TaD-PT

Pressure Charging
Turbo Charging

P.H.Mesman
Contents (1)
1. Introduction
1.1 Overview common pressure charge systems

2. Matching
2.1 Definition
2.2 Limits
2.3 Turbo choice
2.4 Turbo variables
2.5 Turbo sizing basics (deleted)
2.6 Turbine matching
2.7 Knock resistance
Contents (2)
3. Basic turbo systems (see turbo 1+2)
3.1 Free floating
3.2 Waste gate controlled
3.3 Variable turbine geometry (VTG)

4. Special turbo constructions

4.1 Twin Scroll
4.2 Multiple stage turbo (serial)
4.3 Multiple stage turbo (parallel)
4.4 Additional pressure charging
4.5 Turbo compound system (1)
Contents (3)
4. Special turbo constructions
4.6 Turbo compound system (2)
4.7 Hyperbar turbo system
4.8 Axial turbo system

Goal: Increase the in depth knowledge and understanding

of modern supercharging and turbocharging concepts.

Basic knowledge of Part 1 and 2 should be present during

the lessons.
1. Introduction
1.1 Overview pressure charge systems
Roots blower (mechanical):

https://gifer.com/en/9zhy
1. Introduction
1.1 Overview pressure charge systems
Screw type blower:
1. Introduction
1.1 Overview pressure charge systems
Spiral-type charger / G-lader (VW):

https://www.mvwautotechniek.nl/g-lader/
 Specific Matching Characteristics
• Immediate response due to mechanical connection with the crankshaft
(or when electrical driven)
• Pressure ratio is independ of engine speed and load
 Roots compressor map

See literature reference; Figure 10.6

1. Introduction
1.1 Overview pressure charge systems

Exhaust gas turbocharger

2012 Audi R18 e-tron quattro

 Specific Matching Characteristics
• Respons is strongly depending on inertia of turbocharger wheels
• No mechanical linkage; the turbocharger respons is only depending
on exhaust gas volume flow
• Pressure ratio is depending on turbocharger speed
2. Matching
2.1Definition:
Adapting a pressure charge system to the
demands of the combustion engine.

Requirements:
-Power & Torque curves; especially for downsized
engine due to small swept volume
-Fuel consumption; back pressure and exhaust gas
temperature control (gasoline engines)
-Emissions; engine start and warming up requires
as much exhaust gas energy as possible
(passenger cars)
2. Matching
2.2Turbo Charger limits:
➢Compressor is the weakest part of the turbo;
otherwise: there is enough exhaust gas energy
• Compressor limit 1:
Surge: Compressor speed is too slow, creating pressure
waves in the compressor.
• Compressor limit 2:
Speed: Compressor speed is too fast.
vcompressor > mach 1 or material elasticity too high.
• Compressor limit 3:
Choke: Maximum flow at pressure ratio
2. Matching
Limits:

-Choke (right line)

-Surge (left line)

-Speed (top line)

http://www.turbobygarrett.com/turbobygarrett/compressor_maps May 2013

2. Matching
2.3Turbo Charger choice
The correct combination of turbo and engine
depends on:
• Type of the charger system
• Demanded power output
• Demanded torque output
• Cost price of the system
• Emissions
• Geographic altitude of operation
2. Matching
2.4Turbo variables

•Trim:
- The trim of a turbocharger wheel affects performance by shifting
the airflow capacity.
-A “higher trim” wheel will flow more air than a “smaller trim”
wheel.

http://www.turbobygarrett.com/turbobygarrett/wheel_trim
2. Matching

•A/R (Area/Radius):
- The A/R is the geometric characteristic of a turbo housing (see
picture).
- The influence on the compressor performance is minor with
changes in A/R.
- The turbine performance is greatly affected by changes in A/R.
- The higher the ratio, the more the turbine will be capable of
flowing and vice-versa.
- A high turbine A/R will decrease the exhaust gas velocity and
delays the turbo response and vice-versa.
2. Matching
2.5Turbo variables
-Rotating mass = inertia ➔ Turbo lag
-Safety margin for operation at high altitude
-Maximum exhaust gas temperature
- Use of VTG
- Cooling of turbine
- Engine control measures
-Total mass (heat transfer and heat sink) and volume
(respons) of the connection with the engine ➔
integrated exhaust manifold and/or double walled
with air insulation.
2. Matching
2.5 Turbo sizing basics

Point 1:
- Far away from surge line
- High efficiency

Point 2:
1 2
- Close to speed line
- Sensitive for overspeeding
2. Matching
2.6 Turbine matching
• Turbine A/R is leading for turbine performance

www.turbodriven.com/performance May 2013

2. Matching
2.6 Turbine matching
Matching turbine performance:
- Low A/R= high exhaust backpressure (high pressure ratio)
fast spool up of the turbo
restrictive for high mass flow rates

