DLR s Free Piston Linear Generator FPLG Development of an Innovative Linear Power Unit
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1 DLR s Free Piston Linear Generator FPLG of an Innovative Linear Power Unit Florian Kock September 8, Slide 1 > Kock > FKLG >
2 FPLG Project Overview A Decade of Linear Power Slide 2 > Kock > FKLG >
3 Idea of the FPLG Electricity Generation Directly from Different Fuels Ship Propulsion Passenger Car APU (Truck) Light & Heavy Duty APU (Aircraft) Bus Light Aircraft Propulsion FPLG CHP Hydraulics Virt. Power Plant Special Purpose Vehicle Balancing Electricity Train Emergency Power Slide 3 > Kock > FKLG >
4 Idea of the FPLG Free Piston + Linear Generator + Gas Spring Concept study Slide 4 > Kock > FKLG >
5 Potentials A combination of advantageous properties Variable compression Variable displacement Variable piston movement Simple design with no crankshaft 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 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 Slide 5 > Kock > FKLG >
6 Simulation Various Tools, various models Physical 3D CFD / Multi cycle Signal-Flux and Real-time Experimental Validation 3D CFD / Individual cycle FEM 1D CFD Slide 6 > Kock > FKLG >
7 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 : Longitudinal port scavenging scavenging through ports Slide 7 > Kock > FKLG >
8 3 Developing them One by One Combustion Linear Generator Gas Spring Gen. 6 Gen. 5 Gen. 7 Slide 8 > Kock > FKLG >
9 Developing the On a fully linear hydraulic engine test bench Hydraulic Actuator Position Sensor Subsystem to be tested Slide 9 > Kock > FKLG >
10 Putting the subsystems together Constructive layout 1 combustion chamber, 1 linear generator, 1 gas spring Combustion process 2 stroke spark ignition Displacement volume cm³ Power (indicated) kw 0-12 Operation frequency Hz Moving mass kg Bore mm 82.5 Stroke mm Boost pressure bar abs 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 Dimensions (w.o. aux.) mm³ 1940 * 500 * Proof of Concept 2013: Up to 8 kw Hz - World s first system in this design (CB-LG-GS) Slide 10 > Kock > FKLG >
11 Ignition! Slide 11 > Kock > FKLG >
12 What s next? Proof of Concept 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 Prototype 2015 Switch to opposed piston / longitudinal scavenging Synchronisation Combustion process optimization Piston tribology Bearings Supercharging Package Power electronics Increase of operating frequency Emissions Endurance Slide 12 > Kock > FKLG >
13 Industrial Realisation Road to market Technical in accordance to Products Requirements Forge Technical (internal) Industrial Appliers Observe Comissioning DLR B2B-ing / Partnering Licensing Internal Research Research for Government and Foundations Contract Research Research and Penetration Slide 13 > Kock > FKLG >
14 Questions? Comments? Deutsches Zentrum für Luft- und Raumfahrt e.v. (DLR) German Aerospace Center Institute of Vehicle Concepts Pfaffenwaldring Stuttgart Germany Dr.-Ing. Florian Kock Project Manager FPLG Telephone +49 (711) Telefax +49 (711) Slide 14 > Kock > FKLG >
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