DLR‘s Free Piston Linear Generator FPLG Development of an Innovative Linear Power Unit Florian Kock September 8, 2015 www.DLR.de • Slide 1 > Kock > FKLG > 2015-09-08
FPLG Project Overview A Decade of Linear Power 2002 2013 2015 Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development 2002 2004 2006 2008 2010 2012 2014 www.DLR.de • Slide 2 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Idea of the FPLG Electricity Generation Directly from Different Fuels Passenger Car Ship Propulsion Light & Heavy APU (Truck) Duty Bus APU (Aircraft) FPLG Light Aircraft CHP Propulsion Hydraulics Virt. Power Plant Special Purpose Balancing Vehicle Electricity Emergency Train Power www.DLR.de • Slide 3 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Idea of the FPLG Free Piston + Linear Generator + Gas Spring 2013 2015 Concept study www.DLR.de • Slide 4 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Potentials A combination of advantageous properties • High efficiency (43 – 47% indicated) Variable compression • Even at partial load Variable displacement • Very good flex-fuel capability Variable piston movement • Online downsizing • Controlled compression ignition (HCCI) • All emission requirements fullfilled, includinng EU6 Compact in size – only 15 cm flat • Simple design • Few parts, of which only a small number move with no crankshaft • No lateral piston forces • Reduced friction and wear • Great mass balancing/Quiet in operation • Large quantities / small number of variants • Low production costs (1400 € for a range-extender module) Modular in design • Complete cylinder cutoff Combined heat and power (CHP) possible • • Applications: energy, automotive and more www.DLR.de • Slide 5 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Simulation Various Tools, various models Physical Signal-Flux and 3D CFD / Multi cycle Real-time Experimental Validation 3D CFD / Individual cycle FEM 1D CFD www.DLR.de • Slide 6 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Validating the Simulation Using laser optical methods - Particle Image Velocemetry (PIV): Scavenging Process - Laser Induced Flurescence (LIF): Mixture Formation / Combustion - Experimental setup of the combustion unit: - 2 stroke DI Gasoline - Spark ignition or compression ignition (HCCI realized) - Until 2014 single combustion with head loop scavenging through electromagnetically actuated valves - 2015: Longitudinal port scavenging scavenging through ports www.DLR.de • Slide 7 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development 3 Subsystems Developing them One by One Combustion Linear Generator Gas Spring Gen. 7 Gen. 5 Gen. 6 www.DLR.de • Slide 8 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Developing the Subsystems On a fully linear hydraulic engine test bench Hydraulic Actuator Position Sensor Subsystem to be tested www.DLR.de • Slide 9 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Overall System Putting the subsystems together Constructive layout 1 combustion chamber, 1 linear generator, 1 gas spring Combustion process 2 stroke spark ignition Displacement volume cm³ 321 - 481 kW Power (indicated) 0 - 12 Hz Operation frequency 16 - 21 Moving mass kg 35.12 mm Bore 82.5 Stroke mm 60 - 90 bar abs 0.2 - 1.0 Boost pressure Gas exchange Loop scavenging (2 inlet valves, 1 outlet valve) Compression ratio (CB) 7 - 11 Injection Direct injection, central multi hole injector Compression ration (GS) 2,5 - 15 Generator force N typical 4000, max. 12000 mm³ Dimensions (w.o. aux.) 1940 * 500 * 225 - Proof of Concept 2013: Up to 8 kW el @19.5 Hz - World‘s first system in this design (CB-LG-GS) www.DLR.de • Slide 10 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Overall System Ignition! www.DLR.de • Slide 11 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Technology Development What‘s next? • Simulation • Switch to opposed piston / longitudinal 2015 scavenging • 3rd gen. combustion • Synchronisation • 5th gen. linear generator Proof of Concept • Combustion process optimization • 7th gen. gas spring Prototype • Piston tribology • Hydraulic engine test bench • Bearings • Combustion processes • Supercharging • Head loop scavenging • Package • Control • Power electronics • Start up / shut down • Increase of operating frequency • Safety algorithms • Emissions • Endurance 2018 www.DLR.de • Slide 12 > Kock > FKLG > 2015-09-08
Simulation & Implementation Implementation Technology Series Idea & Concept Market Calculation Subsystems Overall System Development Development Industrial Realisation Road to market Technical Development in accordance to Products‘ Requirements Technology Technical Development Forge (internal) Industrial B2B-Marketing / Appliers Partnering Licensing Observe Comissioning DLR Research for Government and Contract Research Foundations Internal Research Research Technology Development Series Development and Market Penetration www.DLR.de • Slide 13 > Kock > FKLG > 2015-09-08
Questions? Comments? —————————————————————————— Deutsches Zentrum für Luft- und Raumfahrt e.V. (DLR) German Aerospace Center Institute of Vehicle Concepts | Pfaffenwaldring 38-40 | 70569 Stuttgart | Germany Dr.-Ing. Florian Kock | Project Manager FPLG Telephone +49 (711) 6862-798 | Telefax +49 (711) 6862-258 | florian.kock@dlr.de www.DLR.de www.DLR.de • Slide 14 > Kock > FKLG > 2015-09-08
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