מערכות טורבו וניהול ממוחשב

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Brent Blankenship
5 years ago
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1 מערכות טורבו Invented for life וניהול ממוחשב 0 ארז מוספי- מדריך ראשי Aftermarket ומנהל Automotive ההדרכה BOSCH

2 History of exhaust-gas turbocharger Alfred Büchi Patent: Turbocharger by Alfred Büchi (1905) 194 Ship's engine 1938 Commercial vehicle (Saurer) 1974 BMW 00 Turbo 1978 Mercedes Benz 300 SD 1

Turbocharging concept Mechanical supercharging In case of mechanical supercharging, a compressor is driven directly by the internal combustion engine.

rs (compressor) with different designs (e.g. roots charger, sliding-vane supercharger, spiral-type supercharger, exhaust-driven screw-charger) or as the centrifugal turbocompressor (e.g. radial compressor).

3 Turbocharging concept Mechanical supercharging In case of mechanical supercharging, a compressor is driven directly by the internal combustion engine. Mechanically driven compressors are available as positive displacement superchargers (compressor) with different designs (e.g. roots charger, sliding-vane supercharger, spiral-type supercharger, exhaust-driven screw-charger) or as the centrifugal turbocompressor (e.g. radial compressor). The power to drive a mechanical turbocharger is up to 15 % of the engine output. Therefore, fuel consumption is higher when compared with a naturally aspirated engine with the same power output. The main components of an exhaust-gas turbocharger are - an exhaust-gas turbine and a compressor, whose wheels are arranged on a common shaft. These components are seated in the exhaust-gas system, so that the exhaust-gas can drive the exhaust-gas turbine. The compressor compresses the aspirated air and thus, increases the cylinder charge. Exhaust-gas turbocharging

with charge regulation 1. Aneroid capsule. Lubricating oil inlet 1 3 4 3. Swirl duct 4. Aneroid capsule adjustment 19 5 5. Control flap 6. Turbine housing 7. Exhaust gas 18 8. Turbine wheel 9.

4 with charge regulation 1. Aneroid capsule. Lubricating oil inlet Swirl duct 4. Aneroid capsule adjustment Control flap 6. Turbine housing 7. Exhaust gas Turbine wheel 9. Swirl duct Shaft 11.Bearing housing 1.Axial bearing Swirl duct 14.Compressor wheel Compressor outlet 16.Intake air 17.Compressed air to the intercooler 18.Compressor housing 19.Control line 3

Total pressure ratio Exhaust-gas Turbocharger - Compressor 1 3 6 7 4 5 3,0,0 P 0 =981 mbar T 0 =93K 8 1,0 0 0,06 0,1 red. volume m 3 /s 9 10 1. Compressor housing backplate. Swirl duct 3.

Choke line Compressor map of a turbo-charger for passenger cars The compressor consists of the impeller, diffuser, and compressor housing.

5 Total pressure ratio Exhaust-gas Turbocharger - Compressor ,0,0 P 0 =981 mbar T 0 =93K 8 1,0 0 0,06 0,1 red. volume m 3 /s Compressor housing backplate. Swirl duct 3. Compressor wheel 4. Compressor housing 5. Fresh air from the engine 6. Lock nut 7. Compressed air to the intercooler 8. Surge limit 9. Maximum permissible ATL-speed 10.Choke line Compressor map of a turbo-charger for passenger cars The compressor consists of the impeller, diffuser, and compressor housing. As with the exhaust gas turbine-, the compressor is tuned optimally to meet the engine specifications. The radial-flow compressor impeller transfers the majority of the kinetic energy, provided by the turbine, to the air flow. The required pressure increase is then generated in a diffuser in the compressor housing. 4

Turbine 1 4 1. Turbine housing. Swirl duct 3. Rotor shaft=turbine wheel 4.

The turbine converts the engine exhaust gas into mechanical energy to drive the compressor.

6 Turbine Turbine housing. Swirl duct 3. Rotor shaft=turbine wheel 4. Exhaust gas flow 3 Generally, the turbine of a turbocharger consists of the turbine wheel and the turbine housing. The turbine converts the engine exhaust gas into mechanical energy to drive the compressor. The gas, which is restricted by the turbine's flow cross-sectional area, results in a pressure and temperature drop between the inlet and outlet. This pressure drop is converted by the turbine into kinetic energy to drive the turbine wheel. 5

- Lubrication 1 3 4 5 1. Piston-ring seal. Bearing housing 3.

7 - Lubrication Piston-ring seal. Bearing housing 3. Rotor shaft 4. Oil inlet 5. Axial bearing 6. Radial bearing bushing 7. Water inlet 6 7 6

- Cooling 1 1. Oil inlet connection. Water inlet connection The cooling system of the turbocharger is integrated in the cooling circuit of the engine.

