Turbocharging is an efficient approach for addressing power reduction and oil consumption increase in aviation piston engines during high-altitude flights.However,a turbocharger significantly increases the complexity ...Turbocharging is an efficient approach for addressing power reduction and oil consumption increase in aviation piston engines during high-altitude flights.However,a turbocharger significantly increases the complexity of a power system,and its considerably complex matching relation with the engine results in a coupling of failure modes.Conventional analytical methods are hard to identify failure-inducing factors.Consequently,safety issues are becoming increasingly prominent.This study focuses on methods for identifying failure-inducing factors.A whole-machine system model is established and validated through experimentation.The response surface method is employed to further abstract the system simulation model to a surrogate model(average error:~3%)in order to reduce the computational cost while ensuring accuracy.On this basis,an improved Correspondence Analysis(CA)-Polar Angle(PA)-based Classification(PAC)is proposed to identify the key factors affecting the failure mode of turbochargers.This identification method is based on the row profile coordinates G varying with the numerical deviations of the key factors,and is capable of effectively identifying the key factors affecting the failure.In a validation example,this method identifies the diameter of the exhaust valve(e_(2))as the primary factor affecting the safety margin for each work boundary.展开更多
Nowadays alternative and innovative energy recovery solutions are adopted on board ships to reduce fuel consumption and harmful emissions.According to this,the present work compares the engine exhaust gas waste heat r...Nowadays alternative and innovative energy recovery solutions are adopted on board ships to reduce fuel consumption and harmful emissions.According to this,the present work compares the engine exhaust gas waste heat recovery and hybrid turbocharger technologies,which are used to improve the efficiency of a dual-fuel four-stroke(DF)marine engine.Both solutions aim to satisfy partly or entirely the ship’s electrical and/or thermal loads.For the engine exhaust gas waste heat recovery,two steam plant schemes are considered:the single steam pressure and the variable layout(single or dual steam pressure plant).In both cases,a heat recovery steam generator is used for the electric power energy generation through a steam turbine.The hybrid turbocharger is used to provide a part of the ship’s electric loads as well.The thermodynamic mathematical models of DF engines,integrated with the energy recovery systems,are developed in a Matlab-Simulink environment,allowing the comparison in terms of performance at different engine loads and fuels,which are Natural Gas(NG)and High Fuel Oil(HFO).The use of NG always involves better efficiency of the system for all the engine working conditions.It results that the highest efficiency value achievable is 56%at 50%maximum continuous rating(MCR)engine load.展开更多
Power deterioration is a major problem for diesel engines operating at high altitudes.This problem stems from the limited availability of turbocharger energy,which is not enough to increase the boost pressure to the r...Power deterioration is a major problem for diesel engines operating at high altitudes.This problem stems from the limited availability of turbocharger energy,which is not enough to increase the boost pressure to the required level.In this study,a control strategy is introduced in order to achieve engine power recovery at different altitudes.It is shown that as the altitude increases from 0 to 4500 m,the required boost pressure ratio increases from 2.4 to 4.3.The needed turbocharger energy should be increased accordingly by 240%,and the TCC(turbine characterization coefficient)should be adjusted within wide ranges.A 12%decrease in the TCC can lead to a rise of the intake air pressure,which can compensate the pressure decrease due to a 1000 m altitude increase.The fluctuation range of boost pressure was within 14.5 kPa for variations in altitude from 0 to 4500 m.展开更多
The inner and outer oil film dynamic characteristic coefficients of floating ring bearings(FRBs) change due to the manufacturing tolerance of the floating ring, journal and intermediate, which leads to high-speed tu...The inner and outer oil film dynamic characteristic coefficients of floating ring bearings(FRBs) change due to the manufacturing tolerance of the floating ring, journal and intermediate, which leads to high-speed turbocharger's vibration too large and even causes nonlinear vibration accident. However, the investigation of floating ring bearing manufacturing tolerance clearance on the rotordynamic characteristics is less at present. In order to study the influence law of inner and outer clearance on turbocharger vibration, the rotor dynamic motion equations of turbocharger supported in FRBs are derived by analyzing the size relations between floating ring, journal and intermediate for the inner and outer oil film clearances, the time transient response analysis for combination of FRBs clearance are developed. A realistic turbocharger is taken as a research object, the FE model of the turbocharger with FRBs is modeled. Under the conditions of four kinds of limit state bearing clearances for inner and outer oil film, the nonlinear transient analyses are performed based on the established FE dynamic models of the nonlinear rotor-FRBs system applied incentive combinations of gravity and unbalance force, respectively. From the waterfall, the simulation results show that the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different under the four kinds of bearing manufacturing tolerance limit clearances, and fractional frequency does not appear in the turbocharger and the amplitude is minimum under the ODMin/IDMax bearing manufacturing tolerance clearances. The turbocharger vibration is reduced by controlling the manufacturing tolerance clearance combinations of FRBs, which is helpful for the dynamic design and production-manufacturing of high-speed turbocharger.展开更多
