Governments across the world are implementing legislation for ever more strict limits for vehicle emissions; combined with customer expectations for growing levels of performance and equipment, automotive manufacturers face a significant challenge. With the aim of meeting this challenge, downsizing is an established trend in passenger car engine development. However, since downsizing is commonly achieved through pressure charging (turbocharging, for example), the associated benefits in improved fuel economy and emissions are often obtained at the expense of engine dynamic response, and, consequently, vehicle driveability. This thesis presents predominantly simulation-based research into a novel combined charging system comprising a conventional turbocharger used in conjunction with a declutchable supercharger driven through a CVT. An initial investigation using this system in place of a variable geometry turbocharger on an already downsized passenger car diesel engine demonstrated greatly increased low speed torque as well as improved dynamic response. A downsizing project that involved replacing a naturally aspirated gasoline engine with a highly boosted engine with 40% of the original displacement formed the basis for more extensive investigations. Although it was unable to produce the low speed transient response of the naturally aspirated engine, in tip-in tests the CVT-supercharger system was shown to achieve the target torque much quicker than an equivalent system with a fixed supercharger drive ratio. However, balancing this with good fuel efficiency for the initial part load period was a complex trade-off. In vehicle acceleration simulations the CVT-supercharger system did not outperform the fixed drive ratio configuration, but on the CVT system the boost limit was reached at an early stage during the transients. Thus there may be potential to include an ‘over-boost’ facility, allowing boost pressure to temporarily exceed normal steady state limits in order to improve transient performance and bring it closer to that of the baseline vehicle. It is suggested that the CVT-supercharger provides the best flexibility for calibration and compromise between performance and fuel efficiency, perhaps incorporating different user-selectable modes (such as ‘economy’ and ‘sport’ modes).

Driven by the strict fuel consumption and CO2 legislations in Europe and many countries, various technologies have been developed to improve the fuel economy of conventional internal combustion engines. Gasoline engine downsizing has become a popular and effective approach to reduce fleet CO2 emissions of passenger cars. This is typically achieved in the form of boosted direct injection gasoline engines equipped with variable valve timing devices. Downsized gasoline engines reduce vehicle fuel consumption by making engine operate more at higher load to reduce pumping losses and also through reducing total engine friction losses. However, their compression ratio (CR) and efficiency are constrained by knocking combustion as well as the low speed pre-ignition phenomena. Miller cycle is typically achieved in an engine with reduced effective CR through Early Intake Valve Closure (EIVC) or Later Intake Valve Closure (LIVC). This technology has been adopted on modern gasoline engines to reduce in-cylinder charge temperature and enable a higher geometric CR to be used for better fuel economy. The present work investigated the effectiveness and underlying process of a Miller cycle based approach for improving fuel consumption of a boosted downsized gasoline engine. A single cylinder direct injection gasoline engine and the testing facilities were set up and used for extensive engine experiments. Both EIVC and LIVC approaches were tested and compared to the conventional Otto cycle operation with a standard cam profile. Synergy between Miller cycle valve timings and different valve overlap period was analysed. Two pistons with different CRs were used in the Miller cycle engine testing to enable its full potential to be evaluated. The experimental study was carried out in a large engine operation area from idle to up to 4000rpm and 25.6bar NIMEP to determine the optimal Miller cycle strategy for improved engine fuel economy in real applications. In addition, the increased exhaust back pressure and friction losses corresponding to real world boosting devices were calculated to evaluate Miller cycle benefits at high loads in a production engine. The results have shown that EIVC combined with high CR can offer up to 11% reduction of fuel consumption in a downsized gasoline engine with simple setup and control strategy. At the end, this thesis presents an Miller cycle based approach for maximising fuel conversion efficiency of a gasoline engine by combining three-stage cam profiles switching and two-stage variable compression ratio.

