Abstract: Systems and methods are disclosed to recover waste heat from an engine fluid with a heat exchanger subsystem that includes a heat exchanger. The heat exchanger subsystem is thermally coupled to a working fluid and the engine fluid, so the waste heat from the engine fluid is transferred to the working fluid. The engine fluid is bypassed from the heat exchanger in response to a heat exchanger bypass condition.

Abstract: A waste heat recovery system comprises an exhaust system, a thermal oil circuit, and a Rankine cycle circuit. The exhaust system is configured to provide exhaust gases. The thermal oil circuit comprises a first heat exchanger and a second heat exchanger. The first heat exchanger is positioned along the exhaust system. The first heat exchanger receives heat from exhaust gases and separately receives thermal oil such that heat from exhaust gases is transferred to thermal oil within the first heat exchanger. The second heat exchanger receives thermal oil from the first heat exchanger and provides thermal oil to the first heat exchanger. The Rankine cycle circuit circulates working fluid through the second heat exchanger separate from thermal oil such that heat from thermal oil is transferred to working fluid within the second heat exchanger. An expander utilizes heat within working fluid to produce mechanical energy.

Abstract: A waste heat recovery (WHR) system and method for regulating exhaust gas recirculation (EGR) cooling is described. More particularly, a Rankine cycle WHR system and method is described, including an arrangement to improve the precision of EGR cooling for engine efficiency improvement and thermal management.

Abstract: A waste heat recovery system (100) is provided. At least one heat exchanger (104) is fluidically coupled to a waste heat source (102) and is configured for selectively recovering heat from the waste heat source (102) to heat a working fluid (108). An energy conversion device (112) is fluidically coupled to the at least one heat exchanger (104) and is configured to receive the working fluid (108) and to generate an energy for performing work or transferring the energy to another device using the heat recovered from the waste heat source (102). A condenser (122) is fluidically coupled to the energy conversion device (112) and configured to receive the working fluid (108) from the energy conversion device (112) and to condense the working fluid (108) into a liquid phase.

Abstract: A power generation system having a combustion engine with a Rankine bottoming cycle, the system including a first flow path for a process fluid and a second flow path for a working fluid, and a heat exchanger arranged along both the first and the second flow paths to transfer waste heat from the process fluid to the working fluid. The heat exchanger includes a first flow conduit being bounded by a first wall section and configured to convey the process fluid, a second flow conduit to convey the working fluid, the second flow conduit being bounded by a second wall section spaced apart from the first wall section to define a gap therebetween, and a thermally conductive structure arranged within the gap and joined to the first and second wall sections to transfer heat therebetween, the gap being fluidly isolated from both the process fluid and the working fluid.

Abstract: Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.

Abstract: A waste heat recovery system includes a first heat exchanger, a second heat exchanger, and an expander. The first heat exchanger receives working fluid from a first portion of a first loop and provides the working fluid to a second portion of the first loop. The second heat exchanger receives the working fluid from a first portion of a second loop and provides the working fluid to a second portion of the second loop. The expander provides the working fluid to a first portion of a common line. The expander includes a stator. The stator includes a first inlet and a second inlet. The common line provides the working fluid to both the first loop and the second loop upstream of the first portion of the first loop and upstream of the first portion of the second loop.

Abstract: A waste heat recovery (WHR) hybrid power system can be utilized in vehicles to convert heat energy into mechanical energy. The WHR system can include a WHR power unit structured to convert thermal energy into rotation of a WHR drive shaft. A motor/generator having a motor/generator shaft can selectively operate as a motor or a generator. A mechanical linkage can be structured to selectively link a output shaft to one of the WHR drive shaft and the motor/generator drive shaft independently of the other of the WHR drive shaft and the motor/generator drive shaft.

Abstract: A system includes an exhaust passage and a waste heat recovery system. The exhaust passage is structured to fluidly couple to an exhaust manifold of an engine, and to receive exhaust gas from the engine. The waste heat recovery system includes a working fluid circuit, a superheater, and an expander. The working fluid circuit includes a pump to circulate a working fluid through the working fluid circuit, including through the engine. Heat is transferred from the engine to the working fluid. The superheater is positioned along the working fluid circuit downstream of the engine. The superheater is fluidly coupled to the exhaust passage and transfers heat from the exhaust gas to the working fluid. The expander is positioned along the working fluid circuit downstream of the superheater. The expander generates useful energy from the heat transferred to the working fluid from the exhaust gas and the engine.

Abstract: An engine cooling system comprises an engine cooling circuit, comprising a first pump structured to circulate engine coolant fluid therethrough. A remote coolant radiator positioned along the engine cooling circuit downstream of the engine and outside of a vehicle cooling package area is structured to transfer heat from the engine coolant fluid to air. A coolant heat exchanger is positioned along the engine cooling circuit in parallel to the remote coolant radiator. A waste heat recovery system comprises a working fluid circuit comprising a second pump. The coolant heat exchanger is positioned along the working fluid circuit and is structured to transfer heat from the engine coolant fluid to the working fluid. An expander is structured to convert energy from the heat transferred to the working fluid from the engine cooling fluid to mechanical energy. A condenser positioned downstream of the expander is structured cool the working fluid.

