In the current research work, a computational analysis of a high-speed centrifugal compressor stage for turbocharger applications is presented. A detailed investigation about the interactions between backswept impeller and downstream vaneless and vaned diffusers is carried out. ' A unshrouded backswept impeller with splitters was combined with a vaneless diffuser or a number of different designs of vaned diffusers. The CFD solver CFX-TASCow was used. The three-dimensional Reynolds- Averaged Navier-Stokes equations are solved and a pressure correction method is employed to solve the system of equations. A steady simulation and analysis of the interactions between the impeller and the vaneless diffuser is carried out, emphasis is focused on the comparisons of the different interactions at different conditions regarding the flow structures at different radius ratios, effect of rotational speed, mass flow rate and impeller tip clearance. The predicted results were also compared with the available experimental results in terms of radial Velocity, tangential Velocity and flow angle. In general, the predicted results show a reasonable agreement with the experimental data. A steady state simulation and analysis regarding the interaction between the impeller and various vaned diffusers is carried out. For the interface between the rotational impeller outlet and the stationary vaned diffuser inlet, the stage averaging condition is used. A detailed comparison between the predicted and the available experimental data is performed in terms of static pressure rise, total pressure ratio, choking mass flow and efficiency characteristics, and very good agreement is accomplished. In addition, detailed flow distributions are compared, assessed and critically analysed, regarding different number of diffuser vanes, rotational speed, gap between the leading edge of the vaned diffuser and impeller tip, mass flow rate. Emphasis is focused on the steady state study of the effect of the number of diffuser vanes on the stage operating range. Further more, unsteady simulation and analysis regarding the interactions between backswept impeller and downstream vaned diffusers is carried out. In the unsteady simulation, a geometry scaling method is used to modify the diffuser geometry to the nearest integer pitch ratio while keeping the throat area, flow direction and area ratio unchanged in order to deal with the unequal pitch ratio problems which exist in the unsteady simulation. The unsteady investigation was undertaken regarding different number of diffuser vanes, rotational speed, gap between the leading edge of the vaned diffuser and impeller tip, mass flow rate and impeller tip clearance. The detailed interactions at different conditions are compared, assessed and analysed. The studies focus on the analyses of the effect of the different interactions on the stage operating range, peak efficiency, total pressure ratio, level of unsteadiness, flow structures, flow angle or incidence angle, etc. In addition, the' predicted results are compared with available experimental data and a quite good agreement is achieved although the geometry is scaled. On the other hand, a detailed investigation on the differences between the time averaged unsteady simulation results and steady simulation results was performed at different conditions. The comparisons were carried out regarding static pressure, total pressure, speed, flow angle (or incidence angle) and isentropic efficiency. The investigation confirms that unsteady simulation is still quite important, since some of the steady state simulation results are still not similar to the time averaged ones. Designers should take into account the influence of the unsteadiness on the flow fields when they employ the steady state model in the design process.

The thesis is about investigating the inlet and outlet pipes effect on the compressors measured performance. From measurements made in a gas stand, a thermodynamic model is to be created and the compressor efficiency further investigated. The temperatures and pressures entering and leaving the compressor does not have to be the same as the temperatures measured in the gasstand, because of the thermodynamics of the pipes that connects the measurement equipment and the compressor. During a gasstand test the turbocharger is connected in a test bench, it is connected with pipes on both the compressor and turbine side, to simulate the hot exhaust gases from the car engine and the pressure increase over the compressor. The air entering and leaving the turbocharger through the different pipes is controlled and all the entering and leaving temperatures and pressures are measured. Gasstand data from different tests are available during the thesis, one specific turbocharger is used as references during the modeling. Models of the inlet and outlet pipes are created and connected to a compressor model. The model is controlled to give the same mass flow as the measured data, to ensure that the work cycle is followed. The effects of the non ideal inlet and outlet pipes on measured compressor efficiency is studied with help of this model and the main impacts on the measured compressor efficiency are discovered. The result shows that the measured values used to calculate the compressor efficiency could change, depending on the measurement positions on the inlet and outlet pipes.

A turbocharger’s performance is measured in a gas stand in order to provide information of the components characteristics. The measurement procedure is a very time consuming process and it is thus desired to make it more time-efficient. To allow for development of an enhanced control strategy used during the measurements, a 0D model of a gas stand is developed. The physical gas stand components are modeled and validated against measurements, all showing a reasonable result. Turbocharger heat transfers are investigated and modeled using a lumped capacitance approach. The heat transfer models shows approximative results when comparing with measurements which is explained by the lack of temperature measurement made on the bearing housing. When the complete gas stand model is validated against measurements, an improvement of the measurement procedure is examined. By adding an idealized heat source with the possibility to heat the compressor housing, it is possible to reduce the time it takes to reach an equilibrium when switching between two steady state operating points.

