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Research and development of electric generator from exhaust gases of internal combustion engine

To research and develop a device able to produce electricity using the energy of exhaust gasses and deceleration and its logical distribution throughout the vehicle in order to lower its consumption of fuel and also its co2 emissions.

The aim of the project is to develop the key element of the Vehicle Energy Management System (V.E.M.S.), this being a device able to produce electricity using the energy of exhaust gasses and deceleration and its logical distribution throughout the vehicle in order to lower its consumption of fuel and also its CO2 emissions. The V.E.M.S. system presents a new approach to using both kinetic and thermo-mechanic energy produced by the movement of the vehicle (this energy is being wasted at the moment) and using it to lower the consumption of fuel and CO2 emissions. This system is aimed at a vehicle able to run on a combination of a combustion engine and electric motor, while lowering the consumption in places calling for deceleration (city traffic) and on the highway. The basic idea of the system is to use the combustion engine only for propelling the vehicle and to power the peripherals using the electric energy made from the kinetic and thermo-mechanic energy produced by the vehicle. The peripherals here are any electric appliances being powered via the alternator at the moment. The regular alternator is being powered via a gear off the combustion engine, which lowers its output and increases its consumption. The more equipped the vehicles are (with things like automatic air conditioning, heated seats, heated windshields and mirrors, servos, alarms, etc.), the more significant the increase of the electric power is. Even though the modern vehicles come with high efficiency alternators (up to 70%) and use two basic circuits with different voltage (12V/24V/48V), not even such modifications prevent the high load of alternator from occurring during setting the vehicle in motion after starting it up, during accelerating and even going at constant speed. At the moment, the electric energy is being generated only by conversion of the chemical energy of the fuel to mechanical energy via the working of a combustion engine. This energy is then transformed via the alternator to electric energy with rather low total efficiency. The efficiency of conversion of the chemical energy to mechanical one is 30-35% and the efficiency of conversion of the mechanical energy to electric one is 70-80%). The alternator's load on the combustion engine leads to a higher specific consumption of the combustion engine and proportionally also on the level of the CO2 produced. The key element of the system is the so called turbo-generator which will make electric power from exhaust gasses, hence using the energy of these gases that go to waste at the moment. This electric energy is used to power all the electric systems of the vehicle (including the electric air conditioning). The excess electric power made by deceleration and by the turbo-generator will be stored in batteries and super-capacitators and used to power the auxiliary electric motor. This electric motor will help the combustion engine as a parallel hybrid system at the moments of revolutions and load when the combustion engine is the least efficient and exhibits the highest fuel consumption (mainly setting in motion and acceleration phases). Only this system will be able to help us get over the biggest problem of existing hybrid vehicles that do not work properly in need of frequent decelerating. The existing hybrid vehicles consume more fuel on the highways because of the high-capacity battery system being very heavy. The key to significant lowering of the consumption is the combination of the sources of the electric power (energy that goes to waste at the moment), intelligent controlling unit able to predict energy consumption, systems of storing the electric energy (the key is the ability to use the energy quickly, the total capacity of the project is less important) and efficient electric system on board. The applicant has developed a number of system elements (the patent application for the V.E.M.S. system was registered at the beginning of 2010) and some of them are being developed outside of this project. The applicant protects the acquired intellectual property via patents or utility designs (see below). The vital missing part of the system is the electric generator creating energy from exhaust gasses - this is a subject of research and development as part of the project. The V.E.M.S. system consists of six basic elements: 1) Intelligent electronic alternator; 2) The system of quick charging super-capacitators and batteries and working with these energy reserves; 3) Electronic air conditioning; 4) The system of controlling three-phase synchronous electric motors with electronic commutation; 5) The controlling unit combining controlling of the recuperation and output part of the system; 6) Making electric energy from the exhaust gasses. These six key points show that the position of the applicant is very strong, owing to the fact that several elements of the V.E.M.S. system are already protected by patents (the patent for intelligent electronic alternator.
Acronym: 
VEMS
Project ID: 
6 718
Start date: 
01-03-2012
Project Duration: 
46months
Project costs: 
850 000.00€
Technological Area: 
Furnace technology, construction of heating boilers
Market Area: 
Motor Vehicles, Transportation Equipment and Parts

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