Blade vibration failure is one of the main failure modes of compressor wheel of turbocharger for vehicle application. The existing models for evaluating the reliability of blade vibration of compressor wheel are stati...Blade vibration failure is one of the main failure modes of compressor wheel of turbocharger for vehicle application. The existing models for evaluating the reliability of blade vibration of compressor wheel are static, and can not reflect the relationship between the reliability of compressor wheel with blade vibration failure mode and the life parameter. For the blade vibration failure mode of compressor wheel of turbocharger, the reliability evaluation method is studied. Taking a compressor wheel of turbocharger for vehicle application as an example, the blade vibration characteristics and how they change with the operating parameters of turbocharger are analyzed. The failure criterion for blade vibration mode of compressor wheel is built with the Campbell diagram, and taking the effect of the dispersity of blade natural vibration frequency and randomness of turbocharger operating speed into account, time-dependent reliability models of compressor wheel with blade vibration failure mode are derived, which embody the parameters of blade natural vibration frequency, turbocharger operating speed, the blade number of compressor wheel, life index and minimum number of resonance, etc. Finally, the rule governing the reliability and failure rate of compressor wheel and the method for determining the reliable life of compressor with blade vibration is presented. A method is proposed to evaluate the reliability of compressor wheel with blade vibration failure mode time-dependently.展开更多
Semi-floating ring bearing(SFRB) is developed to control the vibration of turbocharger rotor. The outer clearance of SFRB affects the magnitude and frequency of nonlinear whirl motion, which is significant for the d...Semi-floating ring bearing(SFRB) is developed to control the vibration of turbocharger rotor. The outer clearance of SFRB affects the magnitude and frequency of nonlinear whirl motion, which is significant for the design of turbocharger. In order to explore the effects of outer clearance, a transient finite element analysis program for rotor and oil film bearing is built and validated by a published experimental case. The nonlinear dynamic behaviors ofrotor-SFRB system are simulated. According to the simulation results, two representative subsynchronous oscillations excited by the two hearings respectively are discovered. As the outer clearance of SFRB increases from 24 ~tm to 60 pro, the low-frequency subsynchronous oscillation experiences three steps, including a strong start, a gradual recession and a combination with the other one. At the same time, the high-frequency subsynchronous oscillation starts to appear gradually, then strengthens, and finally combines. If gravity and unbalance are neglected, the combination will start starts from high rotor speed and extents to low rotor speed, just like a "zipper". It is found from the quantitative analysis that when the outer clearance increases, the vibration amplitude experiences large value firstly, then reduction, and suddenly increasing after combination. A useful design principle of SFRB outer clearance for minimum vibration amplitude is proposed: the outer clearance value should be chosen to keep the frequency of two subsynchronous oscillations clearly separated and their amplitudes close.展开更多
The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achiev...The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achieving cost and durability performance somewhere between that of cast and machined from solid(MFS) aluminium alloy wheels.Experimental results show SSM material has a superior microstructure and mechanical properties over cast and comparable to MFS materials.Component testing including durability testing,using accelerated speed cycle tests,proves SSM compressor wheels emerge as being significantly more durable than cast equivalents and approaching that of MFS impellers.Further challenges for semi-solid processing in manufacture of other complex components and other materials in automotive industry in terms of both cost and durability are also discussed.展开更多
Casting technology of thin-wall TiAl alloy turbochargers was studied by investment casting and numerical simulation.Misruns and gas holes were the main defects observed in preliminary work due to the poor fluidity of ...Casting technology of thin-wall TiAl alloy turbochargers was studied by investment casting and numerical simulation.Misruns and gas holes were the main defects observed in preliminary work due to the poor fluidity of alloy,and to gas entrapment.In order to eliminate these defects,cast parameters,such as centrifugal rotation rate and mould preheating temperature,were optimized by numerical simulation,meanwhile,the structure of the shell mould was optimized to improve the filling capacity of TiAl alloy.Pouring experiments were carried out by vacuum induction melting furnace equipped with a water-cooled copper crucible based on the above optimization.The quality of the TiAl alloy casting was analyzed by fluorescent penetrant inspection and X-ray detection.The results show that a centrifugal rotation rate of 200 rpm,mould preheating temperature of 600°C,shell preparation through organic fiber addition can dramatically improve the mould filling capacity,and integrated turbochargers were finally prepared.展开更多
The critical speed and unbalance response of a small vehicle gasoline turbocharger in semi-floating bearing are analyzed.The dynamical characters of semi-floating bush bearing used in small vehicle gasoline turbocharg...The critical speed and unbalance response of a small vehicle gasoline turbocharger in semi-floating bearing are analyzed.The dynamical characters of semi-floating bush bearing used in small vehicle gasoline turbocharger were summarized by comparing the structure and shaft rigid mode of semi-floating bush bearings with those of floating bush bearings.The rotor model was built.The first,second and third mode of critical speeds of rotor system were computed,and the changes in the compressor or turbine bushing bearing clearances were analyzed.Compared with the experiment data,the accuracy and the rationality of computation model were verified.The unbalance response and time transient rotor response were also computed.展开更多
