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1

Design of the turbocharger bearing arrangement to increase the overall efficiency of the combustion engine

Sroka Zbigniew, Prakash Srinath, Włostowski Radoslaw

Combustion Engines

|

2022

|

R. 61, nr 1

83--89

EN

The main objective of this study was to design a journal bearing, such that it can withstand the forces that arise in context to increasing the length of the shaft in an automotive turbocharger. The work will also provide information on how the design changes affect the overall performance of the bearing. The design changes include the thickness of the oil film, the number of grooves, the dimension of the grooves, the number of inlets and outlets, the dimension of the babbitt and mainly the length of the journal bearing. The simulation models were created using CATIA V5 and the analysis is done using ANSYS 19.2. The flow is considered to be laminar and is calculated using Reynold’s Equation. The new concept gave insight on how the design considerations affect the pressure distribution and the pressure developed. From the results, it was interpreted that the new design can withstand the four times the pressure while distributing the pressure over twice the original design.

2

Selected Issues of the Internal Combustion Engine Turbocharger Operation

Lotko Wincenty, Lechowski Marcin

Advances in Science and Technology. Research Journal

|

2020

|

Vol. 14, no 2

223--232

EN

A combustion engine turbocharger works in most difficult conditions due to high temperatures of the fuels it is driven by, vibrations and high rotational speeds of its shaft up to 200 thousand rpm. In addition, under these conditions, there are difficulties with lubrication of the blade axes. Thus, the combustion engine turbocharger is exposed to the damages occurring during the engine operation process. The frequency of damages was determined on the basis of tests for a selected group of vehicles. The object of detailed author’s own research was the Audi 3.0 V6 TDI engine of the Audi A6 C6 car which cooperated with a Borg Warner turbocharger with a variable angle of turbine steering wheel blades. These positioners are also exposed to adverse conditions: mainly vibrations and high temperatures. They are subjected to frequent damages, which often affect the engine control parameters. An analysis of the positioner element damage as well as a group of testers to assess their technical condition was made. The evaluated testers were allowed only to determine the efficiency of the turbocharger, but without indicating its technical condition or its positioner separately. Consequently, the author’s own research methodology and the construction of a new tester for the electromechanical turbocharger adjuster was developed. The necessary tests for the vehicle mileage up to 350,000 km were carried out. The self-designed tester can also estimate the degree of electromechanical wear of the positioner in the engine supercharging system as well as the resistance of its movements resulting from the pollution of the VTG turbocharger mechanism with the turbine steering wheel positioner, with variable geometrical parameters.

3

Analysis of shaft wear in turbocharges of automotive vehicles

Hadryś Damian, Bąkowski Henryk, Stanik Zbigniew, Kubik Andrzej

Transport Problems

|

2019

|

T. 14, z. 3

85--95

EN

The article presents the results of the investigations of turbocharger shaft bearing using different kinds of lubrication conditions (dry friction and lubrication with different kind of oils). In particular, the wear of the turbocharger shaft surface was evaluated. One of the most frequent failures is the seizure of the turbocharger shaft in the slide bearing, causing its rotation, which leads to destruction of the assembly and costly repairs. On the basis of the conducted tests, it was found that the average value of representative breaks surface on the turbocharger shaft are reduced using of a less viscous oil. Similar situation was seen using new oil instead overworked oil – it had an influence on the value of diameter of breaks.

4

Turbocharging the aircraft two-stroke diesel engine

Karpiński Paweł, Pietrykowski Konrad, Grabowski Łukasz

Combustion Engines

|

2019

|

R. 58, nr 3

112--116

EN

The power and efficiency of a two-stroke engine strongly depends on the efficiency of the scavenging process which consists in removing the rest of the exhaust gases from the cylinder and filling it with a fresh charge. The quality of the charge exchange process is significantly influenced by the construction of the intake system. The paper presents a zero-dimensional model of the aircraft two-stroke opposed-piston diesel engine with two variants of the intake system: with a mechanical compressor and a turbocharger connected in series with a mechanical compressor. Simulation studies of the developed cases were carried out in the AVL BOOST software. For the defined engine operating points, its performance was compared for different designs of the intake system. It was confirmed that the use of a turbocharger with a mechanical compressor extends the range of operating at high altitudes.

