Abstract: Rotors formed by an additive manufacturing process are presented. In one example, a method of making a rotor is presented including defining a printing order for the application of a first material, and creating a plurality of lobes arranged helically about a central opening or a shaft by adding a first material in the printing order, wherein each of the plurality of lobes defines an outer surface.

Abstract: Rotors formed by an additive manufacturing process are presented. In one example, a method of making a rotor is presented including defining a printing order for the application of a first material, and creating a plurality of lobes arranged helically about a central opening or a shaft by adding a first material in the printing order, wherein each of the plurality of lobes defines an outer surface.

Abstract: Rotors formed by an additive manufacturing process are presented. In one example, a method of making a rotor is presented including defining a printing order for the application of a first material, and creating a plurality of lobes arranged helically about a central opening or a shaft by adding a first material in the printing order, wherein each of the plurality of lobes defines an outer surface.

Abstract: A rotor assembly having a plurality of rotor plates mounted to a shaft, and methods of construction for a rotor assembly are disclosed. Each rotor plate in the assembly may be provided with a central opening extending between the first and second sides through which the shaft extends. In one aspect, the rotor plates are provided with a plurality of lobes extending away from the central opening, wherein each of the lobes has a lobe opening extending through the thickness of the plates. In one embodiment, the rotor plates are rotationally stacked to form a helical rotor.

Abstract: In one aspect, the teachings presented herein include a power generation system including: a power plant having an air intake and an exhaust outlet; a boost device in fluid communication with the power plant air intake, the boost device being for pressurizing air entering the power plant air intake; a waste heat recovery device in fluid communication with the power plant exhaust outlet, the waste heat recovery device being for recovering energy from exhaust from the power plant; a first motor/generator coupled to the boost device; a second motor/generator coupled to the waste heat recovery device; an energy storage device for storing energy generated by the first and second motor/generators and for delivering power to drive the first motor/generator; a controller for controlling the first and second motor/generators, wherein the controller is configured to control the level of power generated by the waste heat recovery device based on a state of charge of the energy storage device.

Abstract: A rotor assembly having a plurality of rotor plates mounted to a shaft, and methods of construction for a rotor assembly are disclosed. Each rotor plate in the assembly may be provided with a central opening extending between the first and second sides through which the shaft extends. In one aspect, the rotor plates are provided with a plurality of lobes extending away from the central opening, wherein each of the lobes has a lobe opening extending through the thickness of the plates. In one embodiment, the rotor plates are rotationally stacked to form a helical rotor.

Abstract: An engine system including a power plant, an intake assist device connected to an air inlet of the power plant, and an expander connected to an exhaust outlet of the power plant is presented. A motor/generator is connected to power the expander to selectively provide power to and capture power from the expander. An expander controller is connected to control the motor/generator connection to the expander, and is configured to select between a passive mode, where exhaust passively moves through the expander, and an active mode, where the motor/generator powers the expander to actively draw exhaust from the exhaust manifold. In one example, the air intake and exhaust flows are controlled independently of the rotational speed of the power plant.

Abstract: An optimized mechanical expander or fluid expansion device with a delayed opening timing is disclosed. In the optimized design, rotors in the expander alternatingly rotate sequentially through an intake position in which the transport volume is open to the housing inlet, a closed position in which the transport volume is closed to the housing outlet, and a discharge position in which the transport volume is open to the housing outlet. During rotation, a first opening forms between the housing and each rotor. After further rotation, a second opening is formed that is located between the first opening and a back end of the rotor. In one aspect, the mechanical expander has an opening profile including an initial opening phase in which the opening between the rotor and outlet forms at a lesser rate than during a subsequent secondary opening phase.

Abstract: The present teachings generally include an energy recovery device with heat dissipation mechanisms. The energy recovery device can include a main housing, rotors disposed in the main housing, rotor shafts associated with the rotors, and a sub-housing. The sub-housing can have an engaging surface that faces and is spaced apart from the first receiving surface of the main housing with a first gap when the first sub-housing is attached to the main housing.