8 - Cooling 1 1. Oil inlet connection. Water inlet connection The cooling system of the turbocharger is integrated in the cooling circuit of the engine. After the engine is shut down, it is possible to actuate an electrical water pump that further drives the small engine cooling circuit. Gasoline engine C Diesel engine C. 7

- Divert-air valve Divert air valve open (overrun

and during deceleration; this back pressure slows

In order to avoid this, the divert air valve is

9 - Divert-air valve Divert air valve open (overrun mode) A back pressure acts during the overrun mode and during deceleration; this back pressure slows down the compressor wheel (turbo lag). In order to avoid this, the divert air valve is opened by an electric actuator. 8 Divert air valve closed (load mode)

10 מומנט מנוע תחומי הפעלת הגידוש תחום פעילות דינמית של מגדש על תחום פעילות בלעדית למגדש טורבו תחום פעילות רציפה של מגדש על 9 סל"ד מנוע

11 המים מניעות את מכלולי העזר של המנועV Poly רצועות מסוג רצועה אחת מניעה את מש' המים, מדחס המזגן והאלטרנטור רצועה שניה מניעה את מגדש העל דרך מצמד חשמלי המותקן ע"ג מכלול מש' אלטרנטור מש' מים מצמד חשמלי מותחן מגדש על מדחס מזגן מותחן 10

12 מגדש העל מגיע כיחידה לא ניתנת לפירוק מגדש על מכלול גלגלי השיניים מלא בשמן מיוחד וללא טיפול המגדש מסתובב במהירות של פי 5 מגל הארכובה מהירות הסיבוב המקסימלית של המגדש היא 17,500 סל "ד מכלול גלגלי השיניים רוטורים 11

Turbocharger with Variable Turbine Geometry (VTG) Compressor wheel Turbine wheel Intake air Guide vane Pneumatic control unit Guide vane

Turbocharger with pneumatic control VTG Turbocharger with electrical control Exhaust-gas temperature sensor Varying the rate of gas flow

13 Turbocharger with Variable Turbine Geometry (VTG) Compressor wheel Turbine wheel Intake air Guide vane Pneumatic control unit Guide vane adjustment Actuator motor Electrical control unit Guide vanes Vaccuum Cooler Atmospheric pressure Exhaust-gas Functional principle VTG Turbocharger with pneumatic control VTG Turbocharger with electrical control Exhaust-gas temperature sensor Varying the rate of gas flow through the turbine by means of variable turbine geometry (VTG) is another method by which the exhaust-gas flow rate can be limited at high engine speeds. The adjustable deflector blades (3) alter the size of the gap through which the exhaust gas flows in order to reach the turbine (variation of geometry). By doing so, they adjust the exhaust-gas pressure acting on the turbine in response to the required turbocharger pressure. 1

14 Boost pressure control - VTG Boost pressure 1. Atmospheric pressure. Vaccuum 3. Solenoid valve 4. Vaccuum unit Exhaust-gas pressure Engine speed low 1 3 Boost pressure 4 Exhaust-gas pressure Engine speed high 13

Boost pressure control - Electro-pneumatic pressure transducer 1 Test: Signal recording with FSA 3 4 1. Supply - vaccuum (VAC). Variable control pressure (OUT) 3.

On the one hand, the supply pressure VAC is actuated by a diaphragm; on the other hand, a controlling magnetic force acts upon the double-seated valve via an armature.

15 Boost pressure control - Electro-pneumatic pressure transducer 1 Test: Signal recording with FSA Supply - vaccuum (VAC). Variable control pressure (OUT) 3. Ventilation connection (ATM) 4. Electrical connection Idling Acceleration The core piece of the EPW is a double-seated valve. On the one hand, the supply pressure VAC is actuated by a diaphragm; on the other hand, a controlling magnetic force acts upon the double-seated valve via an armature. Hence, the EPW forms a mixed pressure from the vacuum and the ambient pressure (control pressure). The vent connection should be equipped with a filter to protect the EPW from contamination. The control unit provides a PWM-signal, to actuate the EPW. 14

16 Diagnosis in the vehicle using KTSxxx 15

Checking shaft play Inspection for the ease of movement and for grinding noises Checking axial and radial play Testing the shaft play 1. Hold the shaft and move it radial.

17 Checking shaft play Inspection for the ease of movement and for grinding noises Checking axial and radial play Testing the shaft play 1. Hold the shaft and move it radial. Thereby, a (required) radial play of 1/10 mm 6/10 mm is permitted. Depends on the manufacturer. Lift the shaft slightly and rotate. In the process, no grinding noises should be noticeable and the turning resistance should not change. Otherwise, bearing damage can be expected. 3. Missing clearance indicates bearing problems, which would arise due to coked oil. 4. An axial clearance (to and fro movement of the shaft) should not be (significantly) perceivable. 16

18 Turbocharger damage types 1 Fault: Poor lubrication or oil loss Foreign objects in the compressor or the turbine. Poor oil quality Fault pattern: Discoloration and bearing metal deposition Damage caused by foreign bodies Dirt ridges on the shaft Twisting of the bearing bush due to lack of oil Compressor wheel damaged by hard foreign bodies Ridges on the radial bearing bush due to dirt particles 17

19 One-stop Solution Invented for life תודה רבה על ההקשבה Spare Parts 18

SUPERCHARGER AND TURBOCHARGER

SUPERCHARGER AND TURBOCHARGER 1 Turbocharger and supercharger 2 To increase the output of any engine more fuel can be burned and make bigger explosion in every cycle. i. One way to add power is to build