DLRs Free Piston Linear Generator FPLG Development of an Innovative - - PowerPoint PPT Presentation

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DLRs Free Piston Linear Generator FPLG Development of an Innovative - - PowerPoint PPT Presentation

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DLRs 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

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SLIDE 1

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

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SLIDE 2

2006

FPLG Project Overview A Decade of Linear Power

2004 2002

Idea & Concept Simulation & Calculation

2008 2010

Implementation Subsystems Implementation Overall System

2014 2012

Technology Development Series Development Market

2002 2013 2015

www.DLR.de • Slide 2 > Kock > FKLG > 2015-09-08

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SLIDE 3

Idea of the FPLG Electricity Generation Directly from Different Fuels

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

Emergency Power Train Special Purpose Vehicle Hydraulics Light Aircraft Propulsion APU (Aircraft) APU (Truck) Ship Propulsion

FPLG

CHP

  • Virt. Power

Plant Balancing Electricity Passenger Car Light & Heavy Duty Bus

www.DLR.de • Slide 3 > Kock > FKLG > 2015-09-08

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SLIDE 4

Idea of the FPLG Free Piston + Linear Generator + Gas Spring

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

2013 Concept study 2015

www.DLR.de • Slide 4 > Kock > FKLG > 2015-09-08

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SLIDE 5

Potentials A combination of advantageous properties

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

Variable compression Variable displacement Variable piston movement

  • High efficiency (43 – 47% indicated)
  • Even at partial load
  • Very good flex-fuel capability
  • Online downsizing
  • Controlled compression ignition (HCCI)
  • All emission requirements fullfilled, includinng EU6

Simple design with no crankshaft

  • Compact in size – only 15 cm flat
  • Few parts, of which only a small number move
  • No lateral piston forces
  • Reduced friction and wear
  • Great mass balancing/Quiet in operation

Modular in design

  • Large quantities / small number of variants
  • Low production costs (1400 € for a range-extender module)
  • Complete cylinder cutoff
  • Combined heat and power (CHP) possible
  • Applications: energy, automotive and more

www.DLR.de • Slide 5 > Kock > FKLG > 2015-09-08

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SLIDE 6

Simulation Various Tools, various models

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market Physical Signal-Flux and Real-time FEM 1D CFD 3D CFD / Individual cycle 3D CFD / Multi cycle

Experimental Validation

www.DLR.de • Slide 6 > Kock > FKLG > 2015-09-08

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SLIDE 7

Validating the Simulation Using laser optical methods

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

www.DLR.de • Slide 7 > Kock > FKLG > 2015-09-08

  • 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

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SLIDE 8

3 Subsystems Developing them One by One

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

Combustion Linear Generator Gas Spring

  • Gen. 6
  • Gen. 5
  • Gen. 7

www.DLR.de • Slide 8 > Kock > FKLG > 2015-09-08

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SLIDE 9

Developing the Subsystems On a fully linear hydraulic engine test bench

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

Hydraulic Actuator

Position Sensor

Subsystem to be tested

www.DLR.de • Slide 9 > Kock > FKLG > 2015-09-08

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SLIDE 10

Overall System Putting the subsystems together

  • Proof of Concept 2013: Up to

8 kWel @19.5 Hz

  • World‘s first system in this

design (CB-LG-GS)

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

Constructive layout 1 combustion chamber, 1 linear generator, 1 gas spring Combustion process 2 stroke spark ignition Displacement volume cm³ 321 - 481 Power (indicated) kW 0 - 12 Operation frequency Hz 16 - 21 Moving mass kg 35.12 Bore mm 82.5 Stroke mm 60 - 90 Boost pressure bar abs 0.2 - 1.0 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 Dimensions (w.o. aux.) mm³ 1940 * 500 * 225 www.DLR.de • Slide 10 > Kock > FKLG > 2015-09-08

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SLIDE 11

Overall System Ignition!

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

www.DLR.de • Slide 11 > Kock > FKLG > 2015-09-08

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SLIDE 12

Technology Development What‘s next?

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

  • Simulation
  • 3rd gen. combustion
  • 5th gen. linear generator
  • 7th gen. gas spring
  • Hydraulic engine test bench
  • Combustion processes
  • Head loop scavenging
  • Control
  • Start up / shut down
  • Safety algorithms

Proof of Concept

  • Switch to opposed piston / longitudinal

scavenging

  • Synchronisation
  • Combustion process optimization
  • Piston tribology
  • Bearings
  • Supercharging
  • Package
  • Power electronics
  • Increase of operating frequency
  • Emissions
  • Endurance

2015 2018

Prototype

www.DLR.de • Slide 12 > Kock > FKLG > 2015-09-08

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SLIDE 13

Technology Forge

Industrial Realisation Road to market

Idea & Concept Simulation & Calculation Implementation Subsystems Implementation Overall System Technology Development Series Development Market

Research Technology Development Series Development and Market Penetration

Internal Research Contract Research Comissioning DLR Technical Development (internal) B2B-Marketing / Partnering Licensing Technical Development in accordance to Products‘ Requirements Observe Research for Government and Foundations Industrial Appliers

www.DLR.de • Slide 13 > Kock > FKLG > 2015-09-08

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SLIDE 14

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