- High A/R= low exhaust backpressure (low pressure ratio)

slow spool up of the turbo
non-restrictive for high mass flow rates
2. Matching
2.6 Turbine matching
Calculating corrected airflow / flow parameter:

With:

Qair: Actual engine mass air flow (engine air consumption)

Abs. temperature: Exhaust gas temperature
Abs. pressure: Exhaust pressure before turbine
2. Matching
2.6 Turbine matching

Variables to turbine performance:

- Exhaust gas temperature:
High temperature = higher turbine flow
Low temperature = lower turbine flow

- Exhaust back pressure:

High pressure = lower turbine flow
Low pressure = high turbine flow
2. Matching
2.6 Turbine matching
Variables to turbine performance:
- Exhaust gas flow
Variable Valve Timing (VVT) → Scavenging?

http://www.sciencedirect.com/science/article/pii/S0016236112008381 May 2013

2. Matching
2.6 Turbine matching

Valve overlap determines engine scavenging:

More overlap ➔ scavenging of more air ➔ higher

exhaust gas flow ➔ increased pexhaust ➔ better
turbo spool up; for gasoline DI fuel injection
required; cooling effect on combustion chamber
2. Matching
2.7 Knock resistance of DISI engine

Use of heat for evaporation of the fuel (latent heat):

•Higher ε possible ➔ pe ↑ and BSFC ↓
•More ignition advance possible ➔ pe ↑ and BSFC ↓
•Higher boosting pressure possible ➔ pe ↑

Consequences for the choice of the turbocharger?

http://www.aachen-colloquium.com/pdf/Vortr_Nachger/2010/A3.1_Lueckert.pdf May 2013

2. Matching

2.8 Influence of geographical height

Lower ambient air pressure ➔ Δp turbine ↑
➔more energy for turbine ➔ speed turbo↑
➔pressure ratio compressor ↑ ➔
compensation for decreased ambient pressure, but
higher thermal load on the intercooler and risk of
over speeding of the turbo ➔ influence on safety
margin for turbo
3. Basic turbo systems*
3.1 Free floating (BMW 2002, Porsche 911 mk1)
• nturbo is f(exhaust gas flow)
• No waste gate
• pmax at nmax

Advantages:
- Simple, cheap and reliable

Disadvantages:
- Turbo lag (late turbo spooling)
- Abrupt release of torque at boost ➔ Impractical handling
3. Basic turbo systems

3.1 Free floating

1. Inlet air from filter
2. Compressor discharge
3. Charge air-air cooler
4. Inlet side of engine
5. Outlet side of engine
6. Turbine entrance
7. Turbine discharge

http://www.turbobygarrett.com/turbobygarrett/basic May 2013

3. Basic turbo systems
3.2 Wastegate controlled (conventional system for SI/CI engines)
• nturbo is not directly related with exhaust gas flow
• Bypass of exhaust gas
• Pneumatic / electro-pneumatic / electronically controlled

Advantages:
- Simple, cheap and reliable control
- Smaller turbo can be used ➔Less turbo lag in comparison with direct
control of the intake pressure with a blow-off valve or pressure relief
valve

Disadvantages:
- Waste of exhaust gas energy when waste gate is activated
- Increased back pressure in comparison with –maximum- capacity
turbine
3. Basic turbo systems
3.2 Wastegate controlled (mechanical)

10. Wastegate
11. Control signal
12. Wastegate discharge

Now: Electronic control

f(torque, speed) over engine
map; open waste gate to
speed up catalyst heating
process; close waste gate for
limited amount of extra boost
pressure
3. Basis turbo systems
Waste gate vs pressure-relief valve
• Indirect control of the boost pressure vs direct control
• Use of a limited amount of exhaust gas vs use of all exhaust gas
• Use of a smaller turbine vs use of a turbine for the maximum exhaust
gas flow
➔ Less inertia possible with waste gate control system
 Boost Control

See literature reference Figure 10.30

Boost strategy

http://www.dieselnet.com/tech/air_turbo_fixed.php
3. Basic turbo systems
3.3 Variable Geometry Turbo (VGT or VNT)
(conventional on CI & upcoming on SI engines)
• nturbo is non-lineair with exhaust gas flow
• Free floating turbo system
• Pneumatic / electro-pneumatic / electronically controlled

Advantage:
- Variable A/R ➔ variable turbine size ➔ no waste of exhaust gas energy
(speed and load range of the engine?)