The aim is to share experience gained when simulating (and doing measurements on) the turbocharged SI-engine as well as describing the limits of current state of the technology. In addition an overview of current boosting systems is provided. The target readers of this text are engineers employed in the engine industry as well as academia who will get in contact, or is experienced, with 1D engine performance simulation and/or boosting systems. Therefore the text requires general knowledge about engines. The papers included in the thesis are, in reverse chronological order: [8] SAE 2005-XX-XXX Calculation accuracy of pulsating flow through the turbine of SI-engine turbochargers - Part 2 Measurements, simulation correlations and conclusions Westin & Ångström To be submitted to the 2005 SAE Powertrain and Fluid Systems Conference in San Antonio [7] SAE 2005-01-2113 Optimization of Turbocharged Engines’ Transient Response with Application on a Formula SAE / Student engine Westin & Ångström Approved for publication at the 2005 SAE Spring Fuels and Lubricants Meeting in Rio de Janeiro [6] SAE 2005-01-0222 Calculation accuracy of pulsating flow through the turbine of SI-engine turbochargers - Part 1 Calculations for choice of turbines with different flow characteristics Westin & Ångström Published at the 2005 SAE World Congress in Detroit April 11-14, 2005 [5] SAE 2004-01-0996 Heat Losses from the Turbine of a Turbocharged SI-Engine – Measurements and Simulation Westin, Rosenqvist & Ångström Presented at the 2004 SAE World Congress in Detroit March 8-11, 2004 [4] SAE 2003-01-3124 Simulation of a turbocharged SI-engine with two software and comparison with measured data Westin & Ångström Presented at the 2003 SAE Powertrain and Fluid Systems Conference in Pittsburgh [3] SIA C06 Correlation between engine simulations and measured data - experiences gained with 1D-simulations of turbocharged SI-engines Westin, Elmqvist & Ångström Presented at the SIA International Congress SIMULATION, as essential tool for risk management in industrial product development in Poissy, Paris September 17-18 2003 [2] IMechE C602/029/2002 A method of investigating the on-engine turbine efficiency combining experiments and modelling Westin & Ångström Presented at the 7th International Conference on Turbochargers and Turbocharging in London 14-15 May, 2002 [1] SAE 2000-01-2840 The Influence of Residual Gases on Knock in Turbocharged SI-Engines Westin, Grandin & Ångström Presented at the SAE International Fall Fuels and Lubricants Meeting in Baltimore October 16-19, 2000 The first step in the investigation about the simulation accuracy was to model the engine as accurately as possible and to correlate it against as accurate measurements as possible. That work is covered in the chapters 3 and 5 and in paper no. 3 in the list above. The scientific contribution here is to isolate the main inaccuracy to the simulation of turbine efficiency. In order to have anything to compare the simulated turbine efficiency against, a method was developed that enables calculation of the CA-resolved on-engine turbine efficiency from measured data, with a little support from a few simulated properties. That work was published in papers 2 and 8 and is the main scope of chapter 6 in the thesis. The scientific contributions here are several: · The application on a running SI-engine is a first · It was proven that CA-resolution is absolutely necessary in order to have a physically and mathematically valid expression for the turbine efficiency. A new definition of the time-varying efficiency is developed. · It tests an approach to cover possible mass accumulation in the turbine housing · It reveals that the common method for incorporating bearing losses, a constant mechanical efficiency, is too crude. The next step was to investigate if different commercial codes differ in the results, even though they use equal theoretical foundation. That work is presented in chapter 4, which corresponds to paper 4. This work has given useful input to the industry in the process of choosing simulation tools. The next theory to test was if heat losses were a major reason for the simulation accuracy. The scientific contribution in this part of the work was a model for the heat transport within the turbocharger that was developed, calibrated and incorporated in the simulations. It was concluded that heat losses only contributed to a minor part of the inaccuracy, but that is was a major reason for a common simulation error of the turbine outlet temperature, which is very important when trying to simulate catalyst light off. This work was published in paper 5 and is covered in chapter 7. Chapter 8, and papers 6 and 8, covers the last investigation of this work. It is a broad study where the impact of design changes of both manifold at turbines on both simulation accuracy as well as engine performance. The scientific contribution here is that the common theory that the simulation inaccuracy is proportional to the pulsation amplitude of the flow is non-valid. It was shown that the reaction was of minor importance for the efficiency of the turbine in the pulsating engine environment. Furthermore it presents a method to calculate internal flow properties in the turbine, by use of a steady-flow design software in a quasi-steady procedure. Of more direct use for the industry is important information of how to design the manifolds as well as it sheds more light on how the turbine works under unsteady flow, for instance that the throat area is the single most important property of the turbine and that the system has a far larger sensitivity to this parameter than to any other design parameters of the turbine. Furthermore it was proven that the variation among individual turbines is of minor importance, and that the simulation error was of similar magnitude for different turbine manufacturers. Paper 7, and chapter 9, cover a simulation exercise where the transient performance of turbocharged engines is optimised with help from factorials. It sorts out the relative importance of several design parameters of turbocharged engines and gives the industry important information of where to put the majority of the work in order to maximize the efficiency in the optimisation process. Overall, the work presented in this thesis has established a method for calibration of models to measured data in a sequence that makes the process efficient and accurate. It has been shown that use of controllers in this process can save time and effort tenfold or more. When designing turbocharged engines the residual gas is a very important factor. It affects both knock sensitivity and the volumetric efficiency. The flow in the cylinder is in its nature of more dimensions than one and is therefore not physically modelled in 1D codes. It is modelled through models of perfect mixing or perfect displacement, or at a certain mix between them. Before the actual project started, the amount of residual gases in an engine was measured and it’s influence on knock was established and quantified. This was the scope of paper 1. This information has been useful when interpreting the model results throughout the entire work.

