14th International Conference on Turbochargers and Turbocharging: Proceedings of the International Conference on Turbochargers and Turbocharging (London, Uk, 2021) 9780367676452, 9781003132172, 0367676451

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14TH INTERNATIONAL CONFERENCE ON

The contributions focus on the development of air management solutions and waste heat recovery ideas to support thermal propulsion systems leading to high thermal efficiency and low exhaust emissions. These can be in the form of internal combustion engines or other propulsion technologies (e.g. Fuel cell) in both direct drive and hybridised configuration. 14th International Conference on Turbochargers and Turbocharging also provides a particular focus on turbochargers, superchargers, waste heat recovery turbines and related air managements components in both electrical and mechanical forms.

TURBOCHARGERS AND TURBOCHARGING

14th International Conference on Turbochargers and Turbocharging addresses current and novel turbocharging system choices and components with a renewed emphasis to address the challenges posed by emission regulations and market trends.

Institution of Mechanical Institution Of Mechanical Engineers 1 Birdcage Walk Westminster London SW1H 9JJ

14TH INTERNATIONAL CONFERENCE ON TURBOCHARGERS AND TURBOCHARGING

Engineers

T: +44 (0)20 7973 1251 F: +44 (0)20 7304 6845 E: [email protected]

Institution of Mechanical Engineers

www.imeche.org/events

ISBN: 978­0­367­54652­6

9 780367 546526

A BALKEMA BOOK

TURBOCHARGERS AND TURBOCHARGING XIV

TURBOCHARGERS AND TURBOCHARGING XIV. PROCEEDINGS OF THE INTERNATIONAL CONFERENCE ON TURBOCHARGERS AND TURBOCHARGING (LONDON, UK, 2021)

TURBOCHARGERS AND TURBOCHARGING XIV

Edited by Institution of Mechanical Engineers

CRC Press/Balkema is an imprint of the Taylor & Francis Group, an informa business Typeset by Integra Software Services Pvt. Ltd., Pondicherry, India The Open Access version of this book, available at www.taylorfrancis.com has been made available under a Creative Commons Attribution-Non CommercialNo Derivatives 4.0 license. Published by: CRC Press/Balkema Schipholweg 107C, 2316XC Leiden, The Netherlands e-mail: [email protected] www.routledge.com – www.taylorandfrancis.com ISBN: 978-0-367-67645-2 (Hbk)

ISBN: 978-1-003-13217-2 (eBook)

DOI: 10.1201/9781003132172

https://doi.org/10.1201/9781003132172

4

Turbochargers and Turbocharging XIV – Institution of Mechanical Engineers, ISBN: 978-0-367-67645-2

Table of Contents Organising Committee

ix

Design and evaluation of an active inlet swirl control device for automotive turbocharger compressors Charles Stuart, Stephen Spence, Queen’s University Belfast Sönke Teichel, Andre Starke, IHI Charging Systems International GmbH Steady-state CFD calculation of a complete turbocharger radial turbine performance map: Mass flow rate and efficiency Georges Salameh, Pascal Chesse, David Chalet, Pierre Marty, Ecole Centrale de Nantes Aerodynamic design of a fuel cell compressor for passenger car application Hua Chen, Dalian Maritime University Lei Huang, Kai Guo, Koen Kramer, Zeyu Zhang, Great Wall Motors Design and validation of a pulse generator for the pulse shaping of the turbine inlet pressure at the hot-gas test bench Philipp Nachital, Henning Rätz, Joerg Seume, Leibniz University Hannover, Institute of Turbomachinery and Fluid Dynamics Holger Mai, Kratzer Automation AG 1D gas exchange modelling of double scroll turbines: Experimental validation and improved modelling Tetsu Suzuki, Georgios Iosifidis, Jörg Starzmann, Dietmar Filsinger, IHI Charging Systems International GmbH Wataru Sato, Takahiro Bamba, IHI Corporation Study on analytical method for thermal and flow field of a VG turbocharger Tsuyoshi Kitamura, Toru Suita, Toyotaka Yoshida, Mitsubishi Heavy Industries Yosuke Danmoto, Yoji Akiyama, Mitsubishi Heavy Industries Engine & Turbocharger