5

Optimization of diesel engine dynamics with electronic boost controller

Hanko Branislav, Morgos Jan, Drgoňa Peter, Dobrucký Branislav

Autobusy : technika, eksploatacja, systemy transportowe

|

2019

|

R. 20, nr 1-2

372--374

EN

This paper dals with design of optimized electronic control for diesel engines for all-terrain vehicles. In paper the detailed proposal of control algorithm, as well as procedure for turbocharger innovation is described. Designed optimization algorithm is verified on real Land Rover Defender vehicle. In last part of paper, the measurements on electrodynamic dynamometer are discussed.

PL

Niniejszy dokument przedstawia projekt zoptymalizowanego sterowania elektronicznego dla silników wysokoprężnych do pojazdów terenowych. W pracy opisano szczegółową propozycję algorytmu sterowania, a także procedurę dotyczącą innowacji turbosprężarki. Zaprojektowany algorytm optymalizacyjny jest weryfikowany na prawdziwym pojeździe Land Rover Defender. W ostatniej części artykułu omówiono pomiary elektrodynamicznego dynamometru.

6

Investigating the Effects of Variable Valve Timing on Spark Ignition Engine Performance

Bapiri Sepehr, Sorusbay Cem

Advances in Science and Technology. Research Journal

|

2019

|

Vol. 13, no 2

100--111

EN

In this study, a prototype four-stroke spark ignition engine with four cylinders (two valves per cylinder), with and without turbocharger, as well as variable valve timing system to adjustment of variable valve duration has been investigated. This study covers the effects of intake valve opening (IVO), Intake valve closing (IVC), exhaust valve opening (EVO) and exhaust valve closing (EVC) angles on engine performances and fuel economy. The calculations of engine performance were carried out using the 1-Dimensional simulation with AVL BOOST software. The effects of different valve timing strategies and a combination of them from simulations were analyzed and compared with the reference fixed valve timing cases. It was shown that substantial improvements in fuel consumption and performance can be achieved. The improvements of Indicated Specific Fuel Consumption (ISFC) are remarkable in turbocharged models. Furthermore, we can see the noticeable improvements in torque and power in the naturally aspirated engine.

7

Reliability Assessment of Main Engine Subsystems Considering Turbocharger Failure as a Case Study

Anantharaman M., Khan F., Garaniya V., Lewarn B.

TransNav : International Journal on Marine Navigation and Safety of Sea Transportation

|

2018

|

Vol. 12, no. 2

271--276

EN

Safe operation of a merchant vessel is dependent on the reliability of the vessel’s main propulsion engine. Reliability of the main propulsion engine is interdependent on the reliability of several subsystems including lubricating oil system, fuel oil system, cooling water system and scavenge air system. Turbochargers form part of the scavenge sub system and play a vital role in the operation of the main engine. Failure of turbochargers can lead to disastrous consequences and immobilisation of the main engine. Hence due consideration need to be given to the reliability assessment of the scavenge system while assessing the reliability of the main engine. This paper presents integration of Markov model (for constant failure components) and Weibull failure model (for wearing out components) to estimate the reliability of the main propulsion engine. This integrated model will provide more realistic and practical analysis. It will serve as a useful tool to estimate the reliability of the vessel’s main propulsion engine and make efficient and effective maintenance decisions. A case study of turbocharger failure and its impact on the main engine is also discussed.

8

Analiza wytrzymałościowa elementów wirujących z wykorzystaniem technologii skanowania 3D

Andrearczyk A., Bagiński P.

Przegląd Mechaniczny

|

2018

|

nr 9

43--45

PL

W artykule zaprezentowano analizę wytrzymałościową tarczy wirnikowej wykonanej z tworzywa sztucznego. Opisano w nim wykonanie modelu tarczy kompresora za pomocą skanera 3D oraz zaprezentowano błędy powstałe podczas tworzenia siatki na modelu utworzonym przy wykorzystaniu tej technologii. Zaprezentowano także wyniki analizy wytrzymałościowej dla zaproponowanych poprawek modelu zeskanowanej tarczy wirnikowej.

EN

In this work strength analysis of made of plastics rotor disk was presented. The first part of the article describes the implementation of research model using a 3D scanner. The next part is devoted to present the errors which occurred during mesh creation on the model created from above-mentioned technology. The last chapters present the results of the strength analysis after the proposed mesh corrections of the scanned rotor disk was used.

9

Test stand for the experimental investigation of turbochargers with 3d printed components

Andrearczyk A., Bagiński P., Żywica G.