Disadvantages:
- Limited Texhaust possible (SI)
- Sensitivity to clogging and jamming of vanes depends on VGT system ≠
Variable Nozzle Turbine with a sleeve in the turbine housing
(Cummins/Holset; DAF and Scania)
- Flow in turbine is not optimal
3. Basic turbo systems
3.3VGT Turbo

Vanes closed Vanes open

http://paultan.org/2006/08/16/how-does-variable-turbine-geometry-work/ May 2013
4. Special turbo constructions
4.1 Twin Scroll turbo (turbine)
• Most often used with waste gate
• 2 turbine entries for ≥ 4 cylinders and one turbine
• Better use of exhaust gas flow pulses
• Less back pressure due to lower pressure level in the exhaust
system; less influence of pulses of other cylinders
• Smaller turbine compared to a single turbo with one entry ➔ better
spool up

Disadvantages:
- Increased costs of the turbo

Example:
Use in MINI Cooper S, replacement of mechanical compressor
4. Special turbo constructions
4.1 Twin Scroll turbo (turbine)

http://www.turbodriven.com/en/performanceturbos/efrTechnicalData.aspx May 2013

4. Special turbo constructions
4.2 Multiple stage turbocharging serial

•2 (or more) serial connected turbos

•Expansion and compression in two steps ➔ different
size of the turbochargers because of the different
volumetric flow; low pressure step ➔ large turbo;
high pressure step ➔ smaller turbo
•Where to place the intercooler(s)?
•Example: Boost pressure of 10 bar with natural gas
engine with Miller valve timing principle pemax = 20
bar! (GE Jenbacher Werke MTZ 05/2013 p386-391)
4. Special turbo constructions
4.2 Multiple stage turbocharging
Control: Low speed+
low load→small
exhaust gas
flow→small turbo-
charger
High speed+high
load→high exhaust
gas flow→large
small turbo-charger
➢Role of the valves?
➢Design for
large passenger car?
➢EGR flow?

http://www.gtisoft.com/upload/BorgWarner_ChargingSystems.pdf May 2013

Background information

After this slide

Let op, wel 2-stage charging meenemen!

4. Special turbo constructions
4.2 Multiple stage turbocharging

http://www.gtisoft.com/upload/BorgWarner_ChargingSystems.pdf May 2013

4. Special turbo constructions
4.2 Multiple stage turbocharging

http://www.gtisoft.com/upload/BorgWarner_ChargingSystems.pdf May 2013

4. Special turbo constructions
4.2 Multiple stage turbocharging

http://www.gtisoft.com/upload/BorgWarner_ChargingSystems.pdf May 2013

 Two-stage turbocharging

See literature reference Figure 10.32

4. Special turbo constructions

•Commercial vehicles/trucks ➔ limited speed

range of the engine ➔ limited change in exhaust
gas flow ➔ not necessary to restrict the flow
through the low pressure stage turbocharger
http://www.3k-warner.de/en/products/r2s.aspx, May 13th 2014
4. Special turbo constructions
4.3 Multiple stage turbocharging (parallel)
• 2 (or more) identical sized turbos (parallel)
• Also called: Bi-turbo or twin-turbo?
• Each turbo is fed by an equal part of exhaust gas (2 turbos = ½,
3 turbos = ⅓, etc.)
• Mostly used in V-, and Boxer engines, one turbo per cylinder
bank
• Short piping from and to the turbo, thus small volume after the
compressor and before the turbine ➔ better spool up
• Low inertia per turbo ➔ better spool up
• Smaller turbo is less efficient ➔ slightly decreased turbine
efficiency compared to a single turbo
4. Special turbo constructions
Register turbocharging:
• Use two turbochargers of the same size; one for each
cylinderbank (with two, three cylinders).
• Start at low speed and load with one turbo for all the exhaust
gases.
• Switch over to parallel use of both turbochargers when you
have enough exhaust gas energy; use one turbo for each
cylinderbank (parallel situation).
• Result: Increased torque at low speed and load in comparison
with bi turbo (only parallel use).
• However, system is more complicated due to extra valves for
switching
• Example: Porsche 959
4. Special turbo constructions
4.3 Multiple stage turbocharging (parallel)

http://upload.wikimedia.org/wikipedia/commons/2/2c/Porsche_935_Bi-Turbo_engine_TCE.jpg May 2013

4. Special turbo constructions
4.3 Multiple stage turbocharging (parallel)

http://cars-database.com/data_images/gallery/02/bugatti-veyron-w16/bugatti-veyron-w16-01.jpg May 2013

4. Special turbo constructions

4.4 Additional (mechanical) pressure charging

•Also called: twincharge
•Turbocharger + supercharger(=mechanically driven
compressor)
•1 “large” turbo; no waste gate?
•Supercharger provides boost during turbo lag
•After turbo lag the supercharger is disconnected
• Better engine efficiency ➔ better fuel efficiency in comparison
with only supercharging
• Torque increase over the whole engine speed range, thus
better torque in comparison with only turbocharging
 4. Special turbo constructions
4.4Additional (mechanic) pressure charging
➢Role of the different
valves?
➢Restriction of
turbocompressor?
➢Influence choice
turbocharger size also
depends of required
power output?
➢Expensive solution; twin
scroll turbine is less
expensive

http://bioage.typepad.com/photos/uncategorized/tsi_airflow.png May 2013

4. Special turbo constructions

4.4 Additional (mechanic) pressure charging

Lancia Delta S4
DATA?

