Eaton India Engineering Center & IIT Madras Research & Technology Collaboration Sudhakar Potukuchi, PhD VP Engineering Srinivas Mutukuri, PhD Head, Corporate Research & Technology Nikhil Tambe, PhD Manager, Advanced Mechanical Systems IIT Madras, Jan 2014
Areas Thermal energy transfer Waste heat energy recovery Advanced fluid power Motion mechanisms & actuation Mechanical power & NVH 2 2
Technology Focus: Thermal energy transfer Multiple applications across industrial & electrical sectors demand better thermal management for reasonable product performance over life Increasingly power density improvements are pushing heat flux >10 W/cm 2. C Advanced cooling technologies, ideally passive, but also closed loop self sufficing active Attractive technology solutions would be ones that allow for compactness and also minimize auxiliary systems such as water pumps, plumbing etc. Mudawar (2001) IEEE Trans. Components & Packaging Technol., 24 3 3
Technology Focus: Waste heat energy recovery Power electronics today is migrating more and more towards higher power levels & higher power density from miniaturization. Many applications are increasingly handling power in the MW range. Parallel technology advances in electronics and packaging are definitely leading towards improved efficiencies, nonetheless the quantum of waste heat being generated is going to be significantly larger. Harnessing the low temperature heat from the small real estate available Effective waste heat recovery techniques Technologies that allow strap-on onto the electronics packaging are desirable. 4 4
Technology Focus: Advanced Fluid Power Stringent fuel efficiency norms (EU, US, India?) are demanding higher engine efficiency from next generation automotive engines. Boosted engine air intake is a key enabler and will play a huge role in meeting future fuel economy and performance goals. Positive displacement boosting devices providing pressure ratios over 1:5. Novel architectures for boosting that not only meet performance requirements like high volumetric efficiency, isentropic efficiency, power consumption but quieter systems. Noise generation in high power fluid power system is an important problem in current application. 5 5
Technology Focus: Motion mechanisms & actuation State-of-the-art actuation mechanisms in electrical switchgear have been used for decades without significant advancements Systems are often complex & bulky due to stringent operating condition related to life, actuation speed and control. Miniature circuit breaker Medium voltage breakers Alternative intelligent actuation technologies and architectures that significantly reduce the complexity, minimize the auxiliary systems, and improve the controllability and response time of the breakers without compromising safety & reliability are required Air circuit breakers Molded case circuit breaker 6 6
Technology Focus: Mechanical power & NVH Regulation dictates the maximum acceptable overall noise level for the vehicle and the transmission. Eaton maintains that our transmission will be a secondary noise source. A secondary noise source is one that does not contribute to the overall noise level of the vehicle (10 db below the overall limit). Passive noise control techniques such as ribbing, damping patch already exist. Future vehicle level noise regulations combined with trends in usage of lightweight materials demand advanced techniques for controling dynamics & vibrations 7 7
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Technology Sub Focus Area Problem statement TOPICS Energy recovery The trend in power electronics today is more and more towards high power, high density & miniaturization. With the rapid increase of power levels in electronics components a significant amount of heat that is generated needs to be dissipated. Instead it could potentially be put to a usable form through effective heat recovery methods from high power electronics that can be simply integrated onto electronics and convert energy in to other usable forms of work are required. Thermal transfer energy Industrial brakes/clutches need to be effectively cooled. Water cooled brakes already exist. These are challenged by energy capacity. Advanced liquid cooling including phase change materials would allow for compactness and also minimize auxiliary systems such as water pumps, plumbing etc. In Air cooled Clutch/Brake application with dry friction we are being able to absorb the heat around 1.2 HP/in2 of organic friction material which limits the use. If we change the friction material to metallic friction lining the other mating part becomes weak as temperature reach close to annealing temperature. We want to reach the stage where we should be able to absorb the heat above 2 HP/in2. This will help us to reach to the market where we are currently not serving as well as help us to provide smaller clutch or brake to existing customer/applications. Fluid power (Engine intake) Supercharging intake air into an IC engine provides higher engine efficiency. Novel architectures for supercharging that not only meet preformance requirements like high volumentric efficiency, but are also quieter systems would be adopted by market. Noise generation in fluid power system is an important problem in current application. Positive displacement compressor/pump creates pressure oscillations in discharge line and this is source of noise in system called fluid borne noise. Standard silencer and dampers can be useful to reduce it to some extent however these tend to be bulky and expensive. Effective methods to reduce fluid borne noise in positive displacement devices are needed. Motion mechanisms & actuation Mechanical power State-of-the-art actuation mechanisms in electrical switchgear are complex electromechanical systems that are often bulky and complex due to stringent operating condition related to life, actuation speed and control. These systems have been used for decades without significant advancements. Alternative intelligent actuation technologies and architectures that significantly reduce the complexity, minimize the auxiliary systems, and improve the controllability and response time of the breakers without compromising safety & reliability are required. Geared systems need to operate with less mechanical noise as they are deployed into customer applications that are noise sensitive. Next-gen transmissions are moving towards lightweight materials owing to the cost advantage inherent in system weight, thereby however making them prone to acoustics radiations. The challenge is to control/eliminate the noise using passive noise control ideas/techniques.