Mechanics and Mechanical Engineering

|

2018

|

Vol. 22, nr 2

397--404

EN

The paper discusses the universal test stand which allows determining the characteristics of turbochargers. Currently, there are works carried out in the world aimed to develop innovative fluid-flow machines, made partly with the use of rapid prototyping technology. This type of manufacturing technology allows reducing production time and costs in comparison to conventional methods of prototyping. This article also discusses start-up tests of the experimental test stand using a commercial turbocharger and the comparison between calculated and experimental results. In this paper, there are also described some modifications of the test stand, made prior to the start-up test, which were necessary to get more accurate characteristics of turbochargers. This work is an introduction to the investigation on turbomachines, whose elements were manufactured using the rapid prototyping technology.

10

Improving risk analysis capability of FMEA using evaluation based on distance from average solution (EDAS): a case study of turbocharger system

Emovon I.

Journal of Mechanical and Energy Engineering

|

2018

|

Vol. 2, No 1

13--16

EN

Failure Mode and Effect Analysis (FMEA) is a key risk management tool used in detecting and eradicating potential failure for the purpose of improving the reliability and safety of a system. However, the traditional FMEA in spite of its popularity has inadequacies that have hindered the effectiveness of the tool in analyzing risk of failure modes. Due to the shortcomings of the technique, different improved versions have been suggested in the literature in order for risk to be analysed more effectively but majority of these versions are computationally challenging. In this paper, a simple approach is in troduced for improving the risk analysis capability of the FMEA. The approach utilizes Evaluation based on Distance from Average Solution (EDAS) as an alternative to RPN of FMEA in analyzing risk of failure. A case study of the turbocharger system of a diesel engine is applied to demonstrate the usefulness of the method. The result obtained from the EDAS method were compared with approaches in the literature previously used to address risk analysis of a turbo charger. The result of the analysis indicated that the EDAS method is a feasible alternative technique for risk analysis.

11

Evaluation of the possibility of occurrence of selected damage to a car engine turbocharger using the event tree analysis (ETA)

Bor M., Karpiuk W., Smolec R., Spadło M.

Journal of KONES

|

2018

|

Vol. 25, No. 3

71--76

EN

The subject of the article is the identification of factors behind the incorrect operation of a car turbocharger that, in longer perspective, lead to the damage of the device. Due to the operating principle and design features, the device works with many engine systems – intake, exhaust, lubrication systems and also, increasingly more often, with the cooling system. A multitude of relations, complexity, and working conditions are reasons due to which the device is sensitive to disturbances of quality parameters of the working media (e.g. oil). In the article based on the selected causes of damage of turbochargers, we focused on the following initiating event, concerning the bearings lubrication system, which is clogged oil strainer. The authors aims at performing an analysis allowing to increase the detectability of emerging malfunctions that lead to deterioration of operating conditions of the device. For this task tool such as ETA (Event Tree Analysis) was used. It is a tool for assessing system and process safety. It facilitates detecting potential risks, as well as relations existing between actions or events. This method explores the path from the initiating event to the outcome (most often representing the immobilization of the tested object), with particular emphasis on intermediate stages affecting the technical condition of the object. Unlike the FTA analyses, which have a deductive nature, the ETA analysis is inductive. The analysis of the obtained results, supported with validation by means of ETA, allowed proving that, given the current state of knowledge and advancements in technology, it is possible to apply additional sensors for monitoring the operation of a turbocharger. The proposed modifications were considered minor design changes that significantly increase the reliability of the device.

12

The Use of Plastic Working Alloys Feal to Perform Controls Elements of Turbocharger in Diesel Engine

Cebulski J., Pasek D.

Archives of Metallurgy and Materials

|

2018

|

Vol. 63, iss. 3

1423--1427

EN

Operating conditions turbocharger (high temperature and corrosive environment) mean that the device is classified into one of the most elements of the emergency drive unit of the car. The failure rate can be reduced through the use of modern heat-resistant materials, which include based alloys FeAl intermetallic phase. Intermetallic alloys belong to the group of materials known as prospective due to their advantageous properties, in particular their high specific strength, high melting point and good resistance to corrosion and oxidation at high temperatures. In the article presented results of the research axis roll control system variable geometry blades made of intermetallic alloy Fe40Al5Cr0,2TiB as a substitute so far made of austenitic steel. A verification service conditions, comparing the degradation of the material previously used by manufacturers of turbochargers for elements of the control system degradation axes made of intermetallic alloy Fe40Al5Cr0,2TiB. The study consisted of determining microstructure and corrosion products after use. Observations of the structure and the surface of the corrosion tests were performed using light microscopy, scanning electron microscopy and X-ray microanalysis EDS chemical composition.

