Analysis of Sequential Turbocharger Systems for Diesel Engines Rob Stalman, Vanco Smiljanowski, Uwe Späder, Ford Research & Advanced Europe

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1 Analysis of Sequential Turbocharger Systems for Diesel Engines Rob Stalman, Vanco Smiljanowski, Uwe Späder, Ford Research & Advanced Europe October 24 th 2011, Ford Forschungszentrum Aachen GmbH, All rights reserved

2 Contents: Introduction & motivation Comparison of Sequential Turbocharging Systems Switching of a parallel sequential system Summary Page 2

3 Contents: Introduction & motivation Comparison of Sequential Turbocharging Systems Switching of a parallel sequential system Summary Page 3

4 Introduction Specific Power of Passenger Car Diesel Engines in Europe. 100 Specific Power [kw/l] Naturally Aspirated Turbocharged Turbocharged & Intercooled Sequential Systems Year [-] Page 4

5 Introduction % PM PM [mg/km] % NO x -28% NO x 5 0 EU6 EU5 EU NO x [mg/km] Page 5

6 Contents: Introduction & motivation Comparison of Sequential Turbocharging Systems Switching of a parallel sequential system Summary Page 6

7 Sequential Boosting Systems Layout Parallel Sequential Series Sequential TC1 Turbine Shutoff Valve Compressor Bypass Valve TC2 wastegate Compressor Recirc Valve Turbine Bypass Valve TC1 TC2 Page 7

8 Sequential Boosting Systems Layout Parallel Sequential Series Sequential Page 8

9 Compressor Maps Parallel Sequential Compressor 1 Compressor 2 Pressure ratio Druckverhältnis Pressure ratio Druckverhältnis Mass flow Mass flow Massenstrom Massenstrom Page 9

10 Compressor Maps Parallel Sequential Compressor 1 Compressor 2 first operating point parallel (twin turbo) Pressure ratio Druckverhältnis Full load single turbo Pressure ratio Druckverhältnis first operating point parallel (twin turbo) Mass flow Mass flow Massenstrom Massenstrom Page 10

11 Compressor Maps Parallel Sequential Compressor 1 Compressor 2 Pressure ratio Druckverhältnis Full load parallel Pressure ratio Druckverhältnis Full load parallel Mass flow Mass flow Massenstrom Massenstrom Page 11

12 Compressor Maps Series Sequential Druckverhältnis Pressure ratio C:\users\hkindl\CTI\2stufig2.ipw Massenstrom flow

13 Full Load Performance & Emissions Range Single VNT Series Sequential Series Sequential + VNT Parallel Sequential Torque FTP75 & US06 Application with lowest weight 1000 Engine Speed 4000 Page 13

14 Comparison Package: Series Sequential general has a very big TC2 which is a challenge to package. Parallel Sequential is more compact and flexible to package. All are more complex to package than single VNT. Aftertreatment / Emissions: Series sequential turbine side has a high thermal inertia that impacts temperature available for the aftertreatment system.. The boosting systems in general compete for the same package space as parts of the aftertreatment system. This can lead to unfavourable compromises. Transient & driveability: Both sequential systems have better transient behaviour than single VNT Parallel has slightly better transient behaviour. Series Sequential is more suited to extend engine rpm range Page 14

15 Comparison Fuel economy over NEDC slightly better for parallel sequential Longer design lead time for complex boosting systems, special care must be taken in case of series sequential. Series Sequential usually involves a big exhaust manifold casting including one of the turbine stages, requiring design effort Turbine side valves are critical for both (leakage, DP, response, robustness). Both systems cost more than a single VNT. Mode switching performance critical. Mode switch of parallel sequential discrete, serial sequential much more smooth Switching with EGR? Page 15

16 Contents: Introduction & motivation Comparison of Sequential Turbocharging Systems Switching of a parallel sequential system Summary Page 16

17 Parallel Sequential Switching - Valves Open Parameter [%] Turbine shut-off valve 20 Closed Time [sec] Page 17

18 Parallel Sequential Switching - Valves Open Parameter [%] Turbine shut-off valve Compressor bypass valve Recirculation valve 20 Closed Time [sec] Page 18

19 Parallel Sequential Switching - Valves Open Parameter [%] Turbine shut-off valve Compressor bypass valve Recirculation valve Turbine VNT position Closed Time [sec] Page 19

20 Parallel Sequential Switching - Valves Open Parameter [%] Turbine shut-off valve Compressor bypass valve Recirculation valve Turbine VNT position Dashed: measured signals Closed Time [sec] Page 20

21 Parallel Sequential Switching - Measured TC speed [rpm] Speed TC1 Speed TC2 110 Torque Boost Pressure Pressure ds TC1 Pressure ds TC Torque, Pressure (rel) [%] Signal [%] VT2 VNT Position Compressor Shut Off Valve Recirculation Valve time [s] Page 21

22 Parallel Sequential Switching - Measured Switch from single turbo to biturbo, high partload, measured. Video courtesy of L. Bartsch Page 22

23 Contents: Introduction & motivation Comparison of Sequential Turbocharging Systems Switching of a parallel sequential system Summary Page 23

24 Summary Both Parallel Sequential and Series Sequential offer the potential to increase specific power and torque, with Series Sequential more suitable for engine rpm increase. This increase can either be used to increase performance or allow downsizing. Both systems face a number of constraints: package cost complexity High thermal inertia is a risk for series sequential Step-wise switching poses a challenge for parallel sequential Correct system choice depends entirely on the application (In-Line or V-engine, vehicle, duty cycle etc...) Page 24

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