Engineering topics

Kruiswyk, Rich

Publications and source records attributed to Kruiswyk, Rich.

4 records

DOE OSTI2024

A Hybrid Heavy Duty Diesel Power System for Off-Road Applications—Concept Validation

A multiyear power system R&D program was completed with the objective of developing an off-road hybrid heavy duty diesel engine with front end accessory drive-integrated energy storage. This system was validated to deliver 10.5–25.6% reduction in fuel consumption over current Tier 4 Final-based 18L diesel engines, over various off-road machine application cycles. The power system consisted of a downsized heavy-duty diesel 13L engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, thermal barrier coatings, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy assisting and recovery through both mechanical and electrical systems. Following the concept definition, design, and analysis phases of the program, the final phase focused on building and validating the performance and efficiency in laboratory tests. While aspects of the system such as start/stop and reduced off-road cooling package energy losses were only analytically evaluated, the main 13L concept engine with full hybrid system was successfully built and tested in steady-state and in transient certification and real-world application cycles. Extensive simulations in Caterpillar's DYNASTY™ software environment utilized the validation test data to assess performance more fully and confidently over varied cycles and strategies. An average fuel consumption reduction of 17.9% was realized, and the majority (~13%) of the benefit stemmed from the core concept 13L engine. In conclusion, a total cost of ownership analysis provides context to commercial viability and where adoption focus should be placed.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Hybrid Heavy Duty Diesel Powertrain for Off-Road Applications (Final Technical/Scientific Report)

In this program, a heavy-duty hybrid powersystem, consisting of a 30% downsized diesel engine and a front-end accessory drive (FEAD) incorporating a high-speed flywheel (HSFW) energy storage system, a mechanical-drive turbocharger (SuperTurbo), and motor-generator units (MGU) was developed and demonstrated. The high efficiency core 13L engine coupled with the hybrid elements was physically validated across various off-road machine and transient work cycles with the ultimate goal of demonstrating 17% efficiency improvement with equivalent transient response as the 18L diesel engine this concept powersystem would replace. The project culminated in a physical demonstration of the high-efficiency powersystem in a high-capability test cell with the engine, all the hybrid devices, controls, and required performance and emissions measurements. Based on the combination of physical validation and rigorous system simulation, the following program conclusions may be drawn: (1) The developed hybrid H2D2 powersystem demonstrated a range of efficiency improvement of 10.5 - 25.6%, with a midpoint of 17.9%; (2) Transient load response on; (3) The HSFW system was validated to achieve peak assisting of 110kW at 12,000 Nm/sec ramp rates; (4) The powersystem was validated to be capable of meeting U.S. EPA Tier 4 Final off-road emissions through transient NRTC testing; (5) A Total Cost of Ownership (TCO) analysis and found that the core 13L engine would pay back immediately (adoption of start/stop would pay back in less than one year, and the full hybrid system payback was three years.)

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

A Hybrid Heavy-Duty Diesel Power System for Off-Road Applications - Concept Definition

A multi-year Power System R&D project was initiated with the objective of developing an off-road hybrid heavy-duty concept diesel engine with front end accessory drive-integrated energy storage. This off-road hybrid engine system is expected to deliver 15-20% reduction in fuel consumption over current Tier 4 Final-based diesel engines and consists of a downsized heavy-duty diesel engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy recovery through both mechanical (high speed flywheel) and electrical systems. The first year of this project focused on the definition of the hybrid elements using extensive dynamic system simulation over transient work cycles, with hybrid supervisory controls development focusing on energy recovery and transient load assist, in Caterpillar’s DYNASTY™ software environment. Three key off-road applications were the focus of the hybrid concept definition with an aim of understanding the system’s modular capability for the diverse off-road heavy-duty market. Core engine performance 1D and 3D simulations isolated the efficiency contributions from the downsized engine, turbocompounding, and in-cylinder thermal barrier coatings. A fuel consumption improvement range of 14 to 24% was predicted, resulting in successful project progression to the design and experimental validation phase. Furthermore, an overview of the experimental engine and hybrid system status concludes the discussion along with the multi-year project’s next steps.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2010

High Efficiency Engine Technologies Program

Caterpillar's Product Development and Global Technology Division carried out a research program on waste heat recovery with support from DOE (Department of Energy) and the DOE National Energy Technology Laboratory. The objective of the program was to develop a new air management and exhaust energy recovery system that would demonstrate a minimum 10% improvement in thermal efficiency over a base heavy-duty on-highway diesel truck engine. The base engine for this program was a 2007 C15 15.2L series-turbocharged on-highway truck engine with a LPL (low-pressure loop) exhaust recirculation system. The focus of the program was on the development of high efficiency turbomachinery and a high efficiency turbocompound waste heat recovery system. The focus of each area of development was as follows: (1) For turbine stages, the focus was on investigation and development of technologies that would improve on-engine exhaust energy utilization compared to the conventional radial turbines in widespread use today. (2) For compressor stages, the focus was on investigating compressor wheel design parameters beyond the range typically utilized in production, to determine the potential efficiency benefits thereof. (3) For turbocompound, the focus was on the development of a robust bearing system that would provide higher bearing efficiencies compared to systems used in turbocompound power turbines in production. None of the turbocharger technologies investigated involved addition of moving parts, actuators, or exotic materials, thereby increasing the likelihood of a favorable cost-value tradeoff for each technology. And the turbocompound system requires less hardware addition than competing bottoming cycle technologies, making it a more attractive solution from a cost and packaging standpoint. Main outcomes of the program are as follows: (1) Two turbine technologies that demonstrated up to 6% improvement in turbine efficiency on gas stand and 1-3% improvement in thermal efficiency in on-engine testing. (2) A compressor technology that demonstrated 1.5% improvement in compressor efficiency on gas stand compared to production available compressors. (3) A power turbine with high efficiency bearing system that demonstrated excellent rotordynamic stability throughout the required speed range, up to 60,000 rpm. (4) A predicted improvement (using engine simulation) in engine thermal efficiency of 7% at the peak torque design point, when combining the technologies developed in this program.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