Abstract: A system for cooling a cylinder head includes a cylinder head, a cylinder block, and a waste heat recovery system. The cylinder head includes a first water jacket and a second water jacket. The cylinder block is coupled to the cylinder head. The cylinder block includes a third water jacket. The first water jacket is coupled to a first cooling circuit. The second water jacket is coupled to a second cooling circuit. The third water jacket is coupled to a third cooling circuit. The waste heat recovery system is coupled to at least one of the first cooling circuit, the second cooling circuit, and the third cooling circuit.

Abstract: Systems and methods are disclosed to recover waste heat from an engine fluid with a heat exchanger subsystem that includes a heat exchanger. The heat exchanger subsystem is thermally coupled to a working fluid and the engine fluid, so the waste heat from the engine fluid is transferred to the working fluid. The engine fluid is bypassed from the heat exchanger in response to a heat exchanger bypass condition.

Abstract: A waste heat recovery system comprises an exhaust system, a thermal oil circuit, and a Rankine cycle circuit. The exhaust system is configured to provide exhaust gases. The thermal oil circuit comprises a first heat exchanger and a second heat exchanger. The first heat exchanger is positioned along the exhaust system. The first heat exchanger receives heat from exhaust gases and separately receives thermal oil such that heat from exhaust gases is transferred to thermal oil within the first heat exchanger. The second heat exchanger receives thermal oil from the first heat exchanger and provides thermal oil to the first heat exchanger. The Rankine cycle circuit circulates working fluid through the second heat exchanger separate from thermal oil such that heat from thermal oil is transferred to working fluid within the second heat exchanger. An expander utilizes heat within working fluid to produce mechanical energy.

Abstract: A waste heat recovery (WHR) and coolant system with active coolant pressure control includes an engine cooling system, a WHR system, and a coolant pressure control system. A coolant heat exchanger positioned along each of the engine cooling and working fluid circuits, and is structured to transfer heat from the coolant fluid to the working fluid. The coolant pressure control system includes a pressure line operatively coupled to an air brake system and to the coolant tank. A valve is coupled to the pressure line upstream of the coolant tank. A coolant pressure controller is in operative communication with each of the valve, an air pressure sensor, and a coolant temperature sensor. The coolant pressure controller is structured to determine a target coolant pressure based on a coolant temperature and control a valve position of the valve so as to cause the air pressure to approach the target coolant pressure.

Abstract: A waste heat recovery system includes a Rankine cycle (RC) circuit having a pump, a boiler, an energy converter, and a condenser fluidly coupled via conduits in that order, to provide additional work. The additional work is fed to an input of a gearbox assembly including a capacity for oil by mechanically coupling to the energy converter to a gear assembly. An interface is positioned between the RC circuit and the gearbox assembly to partially restrict movement of oil present in the gear assembly into the RC circuit and partially restrict movement of working fluid present in the RC circuit into the gear assembly. An oil return line is fluidly connected to at least one of the conduits fluidly coupling the RC components to one another and is operable to return to the gear assembly oil that has moved across the interface from the gear assembly to the RC circuit.

Abstract: A system includes an exhaust passage and a waste heat recovery system. The exhaust passage is structured to fluidly couple to an exhaust manifold of an engine, and to receive exhaust gas from the engine. The waste heat recovery system includes a working fluid circuit, a superheater, and an expander. The working fluid circuit includes a pump to circulate a working fluid through the working fluid circuit, including through the engine. Heat is transferred from the engine to the working fluid. The superheater is positioned along the working fluid circuit downstream of the engine. The superheater is fluidly coupled to the exhaust passage and transfers heat from the exhaust gas to the working fluid. The expander is positioned along the working fluid circuit downstream of the superheater. The expander generates useful energy from the heat transferred to the working fluid from the exhaust gas and the engine.

Abstract: Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.

Abstract: This disclosure relates to a waste heat recovery (WHR) system and method for regulating exhaust gas recirculation (EGR) cooling, and more particularly, to a Rankine cycle WHR system and method, including a recuperator bypass arrangement to regulate EGR exhaust gas cooling for engine efficiency improvement and thermal management. This disclosure describes other unique bypass arrangements for increased flexibility in the ability to regulate EGR exhaust gas cooling.

Abstract: A Rankine cycle waste heat recovery system uses a receiver with a maximum liquid working fluid level lower than the minimum liquid working fluid level of a sub-cooler of the waste heat recovery system. The receiver may have a position that is physically lower than the sub-cooler's position. A valve controls transfer of fluid between several of the components in the waste heat recovery system, especially from the receiver to the sub-cooler. The system may also have an associated control module.

Abstract: The disclosure describes a non-condensable gas collection, detection, and removal system for a WHR system that helps to maintain cycle efficiency of the WHR system across the life of an engine system associated with the WHR system. A storage volume is configured to collect non-condensable gas received from the working fluid circuit, and a release valve is configured to selectively release non-condensable gas contained within the storage volume.