New Methods for Proper Boosting Systems

Authors

Prof. Dr.-Ing. H. Zellbeck, Dipl.-Ing. T. Roß, Dipl.-Ing. C. Guhr, Technische Universität Dresden

Year

2008

Print Info

Fortschritt-Berichte VDI, Reihe 12, Nr. 672

Summary

Any development of appropriate charging systems for internal combustion engines means an enormous challenge. For the most part, exceeding the performance of the previous engine model and attaining increased emission regulations are the main targets. The requirements for a high quality of control during driving operation also have an impact. Therefore, single-stage charging systems are often insufficient. Unlike spark ignition engines diesel engines are predestined for regulated two-stage turbocharging due to lower exhaust gas temperature and less sensitivity to residual gas. As a result of their complexity dimensioning and testing of modern charging systems require extraordinary efforts. This process starts with theoretical preliminary considerations and ends with the final test of the vehicle equipped with the complete charging system. For configuring that process as efficient as possible not only different methods of development and simultaneous engineering are required, but their tight combination is ultimately the key. A 1D simulation model can already be created in an early state of the development process based on the thermodynamic behaviour of the basic engine. Having preselected the charging system by theoretical concept studies the interaction with the basic engine is matched by using 1D simulation. The measurement data are acquired on an alternative hot gas test bench. The computer-aided design of the charging system provides both the data for a future production and the basis for a 3D CFD simulation. In-depth analysis can be obtained by direct coupling of the 1d- and 3d-simulation. By now, the attained results can be utilized to affect the design engineering. It is only now that the prototype charging system is manufactured followed by tests on the basic engine. Necessary control structures are developed parallel to tests on a highly dynamic engine test stand. Also in this case it is important to support the development by using a 1D simulation model. That means a multiple of possibilities for investigation, for operating conditions can be realized that are difficult or impossible to be tested on the experimental system. Through this a closed loop of all development tools is achieved, which leads to an optimized efficiency of the whole development process. This article uses the example of a regulated two-stage turbocharging on a diesel engine to present such an interlinked process of development.

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