13

Modelling and testing of dynamic properties of C0-45 turbochargers

Budzik G., Mazurkow A.

Zeszyty Naukowe. Transport / Politechnika Śląska

|

2017

|

z. 97

17--25

EN

The paper presents modelling process and results of the bench tests of the C0-45, which is a turbocharger for heavy-duty diesel engines. For turbochargers like this, it is necessary to measure the level of vibration. This paper presents the test results for 115 turbochargers. Rotor speed during the tests varied between 25,000 and 42,000 rpm. Rotor speed during the tests on a C0-45 turbocharger varied within three ranges, i.e., Range I: n=25,000÷32,000 rpm and a=0.5g; Range II: n=33,000÷38,000 rpm and a=1.0g; Range III: n=39,000÷42,000 rpm and a=1.5g; (g=9.81m/s2). Measurement of vibrations was realized by a sensor located on the body of the turbocharger. Bench tests also included measurement of key charge parameters such as the amount of mass trapped, mean flow velocities, turbulence level, gas pressure, temperature and oil flow. The results are presented in the form of diagrams showing the amplitude of the acceleration function with regard to the rotor’s RPM. Research shows that using the correct parameters in construction and technological processes of assembly are very important for the effective functioning turbochargers.

14

Badania eksperymentalne na stanowisku wyznaczania charakterystyk turbosprężarek

Andrearczyk A., Bagiński P.

Przegląd Mechaniczny

|

2017

|

nr 6

60--62

PL

W artykule zaprezentowano stanowisko badawcze wraz z układem pomiarowym, służące do wyznaczania charakterystyk turbosprężarek. Pierwszą część artykułu poświęcono opisowi stanowiska badawczego oraz jego przydatności do badań innowacyjnych turbosprężarek. Kolejna część dotyczyła układu pomiarowego wraz z aplikacją do monitorowania i akwizycji wartości mierzonych opracowaną w środowisku LabView. W ostatniej części przedstawiono test aplikacji oraz wstępne wyniki z badań rozruchowych stanowiska na komercyjnej turbosprężarce.

EN

The article presents a test rig for dynamic testing of turbochargers. It is equipped with a measurement system. In the first part of the article, the test rig is discussed in terms of its usability for testing innovative turbochargers. The next part is devoted to the measurement system and an application - created in the LabView environment - used for control and acquisition of data. The last part of the article presents the findings of a usability test of the application and preliminary results of the start-up of a commercially available turbocharger.

15

Improvement of BSFC and effective NOx and PM reduction by high EGR rates in heavy duty diesel engine

Aoyagi Y.

Combustion Engines

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2017

|

R. 56, nr 4

4--10

EN

The test engine was a turbocharged 10.5L engine with an intercooler. A performance target was set at a rated power of 300 kW (BMEP = 1.7 MPa) and peak torque of 1842 Nm (BMEP = 2.2 MPa). Emission targets were set at a level of near future and stringent regulation standards in Japan. The engine was equipped with new technologies such as a high pressure common rail system, FCD piston, a high pressure ratio VGT and an aftertreatment system. The high and low pressure loop EGR system was installed and this system with a VGT had a high performance and could increase an EGR rate in order to reduce BSNOx while maintaining the satisfied BSFC and PM performance simultaneously not only in the steady state condition but also in the transient condition.

16

Comparison of two measurement methods for the determination of extended turbine maps at the eATL test bench of the Ostfalia UAS

Vanhaelst R., Bannack C., Klose M.

Combustion Engines

|

2017

|

R. 56, nr 2

43--48

EN

This document compares two measurement methods for the determination of extended turbine maps. One method is to minimize heat flows and thus to maintain the assumption of adiabatic processes even in low speed ranges of turbines. The results obtained were compared with those of the Ostfalia eATL method. Here, is slowed down electrically by an electric motor. The direct comparison of the measurement results shows considerable differences in the turbine efficiency. Furthermore, the graphical comparison illustrates clear advantages of the eATL concept for the evaluation, which result from the width and the position of the generated measurement points.

17

Operational malfunctions of turbochargers – reasons and consequences

Dziubak T., Karczewski M.

