Charging the Internal Combustion Engine (Powertrain) - Automobiles Repair Manuals, Workshop Manuals, Special Tools

Book Description:

The book focuses on all aspects of supercharging internal combustion engines. Charging systems and components, the theoretical basic relations between engines and charging systems as well as layout and evaluation criteria for best interaction are addressed in detail.
Recent experiences in design and development of supercharging systems, improved graphical presentations and most advanced calculation and simulation tools are described.
The book is prepared for students enrolled in mechanical engineering courses on the one hand, and for research-, development- and application-engineers, specialised in the field of supercharging systems for combustion engines, on the other leading to improved knowledge about benefits and problems of supercharging and providing help and tips for application engineers to design, optimise and develop supercharged internal combustion engines.
A large number of selected examples as well as an outlook on possible future developments of supercharging systems finally close the book.

Symbols, indices and abbreviations XII
Introduction and short history of supercharging
1 Basic principles and objectives of supercharging
5 Interrelationship between cylinder charge and cylinder work as well as between charge mass flow and engine power output 5
Interrelationship between cylinder charge and cylinder work 5
Interrelationship between charge mass flow and engine power output 6
Influence of charge air cooling 8
Definitions and survey of supercharging methods 9
Supercharging by means of gas dynamic effects 9
Intake manifold resonance charging 9
Helmholtz resonance charging 11
Supercharging with supercharging units 13
Charger pressure-volume flow map 13
Displacement compressor 14
Turbo compressor 15
Interaction between supercharger and internal combustion engine 17
Pressure-volume flow map of the piston engine 17
Interaction of two- and four-stroke engines with various superchargers 20
Thermodynamics of supercharging 23
Calculation of charger and turbine performance 23
Energy balance of the supercharged engines' work process 24
Engine high-pressure process 24
Gas exchange cycle low-pressure processes 24
Utilization of exhaust gas energy 25
Efficiency increase by supercharging 26
Characteristic values for the description of the gas exchange and engine efficiencies 26
Influencing the engine's total efficiency value via supercharging 30
Influence of supercharging on exhaust gas emissions 31
Gasoline engine 33
Diesel engine 33
Methods for exhaust gas aftertreatment 34
Thermal and mechanical stress on the supercharged internal combustion engine 34
Thermal stress 34
Mechanical stress 35
Modeling and computer-aided simulation of supercharged engines 36
Introduction to numeric process simulation 36
Cycle simulation of the supercharged engine 37
Numeric 3-D simulation of flow processes 48
Numeric simulation of the supercharged engine in connection with the user system 49
Mechanical supercharging 51
Application areas for mechanical supercharging 51
Energy balance for mechanical supercharging 52
Control possibilities for the delivery flow of mechanical superchargers 53
Four-stroke engines 53
Two-stroke engines 55
Designs and systematics of mechanically powered compressors 55
Displacement, compressors 55
Turbo compressors 59
Exhaust gas turbocharging 60
Objectives and applications for exhaust gas turbocharging 60
Basic fluid mechanics of turbocharger components 60
Energy transfer in turbo machines 60
Compressors 61
Turbines 65
Energy balance of the charging system 74
Matching of the turbocharger 75
Possibilities for the use of exhaust energy and the resulting exhaust system design 75
Turbine design and control 82
Compressor design and control 89
Layout and optimization of the gas manifolds and the turbocharger components by means of cycle and CFD simulations 92
Layout criteria 92
Examples of numeric simulation of engines with exhaust gas turbocharging 97
Verification of the simulation 101
Special processes with use of exhaust gas turbocharging 105
Two-stage turbocharging 105
Controlled two-stage turbocharging 106
Register charging 108 Single-stage register charging 108
Two-stage register charging 110
Turbo cooling and the Miller process 113
Turbo cooling 113
The Miller process 114
Turbocompound process 116
Mechanical energy recovery 117
Electric energy recovery 119
Combined charging and special charging processes 121
Differential compound charging 121
Mechanical auxiliary supercharging 122
Supported exhaust gas turbocharging 124
Comprex pressure-wave charging process 125
Hyperbar charging process 128
Design of combined supercharging processes via thermodynamic cycle simulations 129
Performance characteristics of supercharged engines 133
Load response and acceleration behavior 133
Torque behavior and torque curve 134
High-altitude behavior of supercharged engines 135
Stationary and slow-speed engines 137
Generator operation 138
Operation in propeller mode 139
Acceleration supports 140
Special problems of turbocharging two-stroke engines 141
Transient operation of a four-stroke ship engine with register charging 143
Operating behavior of supercharged engines in automotive applications 144
Requirements for use in passenger vehicles 144
Requirements for use in trucks 145
Other automotive applications 146
Transient response of the exhaust gas turbocharged engine 146
Passenger car application 147
Truck application 148
Exhaust gas turbocharger layout for automotive application 151
Steady-state layout 151
Transient layout 154
Numerical simulation of the operating behavior of the engine in interaction with the total vehicle system 158
Special problems of supercharged gasoline and natural gas engines 159
Knocking combustion 159
Problems of quantity control 161
Charger control intervention and control philosophies for fixed-geometry and VTG chargers 162
Basic problems of exhaust gas turbocharger control 162
Fixed-geometry exhaust gas turbochargers 163
Control interaction possibilities for stationary operating conditions 163
Transient control strategies 166
Part-load and emission control parameters and control strategies 170
Exhaust gas turbocharger with variable turbine geometry 173
General control possibilities and strategies for chargers 173
Control strategies for improved steady-state operation 173
Control strategies for improved transient operation 175
Special control strategies for increased engine braking performance 177
Special problems of supercharged gasoline and natural gas engines 179
Schematic layout of electronic waste gate and VTG control systems 179
Evaluation of VTG control strategies via numerical simulation models 181
Instrumentation for recording the operating data of supercharged engines on the engine test bench 184
Measurement layout 185
Engine torque 185
Engine speed 186
Turbocharger speed 187
Engine air mass flow 188
Fuel mass flow 189
Engine blowby 189
Pressure and temperature data 189
Emission data 191
Mechanics of superchargers 194
Displacement compressors 194
Housing and rotors: sealing and cooling 194
Bearing and lubrication 195
Exhaust gas turbochargers 195
Small chargers 195
Housing: design, cooling and sealing 195
Rotor assembly: load and material selection 198
Bearing, lubrication, and shaft dynamics 199
Production 200
Large chargers 202
Design, housing, cooling, sealing 202
Rotor assembly 205
Production 207
Charge air coolers and charge air cooling systems 208
Basics and characteristics 208
Design variants of charge air coolers 209
Water-cooled charge air coolers 211
Air-to-air charge air coolers 212
Full-aluminum charge air coolers 212
Charge air cooling systems 213
Outlook and further developments in supercharging 215
Supercharging technologies: trends and perspectives 215
Development trends for individual supercharging systems 215
Mechanical chargers 215
Exhaust gas turbochargers 216
Supercharging systems and combinations 217
Summary 221
Examples of supercharged production engines 222
Supercharged gasoline engines 222
Passenger car diesel engines 233
Truck diesel engines 242
Aircraft engines 245
High-performance high-speed engines (locomotive and ship engines) 245
Medium-speed engines (gas and heavy-oil operation) 248
Slow-speed engines (stationary and ship engines) 251
Appendix 255
References 259
Subject
Index 265