Electromechanical position actuation systems typically consist of an electric motor, driven by a set of power electronics, effecting output through a mechanical transmission. Whilst an optimal fully integrated actuator design from first principles could be considered, this is often not a cost-effective option. It is common to construct designs utilising commercially available subcomponents – the Cummins variable geometry turbocharging application detailed in this thesis provides a typical example. The design problem studied in this work is therefore one of meeting requirements through careful subcomponent selection. Electromagnetic, mechanical and thermal equations are developed to model actuator performance. These may be parameterised based on datasheet values or sample component test data. A set of tests is proposed to extract the required information from example motors; this is demonstrated using five different sample motors. Validation is performed to assess the accuracy of the parameterised models for the sample motors. A process is then developed to use the validated models to assess actuator design performance against a set of requirements. A key contribution of this work is the derivation of a computationally efficient motor model, which may be used with an integrated low-order lumped-parameter thermal model to investigate actuator performance at elevated temperatures – since this is often the limiting factor in machine rating. This allows a user to select the appropriate modelling fidelity, allowing accuracy to be traded against simulation performance. The overall process is demonstrated through the assessment of a full actuator design. The models and design process developed in this work allow a candidate actuator design to be appraised through calculations and simulations at a range of different fidelities, and using only a minimal set of subcomponent parameters. This allows designs that cannot meet the performance requirements to be quickly identified and excluded. Satisfactory designs may then be modelled and evaluated in detail to optimise other requirements, such as cost or volume.

The work presented in this thesis details a novel engine evaluation approach utilising real-time simulation and advanced engine testing systems for general applicability to new generations of air charging systems. A novel engine air charging system including a charge air handling unit (CAHU) has been developed which is connected to an engine to emulate advanced boosting system conditions. Significant analytical and development work has focused on generating a real-time turbocharger model such that the CAHU can be effectively controlled to emulate the turbocharger performance under both steady and pulsating conditions. Experimental work was carried out to evaluate this new engine air charge testing system against a production turbocharged baseline engine. The accuracies with respect to the boost pressure, turbocharger speed, mass air flow, and fuel consumption in the steady state tests are above 95%, and the level of confidence for the engine back pressure is approximately 90%. The difference of turbocharger speed between the steady turbocharger model and the pulsation model is also identified. In engine transient tests, the boost pressure and engine torque have shown fast response characteristics similar to that of the baseline engine. While general transient trends were achieved, some issues were identified with the high speed control of the CAHU interacting with the dSPACE real time turbocharger model. It is proposed that future improvement can be achieved via applying new control algorithms to improve the accuracy and tracking the CAHU control without increasing the system instabilities.

Diploma thesis focus on the design of turbocharger in SW MS Excel. For required flow and pressure ratio, the thermodynamics parameters were calculated for the turbocharger. From these, geometry was designed and the condition of mediums was calculated for each part of the turbine and compressor. At last basic characteristics of the turbine and compressor on varying the regime of engine operation the rotation was made and offered an idea about the working point position.

This article describes the first development phase of a centrifugal compressor with variable geometry which is designed to match the needs of future heavy-duty engines. Requirements of truck engines are analyzed, and their impact on the properties of the compressor map is evaluated in order to identify the most suitable kind of variable geometry. Our approach utilizes the transformation of engine data into pressure ratio and mass flow coordinates that can be displayed and interpreted using compressor maps. One-dimensional and three-dimensional computational fluid dynamics fluid flow calculations are used to identify loss mechanisms and constraints of fixed geometry compressors. Linking engine goals and aerodynamic objectives yields specific recommendations on the implementation of the variable geometry compressor.

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Rotor stability is essential to the life span of any piece of rotating machinery; it becomes increasingly critical in high-speed machinery such as turbochargers. Large turbochargers, such as those found in marine diesel propulsion engines where the rotor alone often exceeds forty pounds, require careful consideration regarding stability as well as load support during the bearing selection process. Logarithmic Decrement is the primary consideration for rotor stability. Commercial software is used to model and analyze a proven unstable turbocharger rotor. After confirming that the model exhibits unstable characteristics, the same turbocharger is then analyzed with various fluid-film bearing configurations. Finally, the tilting-pad bearing is determined to be the best bearing for this turbocharger application, stabilizing the rotor throughout the entire designed operating range. / Master of Science

Diploma thesis deals with the use of residual energy in the exhaust gas through turbine generators. It is a turbine connected to a generator of electricity, which is inserted into the exhaust pipe. The aim of this thesis is to discover how much power turbine generator in the application produces and assess its applicability in practice.