V

1

15

32

48

62

81

One dimensional modelling on twin-entry turbine: An application of TURBODYNA Bijie Yang, Ricardo Martinez-Botas, Peter Newton, Imperial College London Toru Hoshi, Bipin Gupta, Seiichi Ibaraki, Mitshubishi Heavy Industries A system-level study of an organic Rankine cycle applied to waste heat recovery in light-duty hybrid powertrains Antonio Pessanha, Colin Copeland, University of Bath Zhihang Chen, Jaguar Land Rover

97

113

Designing a bespoke high efficiency turbine stage for a key engine condition through pulse utilisation Craig Hasler, Cummins Turbo Technologies

131

Development and validation of a high-pressure compressor stage Robert Lotz, BorgWarner Emissions

149

The smallest CV VNTTM developed for Euro VI+ & Japan PPNLT light duty commercial applications with extreme braking Shuichi Ikeda, Ondrej Senekl, Vinaey Kalyanaraman, Garrett – Advancing Motion

163

Integrated design optimisation and engine matching of a turbocharger radial turbine Piotr Luczynski, Carola Freytag, Manfred Wirsum, Institute of Power Plant Technology, Steam and Gas Turbines, RWTH Aachen Karl Hohenberg, Ricardo Martinez-Botas, Imperial College London Maximum turbocharger efficiency for an engine operating at 50% brake thermal efficiency Parasharan Ananthakrishnan, Seán Egan, Jamie Archer, Cummins Turbo Technologies Timothy Shipp, Cummins Research and Technology Transfer of turbocharger shaft motion behavior from engine testing to hot gas component testing Felix Falke, Adrian Schloßhauer, Hendrik Ruppert, Institute for Combustion Engines, RWTH Aachen University Max Stadermann, Dominik Lückmann, Richard Aymanns, FEV Europe GmbH

VI

174

191

204

Experimental investigation on the transient response of an automotive turbocharger coupled to an electrically assisted compressor Silvia Marelli, Vittorio Usai, Massimo Capobianco, University of Genoa Steady state and transient tuning of a driven turbocharger for commercial diesel engines Thomas Waldron, Ryan Sherill, Jared Brin, Super Turbo Technologies Development of new generation MET turbocharger Yushi Ono, Yoshikazu Ito, Mitsubishi Heavy Industries Marine Machinery and Equipment An approach to thermo-mechanical fatigue life prediction for turbine housings in gasoline engine application Hiroaki Nakai, Masahiro Takanashi, Hidenori Kojima, Kotaro Ito, IHI Corporation Multidisciplinary and multi-point optimisation of radial and mixed-inflow turbines for turbochargers using 3D inverse design method Jiangnan Zhang, Advanced Design Technology Mehrdad Zangeneh, University College London Experimental and computational analysis of the flow passing through each branch of a twin-entry turbine José Galindo, José Ramón Serrano, Luis Miguel García-Cuevas, Nicolás Medina, Universitat Politècnica de València Design and modelling of circular volutes for centrifugal compressors Hamid Hazby, Robert O’Donoghue, Chris Robinson, PCA Engineers SC-VNTTM a route toward high efficiency for gasoline engines Nathaniel Bontemps, David Francois, Juan Camillo Sierra, Peter Davies, Garrett – Advancing Motion Leandro Lazzarini Monaco, Alois Fuerhapter, AVL List GmbH

VII

219

230

242

252

263

278

289

302

Study on loss characteristic of penetrating exhaust manifold for low-speed two-stroke marine diesel engine Yingyuan Wang, Ruiqi Zhang, Mingyang Yang, Kangyao Deng, Shanghai Jiao Tong University Bo Liu, Yuehua Qian, China Shipbuilding Power Engineering Institute Co Heat transfer modelling in vehicular turbochargers for engine simulation Yoshiyuki Watanabe, Nobuyuki Ikeya, Shun Okamoto, IHI Corporation Dietmar Filsinger, IHI Charging System International GmbH Trends in passenger car powertrains and their impact on turbocharger developments Nick Baines, Consultant Eric Krivitzky, Dartmouth College Jiangtao Bai, Xuefeng Zhang, Xeca Turbo Technologies

