History
INTRODUCTION: The power output of a naturally aspirated internal combustion engine can be increased either by enlarging the swept volume or by increasing the rotational speed. An increase in swept volume results in an engine which is larger and heavier and thereby more expensive. There are several limitations and disadvantages in increasing the engine speed, particularly on larger engines. An elegant solution is to increase the engine output by pressure charging, usually using an exhaust gas driven turbocharger. Use of exhaust gas turbochargers is increasing very rapidly to achieve not only fuel economy but also to control exhaust emissions. EXHAUST GAS TURBOCHARGER : Turbocharger normally comprises of a centrifugal compressor and a single stage gas turbine mounted on a common shaft. The turbine recovers part of the exhaust gas energy, thus driving the compressor. The compressor draws fresh air and delivers it under pressure to the engine. This results in a greater mass of air being delivered to the engine which allows more fuel to be burnt and the engine develops more power. A schematic diagram of a 4 cylinder turbocharged engine is shown in Fig 1.
Figure 1
with a
The size of the turbocharged engine is smaller than that of naturally aspirated engine of equal output.
The application range of an existing series of naturally aspirated engine can be extended to various power ranges with flexible matching of the turbocharger.
The high altitude power loss of turbocharged engine is significantly less than that of naturally aspirated engine.
The turbocharged engine has a reduced specific fuel consumption since part of the exhaust gas energy is utilized in the turbocharger. The turbocharged engine can be well adapted for control of exhaust emissions.
The turbocharged engine is quieter than a naturally aspirated engine for the same power.
ENGINE MATCHING OF EXHAUST GAS TURBOCHARGER Although the installation of a turbocharger on the engine is quite simple, the engine must fulfill certain pre-requisites. These are: Thermodynamic compatibility of the engine and the turbocharger over the the complete operational range of the engine. Based on the application of the engine the majority of the operating points (load speed characteristics) should lie in the efficient operating range of compressor and turbine characteristics. Mechanical integrity of the engine: The engine components must be able to withstand the thermal and mechanical stresses which are likely to be higher than the naturally aspirated engine. The objective in matching the turbocharger to an engine is to find the right combination of turbocharger compressor and turbine to suit the engine and its application. The prerequisite for a successful matching needs development of a number of compressor & turbine modules to cover all intended applications. This matching requires very close cooperation between the engine and turbocharger manufacturers. A view of the turbocharger for truck diesel engine and the characteristics of the engine super-imposed on the turbocharger compressor map are shown in Fig.1.
Types of Turbocharging
Pulse Turbocharging
The kinetic energy of the exhaust gas exiting from the cylinders is mostly recovered. The exhaust manifold will be bifurcated to join the cylinders, which do not interfere during gas exchange process. Turbine housing is divided to accept the exhaust pulse from each branch of the exhaust manifold. Better low speed engine performance
A Turbocharger consists of a compressor and a turbine connected by a common shaft. Centrifugal compressors and centripetal turbines are most popular types used in automotive applications and form the basis for most turbochargers today.
Compressor
The turbocharger centrifugal compressor has three essential components. Compressor wheel, diffuser and housing. With the rotational speed of the wheel, air is drawn in axially, accelerated to high velocity and then expelled in a radial direction. The diffuser slows down the high velocity air, so that both pressure and temperature rise. The housing collects the air and slows it down further before it reaches the compressor exit.
Compressor Map:
Turbine
The turbocharger turbine, which consists of a turbine wheel and turbine housing, converts the engine exhaust gas into mechanical energy to drive the compressor. The gas, which is restricted by turbine housing cross sectional area, results in a pressure and temperature drop between the inlet and the outlet. This pressure drop is converted by the turbine into kinetic energy to drive the turbine wheel. Single entry turbine housing Twin entry turbine housing Variable turbine geometry
Turbine Map
Control system
To meet the demands of the engine at low speeds, full boost pressure should be available. At the same time, at high speeds, this boost pressure needs to be controlled to achieve the required engine performance.
The turbine size is chosen to meet the low speed airflow requirements. Beyond certain speed, to control the boost pressure, part of the exhaust is bypassed. The waste gate opens or closes the bypass in response to the boost pressure, thus maintaining the boost pressure.
Torque-motor
DC motor
Conclusions
The application of Turbocharged engines diesel as well as petrol is on the increase world wide due to stringent emission norms and need for more efficient engines. This has been facilitated by the development of extremely small turbochargers as well as various control systems. This has led to better emission control and fuel economy
COMPRESSOR PERFORMANCE
TURBINE PERFORMANCE
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Atlas Copco make ZE4 VSD 0.218 to 0.812 m3 /s 3.5 bar (g)
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Intercooler provision Flow Meter for Fuel flow measurement Smoke Meter AVL make
NVH Facilities for Noise and Vibration Analysis of Turbocharger and parts.
1. LMS - SCADAS System for Data acquisition
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