled through the second chamber 78 .

The expander assembly 60 may be used for multiple stages in a multi-stage arrangement, as illustrated in FIGS. 3 and 4 . In this example, the first chamber 76 corresponds to a high pressure chamber, and the second chamber 78 corresponds to an intermediate pressure chamber. The intermediate pressure chamber 78 of the first stage 86 is fluidly coupled to an intermediate chamber 80 of the second stage 88 via a fluid circuit 84 . The second stage 88 includes a low pressure chamber 82 .

In the example, the expander assemblies 60 of the first and second stages 86 , 88 are disposed within a common housing 62 and supported on a common shaft 71 for rotation together about an axis A. A housing wall separates the cavities of the first and second stages 86 , 88 .

In another example, the sliding vane expander 42 is provided by expander assembly 90 , as illustrated in FIG. 5 . The expander assembly 90 includes a housing 92 providing an elliptical cavity 94 . A hub 96 is disposed within the cavity 94 generally centrally relative thereto. The hub 96 includes multiple vanes 98 disposed in slots 100 arranged circumferentially about the hub 96 . The vanes 98 slidably move radially inwardly and outwardly to maintain engagement with the inner surface of the cavity 94 during rotation. The hub 96 separates the cavity 94 into first and second sides 102 , 104 . Each of the first and second sides 102 , 104 includes first and second chambers 106 , 108 . The first chamber 106 receives high pressure working fluid from the heat exchanger 26 . The high pressure working fluid rotates the hub 96 counterclockwise about its axis A and is expelled out the second chamber 108 .

A multi-stage expander assembly is shown in FIGS. 6 and 7 . In one example, a expander assembly 90 is arranged in each of first and second stages 132 , 134 . The first chambers 106 of the first stage 132 are fluidly coupled by a first fluid circuit 114 . The second chambers 108 of the first stage 132 are fluidly coupled to third chambers 110 via a second fluid circuit 116 . The first and second circuits 114 , 116 respectively correspond to high pressure working fluid and intermediate pressure working fluid. The intermediate pressure working fluid from the third chambers 110 of the second stage 134 is expelled to the third fluid circuit 118 through the fourth chambers 112 .

There may be some instances in which the flows through the first and second stages 132 , 134 are not in balance due to either unequal wear of the vanes 98 or upstream or downstream pressure fluctuations. In such a situation, a balance valve 122 may be used, which is shown schematically in FIG. 7 . In one example, the balance valve 122 includes a piston 124 upon which fluid from first, second and third balance circuits 126 , 128 , 130 acts. The first, second and third balance circuits 126 , 128 , 130 are fluidly coupled respectively to the first, second and third fluid circuits 114 , 116 , 118 . If the flow of the second stage 134 is greater than the first stage 132 , then the low pressure working fluid is greater than the balance condition. In this case, the balance valve opens the bypass port on the third circuit 130 to reduce the inlet pressure for the second stage 134 , which reduces the flow driving force for the second stage 134 . If the flow of the first stage 132 is greater than the second stage 134 , then the intermediate working pressure is greater than the balance condition. In this case, the balance valve opens the second circuit 128 to increase the intermediate pressure, which reduces the flow of the first stage 132 and increases the flow of the second stage 134 . With this flow balance valve 122 , the flow through the first and second stages 132 , 134 of the expander can be balanced to a reasonable degree.

If the rotary expander 90 is to drive an alternator, for example, then the two stage configuration illustrated in FIGS. 6 and 7 may not meet the speed requirement of the alternator. For such applications, a gearbox 140 may be arranged between the rotary expander and the compounding device 44 .

Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.