Controlled Power Technologies COBRA Water Cooled Electric Supercharger
COBRA Water Cooled Electric Supercharger COBRA (Controlled Boosting for Rapid response Applications) is a liquid cooled Switched Reluctance Motor (SRM) directly driving a compressor impeller. It uses stored electrical energy ideally harvested by regenerative braking) to increase the supply of air to an internal combustion engine (ICE). The motor technology has a low rotor inertia which allows rapid acceleration and excellent dynamic response. It supplies instantaneous on-demand air and is an enabling technology for a number of CO 2 and emission reducing air loop solutions for ICEs. Its rapid response and dynamic control also improves air-fuel ratio control, avoiding transient smoke limits and reducing smoke opacity. The increased airflow delivered by COBRA can also improve engine response times and the use of liquid cooling for the motor and power electronics extends the duration of boosting events. These features support both engine down-sizing and down-speeding strategies. XX 2 2018 Federal-Mogul LLC
Specification Based on a 6/4 Switched Reluctance Motor (SRM) Range of standard compressors and volutes C70, C80 & C88 (see Fuel Cell product brochure) Bespoke impeller designs for specific flow rates / pressure ratios feasible Range of voltage 12V/24V/48V (custom electrical configurations can be considered) Flexible installation strategy - can be chassis or engine mounted Designed to meet relevant ISO test standards Liquid-Cooled System Extends duration of higher power events Provides a stable environment for power silicon devices Simpler packaging without the need to seek cool air from the front of the vehicle Integrates to main engine coolant circuit (e.g. 90 C @ 6 l/min) No maintenance sealed for life bearings Low Inertia and High Speed Rapid transient response Energy usage can be optimised Integrated Control & Power Electronics All electronics assembled into a sealed housing on the rear of the machine Significantly reduced electrical losses and improved EMC Monitors and controls against over speed & over temperature operation Communicates with vehicle control systems over CAN 2018 Federal-Mogul LLC 3
Benefits Engine Down-Sizing Maintain or increase transient torque availability Enables fuel economy improvements with smaller engine (eg: 6 cylinder to 4 cyclinder) Addresses packaging constraints Improved air delivery control and less complex mechanical installation than multi-stage turbocharger and other sophisticated mechanical turbocharger solutions Potential 10-15% fuel economy benefit Engine Down-Speeding Maintain or increase transient torque availability Alternative gear shift strategies for improved fuel economy (eg: bus automatic transmission) Potential 5% fuel economy benefit Increased Performance Supports use of engine in diverse applications (eg: marine) Supports use of engine in diverse operating environments (eg: altitude) Reduced Pumping Losses Reduces transient load on turbocharger and therefore reduces back-pressure on base engine Potential 3-5% fuel economy benefit Reduced After-Treatment Loading Increased transient air supply improves combustion, reducing particulate emissions and associated loading on after-treatment system Enables reduced after-treatment system size and cost Extends service interval and reduces operating costs Advanced Air Loop Concepts Enables pumped EGR system to support use of EGR over an extended engine speed range Supports cost effective after-treatment solution Installation Electrical, coolant and CAN connections only Sealed bearings mean less complex system integration 4 2018 Federal-Mogul LLC
Performance Specific performance requirements can be achieved with alternative impeller designs, electromagnetic or electronic configurations and different control strategies and/or calibrations. The following data is typical within a similar mechanical and electronics package. Acceleration to full speed: C80 <350ms to 47,000 RPM, <650ms 54,000 RPM C70 <450ms 70,000 RPM COBRA C70 COBRA C80 Voltage Range 12V, 24V & 48V Peak Electrical Power 8 kw Continuous Electric Power 2.4 kw Peak Pressure Ratio 1.43 1.38 Peak Mass Air Flow 425 kg/h 650 kg/h Peak Compressor Speed 65,000 RPM 52,000 RPM Machine Weight 8 kg 8 kg Machine Length* ± 192 mm *includes integrated electronics Electric Power W CBTC203_12_045 105º C Coolant Temperature 4s on/20s off duration: 15 minutes 47% valve open/54k RPM 300 14000 200 12000 100 10000 8000 6000 4000 2000 0 0-100 -200-300 -400-500 0 100 200 300 400 500 600 700 800 900 Electric Power (Watts) COBRA Current (Amps) Current A CBTC203_12_045 105º C Coolant Temperature Transient Response from 5k RPM to 54k RPM t = 0.58 s 60000 50000 Compressor Speed RPM 40000 30000 20000 10000 0 0 1 2 3 4 5 6 7 8 9 Times 2018 Federal-Mogul LLC 5
Water Cooled Electric Supercharger Family COBRA C70 Applications Include: TC or NA engines with a displacement of 2 to 7 litre Mass flow range 100 300 kg/h 1.45 1.4 CBCC103_12_107 (C70) Electrical Power Consumption <1kW 1-2kW 2-3kW 3-4kW 4-5kW >5kW Steady 68 krpm 1.35 Pressure Ratio (P/P) 1.3 1.25 1.2 1.15 1.1 1.05 30 krpm 40 krpm 50 krpm 60 krpm 1 0 50 100 150 200 250 300 350 400 450 Mass Air Flow (kg/hr) COBRA C80 Applications Include: As C70 but higher mass flow rates Mass flow range 300 800 kg/h 1.4 1.35 CBTC203_12_045 (C80) Electrical Power Consumption <1kW 1-2kW 2-3kW 3-4kW 4-5kW >5-6kW >6Kw 30000 40000 50000 50 krpm 1.3 Pressure Ratio (P/P) 1.25 1.2 1.15 1.1 30 krpm 40 krpm 1.05 1 0 100 200 300 400 500 600 700 Mass Air Flow (kg/hr) 6 2018 Federal-Mogul LLC
Our Company Empowering the Engine of Progress Founded in 2007, UK-based clean-tech developer Controlled Power Technologies (CPT) was acquired by Federal-Mogul Powertrain in 2017. The CPT product range with innovative electrification and hybridization systems enables the development of reduced-emissions powertrains with: 12V, 24V and 48V electric motor-generators for stop-start and mild hybridization applications, exhaust-driven electrification technologies, combustion engine e-boosting and fuel cell e-compressors. As one of two independent divisions that constitute Federal-Mogul LLC, Federal-Mogul Powertrain designs, develops and manufactures original equipment engine components and sealing and systems protection products. Federal-Mogul Powertrain is committed to delivering superior quality through innovation and engineering excellence enabled by cutting-edge proprietary technologies. The division works in partnership with its customers to meet increasingly demanding targets for fuel economy and emissions performance without compromising affordability or reliability. As one of the leaders in the passenger car, light commercial, heavy-duty and off-highway markets, Federal-Mogul Powertrain also supplies related technologies to the power generation, aerospace, marine, rail and industrial sectors. 2018 Federal-Mogul LLC 7
www.federalmogul.com Federal-Mogul Controlled Power Ltd Unit 4, Westmayne Industrial Park, Bramston Way, Laindon, Essex, SS15 6TP Phone +44 (0)1268 564800 CPTinfo@federalmogul.com www.cpowert.com 2018 Federal-Mogul LLC. All rights reserved. All trademarks are owned by Federal-Mogul LLC or one of its subsidiaries, in one or more countries.