Combustion Engines

|

2016

|

R. 55, nr 1

13--21

EN

The paper discusses the most frequently occurring types of damage in turbochargers fitted in modern combustion engines and their influence on the engine basic operational indexes. The following causes of turbocharger malfunctions have been discussed: no lubrication, low lubricant pressure, reduced lubricant quality, foreign objects in the charged air and in the exhaust gas. Example malfunctions resulting from the said causes have been shown. The experimental part discusses the influence of a reduction of the charging pressure resulting from a leakage in the intake system on the effective parameters of a diesel engine fitted in light-duty and heavy-duty vehicles. The leakage in the intake system has been simulated by boring holes of the diameter of 3 and 12 mm in the intake manifold downstream of the turbocharger. The influence has been determined of the leakage of the turbocharging system on the value of the charging pressure, maximum effective power, engine torque, unit and hourly fuel consumption and the concentration of the exhaust components. A significant impact has been observed of the leakage of the turbocharging system on the effective parameters of the tested diesel engine and exhaust gas composition.

PL

W artykule wskazano najczęściej występujące uszkodzenia turbosprężarek stosowanych we współczesnych silnikach spalinowych oraz przedstawiono ich wpływ na podstawowe wskaźniki operacyjne silników. Omówiono takie niesprawności turbosprężarek, jak: brak smarowania lub zbyt małe ciśnienie czynnika smarującego, jakość oleju smarującego, obecność ciał obcych w powietrzu i w spalinach. Przedstawiono przykładowe niesprawności spowodowane poszczególnymi czynnikami. W części doświadczalnej oceniono wpływ zmniejszenia ciśnienia doładowania spowodowanego nieszczelnością układu dolotowego na parametry użyteczne silnika o zapłonie samoczynnym, stosowanego w samochodach dostawczych oraz osobowych. Nieszczelność układu dolotowego została zamodelowana przez wykonanie otworów o średnicy 3 i 12 mm w kolektorze dolotowym za turbosprężarką. Określono wpływ nieszczelności układu doładowania na wartość ciśnienia doładowania, maksymalną moc użyteczną, moment obrotowy silnika, jednostkowe i godzinowe zużycie paliwa oraz stężenie składników toksycznych w spalinach. Stwierdzono istotny wpływ nieszczelności układu doładowania na parametry użyteczne i skład spalin silnika o zapłonie samoczynnym.

18

A systematic analysis of the friction losses on bearings of modern turbocharger

Vanhaelst R., Kheir A., Czajka J.

Combustion Engines

|

2016

|

R. 55, nr 1

22--31

EN

In the article, a novel test rig for determining the friction losses of modern turbocharger is presented. The friction torque of the bearing of turbocharger can be measured direct and stationary at any speed up to 100,000 min–1 by the friction test rig developed by the Ostfalia, University of Applied Science (UAS). Since 2010, over 50 turbochargers were measured on the test bench in extensive measurement series. The results give valuable and new insights of the influence of the next parameters on the bearing friction losses: oil temperature, oil pressure, thrust force and oil flow rate. Furthermore, a comparison between the different bearing types (semi-floating, full floating and ball bearings) was performed. The main observations and results are discussed in the scientific article.

19

Stanowisko badawcze do pomiarów wybranych parametrów eksploatacyjnych turbosprężarki silnika spalinowego

Gustof P., Hornik A.

Autobusy : technika, eksploatacja, systemy transportowe

|

2016

|

R. 17, nr 12

975--978

PL

W artykule omówione zostało stanowisko badawcze do wykonywania pomiarów eksploatacyjnych turbosprężarki zamontowanej w samochodzie marki Fiat Croma z silnikiem 1,9 TD. Stanowisko umożliwiać będzie m.in. pomiar ciśnienia i temperatury oleju silnikowego dla wybranych stanów jego pracy.

EN

The article has been discussed a research station which was made to measure of exploitation parameters of a turbocharger mounted in the car Fiat Croma with an engine 1,9 TD. The station will allow, among others, at the measure the pressure and temperature of the engine oil with the selected conditions of its work.

20

Krytyczna analiza metod napraw turbosprężarek samochodowych

Lotko W., Longwic R., Górski K., Sander Przemysław, Durczak T.

TTS Technika Transportu Szynowego

|

2015

|

R. 22, nr 12

2468--2471, CD

PL

W artykule przedstawiono analizę w zakresie metod napraw turbosprężarek samochodowych. Opisano i omówiono objawy typowych uszkodzeń oraz proces regeneracji turbosprężarek. Bazowano na danych zebranych z praktyki reklamacyjnej i szkoleniowej wiodącej firmy zajmującej się regeneracją turbosprężarek.

EN

The article presents an analysis of automotive turbochargers repair methods. Described and symptoms typical of the damage and the process of regeneration of turbochargers. It was based on data collected from practice complaint and training market leading regenerator turbochargers.