http://www.spannerhead.com/wp-content/uploads/2012/11/Delta_S4_Engine_1.jpg May 2013

Extra mechanical compressor

•Additional mechanical/electrical driven

compressor to improve the response of the
engine at low speed and low load (only small
amount of exhaust gas energy available)
•Switch off this compressor to reduce mechanical
losses at higher speed and load
•Size of the turbocharger can increase ➔ more
use of exhaust gas energy ➔ higher torque at
higher engine speeds ➔ increased torque over
very wide engine speed range
4. Special turbo constructions
4.5 Turbo compound system (1)
Compound: turbo is driving a (crank)shaft other than the
compressor or being driven/supported other than the
turbine
• 2 (or more) turbos; two stage series turbine system
• First turbine (small): pressure charging (high
pressure); use of exhaust gas pulses is possible;
drives compressor
• Second turbine (large): drives crankshaft (low
pressure)
• Crankshaft drive via: visco clutch & gearset in turbo
Turbo compound (1)

•Compound system requires large exhaust gas

flow to be really effective ➔ high load and high
speed of the engine
•Size of the small turbocharger restricts the
exhaust gas flow; but small size is required
because of two stage exhaust gas expansion.
•Use in heavily loaded trucks which require high
amount of power; timber transport in Scandinavia
(60 tons) or heavy road transport.
•Examples: Scania?, Volvo?, Mercedes?
4. Special turbo constructions
4.5 Turbo compound system (1)

1. HP turbo 4. visco clutch

2. LP turbo 5. flywheel / crankshaft
3. Gearset / gearbox

HAN, Automotive, reader 753, page 119, Mesman, May 2013

4. Special turbo constructions
4.5 Turbo compound system (1)

http://automotive.roger.free.fr/image_auto/turbo_truck.jpg May 2013

4. Special turbo constructions
4.6 Turbo compound system (2)
• Compound: turbo is driving a shaft other than the
compressor, or compressor is driven/supported other than
the turbine
• 1 turbo
• Turbo is supported with a built in electric motor
• Electric motor can support turbo during spool-up
• Turbine can feed electric motor for electric energy storage
• F1 regulations / technology for 2014
• Near future commercial turbo technology

Source: http://gb.zinio.com/reader.jsp?issue=416241241&o=int&prev=sub&p=46 May 2013

4. Special turbo constructions
4.6 Turbo compound system (2)

http://www.magnetimarelli.com/press_room/galleries/motorsport-%E2%80%9Cgreen%E2%80%9D-magneti-marelli-illustrates-washington-dc-technological May 2013

4. Special turbo constructions
4.7 Hyperbar turbo system
• Works like a turbine engine ➔ combustion chamber between exhaust ports and
turbine
• Possibility to maintain high turbo speed at low load
• Engine start with electrical drive of the turbo
• Used on ship engines / generator drivers / rally cars / battle tanks due to high
specific power kW/kg or kW/l
From: Fundamentals of Turbocharging,
Baines, 2005, ISBN 0 933283 14 8
From:Aufladung von
Verbrennungssmotoren,
Pucher/Zinner, 2012, ISBN
978-3-642-28989-7
4. Special turbo constructions

•Uses air from the compressor with an extra fuel flow in the
exhaust system.
•Fuel is combusted in a separate combustion chamber to
increase the exhaust gas flow before the turbine ➔ more
energy for the large turbine
•Disadvantages are:
• Low torque without boosting due to reduced ε
• Difficult to start the cold engine due to low ε
• Increased specific fuel consumption
4. Special turbo constructions
4.8 Axial turbo system

• Turbo system developed by Honeywell

• Axial flow turbine
• “Dual sided compressor”
• Waste gated turbo without any nozzles, vanes etc.
• Developed for >1,4 l. engines
• Better (low end) efficiency than radial turbine
• 50% Less inertia than conventional turbo
• 25% faster “time to torque”
• 20% more torque during spool up (in 1 s. after transient
conditions in load)
4. Special turbo constructions
4.8 Axial turbo system

http://turbo.honeywell.com/assets/pdfs/120202-EN-Vienna-Motor-Symposium-Presentation.pdf May 2013

4. Special turbo constructions
4.8 Axial turbo system

(Click on picture)

http://turbo.honeywell.com/whats-new-in-turbo/video/gasoline-dualboost-turbo/?popup=video May 2013

Literature
• Introduction to internal combustion engines, Richard Stone, ISBN
978-0-230-57663-6, Chapter 10