313

326

341

360 Boosting the JCB Fastrac “World’s fastest tractor” Alex Skittery, JCB Power Systems Richard Cornwall, Richard King, Ricardo Automotive & Industrial Author index

379

Turbochargers and Turbocharging XIV – Institution of Mechanical Engineers, ISBN: 978-0-367-67645-2

Organising Committee Powertrains Systems and Fuels Group The Institution of Mechanical Engineers

Member Credits Ricardo Martinez-Botas (Chair)

Imperial College London

Peter Davies (Vice-Chair)

Garett – Advancing Motion

Jamie Archer

Cummins Turbo Technologies

Lutz Aurahs

MAN Energy Solutions

Alan Baker

Jaguar Land Rover

Kian Banisoleiman

Lloyd's Register EMEA

Andrew Banks

Ricardo

Dr Elias Chebli

Porsche

Colin Copeland

University of Bath

Michael Dolton

Cummins Turbo Technologies

Dietmar Filsinger

IHI Charging System Inter­ national GmbH

Dino Imhof

ABB Turbocharging

Steve Johnson

Ford Motor Company

Rogier Lammers

Mitsubishi Turbocharger and Engine Europe B.V.

IX

Per-Inge Larson

SCANIA Power Train Sweden

Nathan McArdle

BorgWarner

Takashi Mori

IHI Corporation

Takashi Otobe

Honda R&D

Prabhu Ramasamy

Caterpillar

Joerg Seume

Leibniz Universitaet Hannover

Stephen Spence

Queen's University Belfast

Bernd Wietholt

Volkswagen AG

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Turbochargers and Turbocharging XIV – Institution of Mechanical Engineers, ISBN: 978-0-367-67645-2

Design and evaluation of an active inlet swirl control device for automotive turbocharger compressors C. Stuart, S.W. Spence School of Mechanical and Aerospace Engineering, Queen’s University Belfast, UK S. Teichel, A. Starke IHI Charging Systems International GmbH, Heidelberg, Germany ABSTRACT It is widely accepted that large swirl angles (>60°) are required to deliver meaningful surge margin extension at the relatively low pressure ratios typical of automotive turbocharger compressors. However, in order to maintain performance towards choke (and hence the rated power point of the engine), the requirement is for delivery of zero pre-swirl. These constraints cannot be met using traditional variable inlet guide vane systems, as whether flat plate or cambered vanes are chosen, significant losses are to be expected at low and high mass flow rates respectively. Taking the above into account, the primary intention of this study was to develop a device capable of efficiently generating large swirl angles for surge margin extension and compressor efficiency enhancement at low mass flow operating points, without adversely affecting performance at other areas of the compressor map. The chosen concept involved placing an axial fan upstream of a standard automotive turbocharger compressor stage. The fan was designed to act as a variable pre-swirl device, which due to being driven by an electric motor, was capable of operating com­ pletely independently of the centrifugal impeller. The chosen concept was progressed through 1-D and 3-D design phases to understand the feasibility of the system, before committing to hardware manufacture and an extensive experimental test campaign to validate the numerical findings and test the surge margin extension potential of the device.

1

INTRODUCTION

In order to ensure compliance with the increasingly stringent emissions targets being levied by legislators around the world, the uptake of the concept of engine downsizing (as well as additional complementary technologies such as Miller valve timing) in the automotive sector is becoming increasingly prevalent. From the perspective of the turbocharger, these strategies place additional demands upon enhancing compressor performance and stability at low mass flow operating conditions. One approach to achieve this goal that is common in larger scale applications is the application of positive pre-swirl (introduction of a non-zero circumferential velocity component, Vu1, in the same direction as impeller rotation) at compressor inlet through the use of inlet guide vanes. For automotive turbocharging applications, the expected improvements can be summarised as follows. Firstly, improvements in com­ pressor efficiency can be expected at low mass flow rates due to the alleviation of inci­ dence based losses. One study utilising an automotive turbocharger compressor [1] cited up to a 3.0%pt improvement in efficiency at a pressure ratio of 2.5 through the application of pre-swirl. Secondly, the possibility to extend the compressor surge

1

margin is a particularly attractive benefit. However, due to the relatively modest pres­ sure ratios of automotive turbocharger compressors, it has been recognised that high levels of swirl are required to achieve a tangible improvement (60°-70° @ PR