Upload
janis-lucas
View
217
Download
2
Embed Size (px)
Citation preview
1
Simulation and Implementation of
Turbocharging a 600cc Engine for Formula
SAEMario Farrugia
Nicholas Grech
Marlon Chircop
Jean Paul Azzopardi
2
Introduction
•FSAE restrictor
•Turbocharging PST vs CPT
•Garrett Honeywell GT 15V vs GT 12
•Kawasaki 600cc engine
3
Objectives
•Simulations in Wave of Turbocharged engine
•Implementation of turbocharger
• Dynamometer testing of turbocharged engine
4
Choice of Turbocharger
•Garrett donate GT 12 fixed geometry
•And also GT15V variable geometry
•Choice of GT 15 V because some experience was gathered at Oakland University (Michigan) on GT 12, so now took the variable geometry challenge
5
Variable Geometry Turbine
•
6
The vane mechanism
•
7
1D engine Simulation
Wave®
8
Simulations
•Simulations in Wave of Turbocharged engine
•Started from naturally aspirated simulations SAE papers 2005-01-0025and 2006-01-3651
9
Compressor Map
GT 15V donated by
Garrett Honeywell
10
The Variable Geometry Turbine Map
FULL RANGE TURBINE MAP - ISOWORKLINE N°4TURBINE: GT15V (7.9 mm shaft) - T109(39) - 58 Trim - 0,42 A/R
0.4
0.4
0.45
0.45
0.5
0.5
0.55
0.55
0.6
0.6
Open
4/5 open
3/5 open
2/5 open
1/5 open
1/10 open
Closed
122550rpm at 0,9 %
0
1
2
3
4
5
6
7
8
1 1.5 2 2.5 3 3.5Turbine Expansion Ratio
corr
ecte
d m
ass
flow
(lb/
min
)
open 4/5open 3/5open 2/5open 1/5open 1/10open closed
WW T
PT
T
* /
/ . 1
1
519
2992N
N
TT
phy
T
1 519/
11
Wave Model
12
Effect of Compression Ratio on Knock
13
Effect of Compression Ratio on Torque
Kawasaki 600cc engine with GT 15V
14
Various PST turbocharging setups
15
25
35
45
55
65
75
3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Engine Speed (rpm)
Torq
ue (N
m)
Boost 1.5bar
Boost 1.5bar, intercooled
Boost 1.5bar, intercooled, modified valve timing
Boost 1.5bar, intercooled, modified valve timing, tuned exhaust length
Final model, CR 7
Naturally Aspirated
15
Exhaust Setup
16
Inlet Manifold
17
Throttle Body and Restrictor
18
Timing Chain Length Inspection
19
Machined Decompression Plate
CNC machined decompression plate, 3mm aluminium sheet
20
Mechanical Seal on Compressor Side
CNC machined compressor back plate and mechanical seal components
21
Scavenge Oil Pump and Breaking Oil Siphon
•.
•.Oil Pump Photos
•.Jean Paul ‘s Photos
Turbo
Oil Pan
Turbo
Oil Pan
22
Cam Sensor Novel Implementation
•.A strong, 250gr rated, magnet was inserted into a bolt and swage locked in the bolt.•Magnet has north and south on the axis
•.The bolt was installed in one of the cam sprocket OEM holes Ol ump Photos
•Cam signal is trace 1, crank signal is trace 2
23
Scavenge Oil Pump and Breaking Oil Siphon
•.Oil supply taken from highest point, and also a point that has connection to atmosphere when engine is stopped so that siphon is broken
24
Dynamometer Testing
25
Exhaust Gas Temperature variation with Spark Timing
• EGT drops with more advanced timing
26
Air Temperature and Manifold Absolute Pressure
• Air temperature increase with rise in boost pressure as expected
27
Charge Air Cooler
•Direction 1 is shorter than direction 2 , so direction 2 was used to have more effectiveness of the heat exchanger.
28
TPS Compensation On Fuel Quantity
•Engine was with MAP as the load parameter but due to large cam overlap high exhaust residuals exist at idle which result in high MAP Values at idle as discussed in SAE 2005-01-0025 .
TPS % Compensation
0 45
5 45
15 50
25 55
50 100
75 100
100 100
•The TPS compensation effectively generates a low throttle map or sometimes called zero throttle map.
29
Toruqe measurements
•Maesurement of Torque on dynamometer with increase in RPM and resulting boost pressures
30
Steady State: Variation of Electrical Power Input with Frequency
• Limited capability to control rpm and MAP
31
Conclusion
32
Concluding Remarks
•Engine was successfully run
•Oil problems solved by mechanical seal and breaking of siphon
•Charge air cooler controlled temperature well
•TPS compensation to counteract High MAP values at idle
•External Wastegate implemented in ongoing project to have a stable system on dyno.
Thank you Questions ?