Ce travail s'inscrit dans le cadre d'un partenariat entre Honeywell Turbo Technologies et le département d'Aérodynamique, Energétique et Propulsion de l'ISAE. En réponse à des objectifs industriels d'amélioration des étages turbine des systèmes de suralimentation automobile, deux axes d'étude sont dégagés: le diagnostique et l'amélioration des étages de turbine à géométrie variable utilisés dans la suralimentation des moteurs Diesel, et l'évaluation d'une turbine axiale spécifiquement conçue pour la suralimentation des moteurs essence. La première partie traite de l'influence des paramètres permettant de réaliser le couplage avec le moteur. Cette étude, basée sur une double analyse, permet d'identifier les enjeux du point de vue des performances de l'étage turbine mais aussi leur intégration dans la performance globale du moteur. Nous traitons ensuite des contraintes d'intégration imposées par le fonctionnement optimal de la boucle de suralimentation. En réponse aux problématiques soulevées, une procédure d'optimisation, basée sur une approche théorique, des étages turbine est présentée. Celle-ci permet de dégager des conclusions fortes sur la spécificité des étages à géométrie variable qui sont finalement déclinées dans un contexte industriel. Une synthèse bibliographique des règles de dimensionnement des turbines axiales débute la seconde partie. Cette architecture de machine, disposant d'une faible inertie et d'une grande compacité, semble toute indiquée pour répondre à la problématique de suralimentation des moteurs essence. La conception a nécessité une étude spécifique des différents critères de design car la géométrie axiale est atypique dans cette gamme de débit. Des résultats de simulations numériques permettent d'évaluer le potentiel aérodynamique de cet étage. Enfin, celle-ci est confrontée à l'étage de turbine radiale actuellement utilisé afin d'évaluer son potentiel dans le cadre du couplage moteur. / This work results from a partnership between Honeywell Turbo Technologies and the département d'Aérodynamique, Energétique et Propulsion of the ISAE. The main industrial goal are improving turbine stages of boosting systems. The problem is tacked through two thematics : the optimization of variable geometry radial turbine used for boosting systems of gasoline engines. The first part deals with the influence of parameters used for matching are first discussed. This study, based on double analysis, is used to identfy the stakes of turbine stage performance but also take global engine performances into account. Contraints ipmposed by peripheral systems such as cooling systems or catalytic converter are then traited. This leads to an optimization process based on theorical approach wich allows to conclude on radial turbine stage characteristics. Finally, we turn in information about industrialization. The second part begin with a literature survey of axial turbine stage design method. This type of machine, with low inertia and high compacity, can be relevant for boosting systems of gasoline engines. Design needs a specific study on criterion parameters because it is unsual to encounter axial turbines with such small diameters. CFD results give aerodynamics performances of axial stage. Then, comparison of turbocharger with engine matching between radial and axial stages is proposed.

The aim of this thesis is the description and performance of four-stroke internal combustion engine, an analysis of the options and finding the most effective treatment for a given engine type. In the next section the author deals with computational design turbochargers, chosen for the turbocharged engine modification. Next chapter of work is a design calculation for the choice of the turbocharger, is then constructed a mathematical model of a given engine in the Lotus Engine Simulation software and final results are presented.

The main subject of this Master’s thesis is a review of turbo-charger efficiency with split turbine channel in the process of various types of supercharging and also with diverse designs of so called divider of turbine channels. I used CFD simulation utilizing Star CCM+ software. A model of turbocharger and mesured data came from commercial model. Efficiency is evaluated on the basis of performance distributed to the turbine with similar input conditions for both steady and unsteady process. For better understanding of this subject I also included theoretical basics of supercharging of combustion engines and fluid dynamics.

Modelování turbínových charakteristik je nutným předpokladem pro detailní simulaci výměny náplně válce turbodmychadlem přeplňovaných spalovacích motorů. Kromě toho je možnost stanovení účinnosti a průtokové kapacity v libovolných pracovních bodech klíčová pro porovnání různých turbínových stupňů. Cílem této práce je předložit jednotnou metodu pro oba účely tak, aby bylo možné provést porovnání použitím přesně stejných modelů turbín jako při následné simulaci pracovního oběhu motoru. Zdrojem vstupních dat je obvykle měření na plynové zkušebně, které však umožňuje zachycení pouze omezeného pracovního rozsahu turbíny. V této práci jsou navrženy metody umožňující zvýšení věrohodnosti a robustnosti extrapolace turbínových charakteristik, přičemž optimalizace je využita k určení takových parametrů hledaných funkcí, které vedou k nejlepší shodě mezi modelem a vstupními daty.

