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Variable Geometry Turbochargers (VGTS) Are A Family of
Variable Geometry Turbochargers (VGTS) Are A Family of
INTRODUCTION
TURBOCHARGING
Basic Theory
In order to achieve this boost, the turbocharger uses the exhaust flow from
the engine to spin a turbine, which in turn spins an air pump. The turbine in the
turbocharger spins at speeds of up to 150,000 rotations per minute (rpm) -- that's
about 30 times faster than most car engines can go. And since it is hooked up to the
exhaust, the temperatures in the turbine are also very high.
Turbochargers allow an engine to burn more fuel and air by packing more
into the existing cylinders. The typical boost provided by a turbocharger is 6 to 8
pounds per square inch (psi). Since normal atmospheric pressure is 14.7 psi at sea
level, you can see that you are getting about 50 percent more air into the engine.
Therefore, you would expect to get 50 percent more power. It's not perfectly
efficient, so you might get a 30- to 40-percent improvement instead.
Inside A Turbocharger
pistons. The exhaust from the cylinders passes through the turbine blades, causing
the turbine to spin. The more exhaust that goes through the blades, the faster they
spin.
On the other end of the shaft that the turbine is attached to, the compressor
pumps air into the cylinders. The compressor is a type of centrifugal pump -- it
draws air in at the center of its blades and flings it outward as it spins. In order to
handle speeds of up to 150,000 rpm, the turbine shaft has to be supported very
carefully. Most bearings would explode at speeds like this, so most turbochargers
use a fluid bearing. This type of bearing supports the shaft on a thin layer of oil that
is constantly pumped around the shaft. This serves two purposes: It cools the shaft
and some of the other turbocharger parts, and it allows the shaft to spin without
much friction.
Fixed Geometry
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The demands on modern engines for wide operating speed ranges, high
torque rise and high specific power / litre have outstripped the capability of fixed
turbine geometry turbocharging. This is particularly true for automotive
applications using mid-range and heavy-duty products. In addition, construction
equipment requiring enhanced low speed response is increasingly specifying
wastegated (turbine bypass) turbochargers.
via an actuator. The angle of the vanes varies throughout the engine RPM range to
optimize turbine behaviour.
In the 3D illustration above, you can see the vanes in an angle which is
almost closed. The variable vanes are highlighted so that you know which is which.
This position is optimized for low engine RPM speeds, pre-boost.
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In this cut-through diagram, you can see the direction of exhaust flow
when the variable vanes are in an almost closed angle. The narrow passage of which
the exhaust gas has to flow through accelerates the exhaust gas towards the turbine
blades, making them spin faster. The angle of the vanes also directs the gas to hit
the blades at the proper angle.
Above are how the VGT vanes look like when they are open.
This cut-through diagram shows the exhaust gas flow when the variable
turbine vanes are fully open. The high exhaust flow at high engine speeds are fully
directed onto the turbine blades by the variable vanes.
VGT COMPONENTS
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Bearing housing
TURBINE WHEEL
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The turbine wheel is made from a high nickel super alloy investment
casting. This method produces accurate turbine blade sections and forms. Larger
units are cast individually. For smaller sizes the foundry will cast multiple wheels
using a tree configuration.
The forged steel shaft is friction welded to the turbine wheel. The
turbine blade edges are machined for accurate trim within the turbine housing. The
shaft bearing journals are induction hardened and ground for dimensional accuracy.
THRUST BEARING
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Hardened steel thrust collars and oil slingers are manufactured to strict
tolerances using lapping. End thrust is absorbed in a bronze hydrodynamic thrust
bearing located at the compressor end of the shaft assembly. Careful sizing provides
adequate load bearing capacity without excessive losses.
COMPRESSOR COVER
Compressor housings are also made in cast aluminium (cast iron for
high-pressure applications). Various grades are used to suit the application. Both
gravity die and sand casting techniques are used. Profile machining to match the
developed compressor blade shape is important to achieve performance
consistency.
emission in diesel engines. Ordinary turbochargers cannot escape from turbo lag
because at low engine rpm the exhaust gas flow is not strong enough to push the
turbine quickly. This problem is especially serious to modern diesel engines,
because they tend to use big turbo to compensate for their lack of efficiency. A
Variable Geometry Turbocharger is capable to alter the direction of exhaust flow to
optimize turbine response. It incorporates many movable vanes in the turbine
housing to guide the exhaust flow towards the turbine. An actuator can adjust the
angle of these vanes; in turn vary the angle of exhaust flow.
At low rpm :
The vanes are partially closed, reducing the area hence accelerating the
exhaust gas towards the turbine. Moreover, the exhaust flow hits the turbine blades
at right angle. Both makes the turbine spins faster.
At high rpm :
At high rpm the exhaust flow is strong enough. The vanes are fully opened
to take advantage of the high exhaust flow. This also releases the exhaust pressure
in the turbocharger, saving the need of wastegate.
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In the same 1989, Garrett produced a VTG turbocharger for use in the
limited production Shelby CSX, a car derived from Dodge Shadow. However, only
500 cars were produced. Neither Chrysler group nor any other car makers would
follow its footprints.
DIFFERENCE
Turbo
compressing ambient air and delivering it to the air intake manifold of the engine at
higher pressure, resulting in a greater amount of the air and fuel entering the
cylinder.
VGT
ADVANTAGES
Controlling the vane angle allows the exhaust flow gases, at low engine
speeds, to pass over narrow, almost closed vanes. Gases accelerate as they move
through the narrow passage towards the turbine blades, which in turn accelerates the
turbine blades. The VGT has the advantage of being able to operate more efficiently
at all engine speeds, including low engine speeds. It has a low boost threshold -in
some cases without a wastegate- and a minimal turbocharger lag.
DISADVANTAGES
• VGT vanes can become clogged with particulate matter over time
CONCLUSION
BIBLOGRAPHY
www.howstuffworks.com
www.cummins.com
www.wikipedia.org