Abstract: A multi-stage expansion device having bypass capabilities and a variable speed drive is disclosed. In one example, the multi-stage expansion device has a housing within which a first stage, a second stage, and a third stage are housed. The housing may also be configured with internal working fluid passageways to direct a working fluid from the first stage to the second stage and/or from the second stage to the third stage. Each of the stages may include a pair of non-contacting rotors that are mechanically connected to each other and to a power output device such that energy extracted from the working fluid is converted to mechanical work at the output device. In one example, a bypass line is provided to bypass working fluid around the first stage and a bypass line is provided to bypass working fluid around the second stage.

Abstract: The present teachings generally include a rotor assembly having a plurality of rotor sheets or layers mounted to a shaft, and methods of construction for a rotor assembly. Each rotor sheet or layer in the assembly may be provided with a central opening extending between the first and second sides through which the shaft extends. In one aspect, the rotor sheets or layers can be provided with a plurality of lobes extending away from the central opening, wherein each of the lobes can have a lobe opening extending through the thickness of the sheets or layers. In one example, the rotor sheets or layers can be rotationally stacked to form a helical rotor. In one example, the rotor sheets are formed from a pre-cured composite material and are bonded together with an adhesive.

Abstract: A rotor assembly having a plurality of rotor plates mounted to a shaft, and methods of construction for a rotor assembly are disclosed. Each rotor plate in the assembly may be provided with a central opening extending between the first and second sides through which the shaft extends. In one aspect, the rotor plates are provided with a plurality of lobes extending away from the central opening, wherein each of the lobes has a lobe opening extending through the thickness of the plates. In one embodiment, the rotor plates are rotationally stacked to form a helical rotor.

Abstract: The present disclosure relates to a Rankine cycle system including a Rankine cycle circuit in which working fluid is cycled through a condensing zone, a heating zone, and a mechanical energy extraction zone. The system also includes a hydraulic accumulator for storing pressurized working fluid from the Rankine cycle circuit when a pressure of the working fluid within the Rankine cycle circuit is above a first pressure level, and for releasing pressurized working fluid to the Rankine cycle circuit when the working fluid within the Rankine cycle circuit is below a second pressure level.

Abstract: A rotor assembly having a plurality of rotor plates mounted to a shaft, and methods of construction for a rotor assembly are disclosed. Each rotor plate in the assembly may be provided with a central opening extending between the first and second sides through which the shaft extends. In one aspect, the rotor plates are provided with a plurality of lobes extending away from the central opening, wherein each of the lobes has a lobe opening extending through the thickness of the plates. In one embodiment, the rotor plates are rotationally stacked to form a helical rotor.

Abstract: Power-generation systems including a power plant and a power conversion unit including an energy recovery device and volumetric compressor are disclosed. In one embodiment, the volumetric fluid compressor has first and second meshed rotors and is configured to generate a stream of relatively high-pressure fluid including oxygen to the power plant. In one embodiment, the volumetric fluid energy recovery device having third and fourth meshed rotors, operatively connected to the compressor, and configured to be rotated by the exhaust gas or other fluid deriving energy from the exhaust gas. The system can additionally include a set of timing gears configured to operatively connect the first and second rotors of the compressor to the third and fourth rotors of the energy recovery device, and prevent contact between the first and second rotors and between the third and fourth rotors.

Abstract: A multi-stage expansion device is disclosed. In one embodiment, the multi-stage expansion device has a housing within which a first stage, a second stage, and a third stage are housed. The housing may also be configured with internal working fluid passageways to direct a working fluid from the first stage to the second stage and/or from the second stage to the third stage. Each of the stages may include a pair of non-contacting rotors that are mechanically connected to each other and to a power output device such that energy extracted from the working fluid is converted to mechanical work at the output device. In one embodiment, a step up gear arrangement is provided between the rotors of the first and second stages. A step up gear arrangement may also be provided between the rotors of the second and third stage.

Abstract: An exhaust gas energy recovery system includes an internal combustion engine, a volumetric fluid expander, and a water injection mechanism. The internal combustion engine includes an air inlet, at least one cylinder, and an exhaust gas outlet for conveying an exhaust gas stream at a first pressure. The volumetric fluid expander generates useful work at an output shaft by expanding the exhaust gas stream to a second pressure lower than the first pressure as the exhaust gas stream moves through the volumetric fluid expander. The water injection mechanism injects water into the system at a location between the air inlet of the engine and the expander to increase the volume of the exhaust received by the expander for increased power output at the expander.