Les turbocompresseurs sont utilisés pour améliorer les performances du moteur thermique par suralimentation. Cette méthode efficace présente cependant des inconvénients majeurs pour des points de fonctionnement à faible débit. En effet, lorsque le débit en entrée du turbocompresseur devient trop faible, un phénomène de pompage apparaît, réduisant la plage d'utilisation du moteur, pouvant endommager le turbocompresseur et le moteur par un fonctionnement instable.Dans cette thèse une configuration expérimentale avec un dispositif à géométrie variable placé en amont du compresseur a été étudiée. Ce système, appelé « dispositif de prérotation » permet de modifier les conditions aérodynamiques en amont du compresseur et en particulier dans les zones de fonctionnement proches du pompage.Cette étude comporte deux grands volets : une partie expérimentale réalisée sur un banc d’essais typique de turbocompresseurs d’automobile équipé d'une vanne de prérotation et une étude numérique permettant d’évaluer les capacités de l’utilisation d’un code du commerce à restituer les modifications des performances expérimentales observées sur l’ensemble. / Automotive turbochargers are used to increase engine performances. This efficient method, however, has major disadvantages for low flow operating points. Indeed, when the input flow of the turbocharger becomes too low, a surge phenomenon appears, reducing the range of use of the engine, which can damage the turbocharger and the engine by unstable operation.In this thesis an experimental configuration with a variable geometry device placed upstream of the compressor has been studied. This system, called "pre-whirl device" makes it possible to modify the aerodynamic conditions upstream of the compressor and in particular in the operating zones close to surge.This study has two main components: an experimental part carried out on a typical test bench of automobile turbochargers equipped with a pre-whirl valve and a numerical study making it possible to evaluate the capacities of the use of a code of the trade to render the modifications of the experimental performances observed on the whole. / Os turbocompressores são utilizados para melhorar o desempenho dos motores térmicos por sobrealimentação. Este método é eficiente, no entanto, tem grandes desvantagens quando o turbocompressor opera em baixa vazão mássica. Quando a vazão de massa na entrada do turbocompressor fica muito baixa, um fenômeno de sobrecarga (surge) aparece, reduzindo a faixa de uso do motor, o que pode danificar o turbocompressor e o motor por meio de operação instável.Nesta tese, uma configuração experimental com um dispositivo de geometria variável colocado na entrada do compressor foi estudada. Este sistema, chamado “dispositivo de pré-rotação” permite modificar as condições aerodinâmicas a montante do compressor e em particular nas zonas de funcionamento próximas da sobrecarga.Este estudo tem dois componentes principais: uma parte experimental realizada em uma bancada de testes típica de turbocompressores automotivos equipada com uma válvula de pré-rotação e um estudo numérico que permite avaliar as capacidades do uso de um código de comércio para realizar as modificações dos desempenhos experimentais observados no todo.

The aim of this thesis is to focus on an application of mixed flow turbine wheel for charging diesel powered combustion engine in a van and to give a summary about current technologies used for charging internal combustion engines. Output of this thesis should be a package study with a few design layouts for the application mentioned above, including models prepared for rapid prototyping. Another part of the package study is a simulation of thermal stress and final deformation of turbine heat shroud. Design layout should contain as many production parts as possible.

Internal combustion engines developments are driven by emissions reduction and energetic efficiency increase. To reach the next standards, downsized/downspeeded engines are required to reduce fuel consumption and CO2 emissions. These techniques place an important demand on the charging system and force the introduction of multistage boosting architectures. With many possible arrangements and large number of parameter to optimize, these architectures present higher complexity than current systems. The objective of this thesis has thus been to investigate the potential of two-stage boosting architectures to establish, for the particular case of passenger car downsized/downspeeded Diesel engines, the most efficient solutions for achieving the forthcoming CO2 emissions targets. To respond to this objective, an exhaustive literature review of all existing solutions has first been performed to determinate the most promising two-stage boosting architectures. Then, a new matching methodology has been defined to optimize the architectures with, on the one hand the development of a new turbine characteristic maps representation allowing straight forward matching calculations and, on the other hand, the development of a complete 0D engine model able to predict, within a reduced computational time, the behavior of any boosting architecture in both steady state and transient operating conditions. Finally, a large parametric study has been carried out to analyze and compare the different architectures on the same base engines, to characterize the impacts of thermo-mechanical limits and turbocharger size on engine performance, and to quantify for different engine development options their potential improvements in term of fuel consumption, maximum power and fun to drive. As main contributions, the thesis provides new modeling tools for efficient matching calculations and synthesizes the main trends in advanced boosting systems to guide future passenger car Diesel engine develop / Varnier ., ON. (2012). Trends and Limits of Two-Stage Boosting Systems for Automotive Diesel Engines [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/16880 / Palancia