The critical speeds for a vehicle turbocharger with hybrid ceramic ball bearing are researched. The ball bearing-rotor system produces resonance when it working in critical speed and that makes the turbocharger injury...The critical speeds for a vehicle turbocharger with hybrid ceramic ball bearing are researched. The ball bearing-rotor system produces resonance when it working in critical speed and that makes the turbocharger injury working for a long time. The calculation and analysis methods of the critical speed for the vehicle turbocharger are described. The critical speed is computed by two methods including Riccati transfer matrix and DyRoBeS finite element method for a vehicle turbocharger with hybrid ceramic ball bearing. The vibration experiment had been taken to validate the calculating result, Comparison between the results by two calculation methods and the test results show that the first critical speed differences are 6.47 % and 5.66 %, the second critical speed differences are 2.87 % and 2.94 % respectively. And then, the primary factors which influence the critical speed are analyzed, the conclusions will be helpful for the vehicle turbocharger bearing-rotor system design.展开更多
As turbocharging diesel engines for vehicle application are applied in plateau area, the environmental adaptability of engines has drawn more attention. For the environmental adaptability problem of turbocharging dies...As turbocharging diesel engines for vehicle application are applied in plateau area, the environmental adaptability of engines has drawn more attention. For the environmental adaptability problem of turbocharging diesel engines for vehicle application, the present studies almost focus on the optimization of performance match between turbocharger and engine, and the reliability problem of turbocharger is almost ignored. The reliability problem of compressor impeller of turhocharger for vehicle application when diesel engines operate in plateau area is studied. Firstly, the rule that the rotational speed of turbocharger changes with the altitude height is presented, and the potential failure modes of compressor impeller are analyzed. Then, the failure behavior models of compressor impeller are built, and the reliability models of compressor impeller operating in plateau area are developed. Finally, the rule that the reliability of compressor impeller changes with the altitude height is studied, the measurements for improving the reliability of the compressor impellers of turbocharger operating in plateau area are given. The results indicate that when the operating speed of diesel engine is certain, the rotational speed of turbocharger increases with the increase of altitude height, and the failure risk of compressor impeller with the failure modes of hub fatigue and blade resonance increases. The reliability of compressor impeller decreases with the increase of altitude height, and it also decreases as the increase of number of the mission profile cycle of engine. The method proposed can not only be used to evaluating the reliability of compressor impeller when diesel engines operate in plateau area but also be applied to direct the structural optimization of compressor impeller.展开更多
For the high-speed gasoline engine turbocharger rotor, due to the heterogeneity of multiple parts material, manufacturing and assembly errors, running wear in impeller and uneven carbon of turbine, the random unbalanc...For the high-speed gasoline engine turbocharger rotor, due to the heterogeneity of multiple parts material, manufacturing and assembly errors, running wear in impeller and uneven carbon of turbine, the random unbalance usually can be developed which will induce excessive rotor vibration, and even lead to nonlinear vibration accidents. However, the investigation of unbalance location on the nonlinear high-speed turbocharger rotordynamic characteristics is less. In order to discuss the rotor unbalance location effects of turbocharger with nonlinear floating ring bearings(FRBs), the realistic turbocharger of gasoline engine is taken as a research object. The rotordynamic equations of motion under the condition of unbalance are derived by applied unbalance force and nonlinear oil film force of FRBs. The FE model of turbocharger rotor-bearing system is modeled which includes the unbalance excitation and nonlinear FRBs. Under the conditions of four different applied locations of unbalance, the nonlinear transient analyses are performed based on the rotor FEM. The differences of dynamic behavior are obvious to the turbocharger rotor systems for four conditions, and the bifurcation phenomena are different. From the results of waterfall and transient response analysis, the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different from the different unbalance locations, and the non-synchronous vibration does not occur in the turbocharger and the amplitude is relative stable and minimum under the condition 4. The turbocharger vibration and non-synchronous components could be reduced or suppressed by controlling the applied location of unbalance, which is helpful for the dynamic design, fault diagnosis and vibration control of the high-speed gasoline engine turbochargers.展开更多
A variable nozzle turbocharger (VNT) was applied to a 2.2-liter L4 natural gas engine,and a VNT control system was designed to operate it.Based on VNT matching test results,a VNT control strategy was studied,in whic...A variable nozzle turbocharger (VNT) was applied to a 2.2-liter L4 natural gas engine,and a VNT control system was designed to operate it.Based on VNT matching test results,a VNT control strategy was studied,in which VNT adjustment is carried out through pre-calibrated VNT handling rod position,combined with a closed-loop target boost pressure feedback using proportional-integral-derivative(PID) algorithm.Experimental results showed that the VNT control system presented in this thesis can lead to optimized performance of VNT,increase engine volumetric efficiency over a wide speed range,improve engine dynamic characteristics and upgrade economic performance.展开更多
To compute the matching performance of diesel engine with variable geometry turboeharger(VGT), the formerly used program is improved through adjustment of turbine mass flow rate and efficiency characteristics. The c...To compute the matching performance of diesel engine with variable geometry turboeharger(VGT), the formerly used program is improved through adjustment of turbine mass flow rate and efficiency characteristics. The calculation result is applied to forecast the performance of J6110Z diesel engine with rotary-vaned VGT70, and to guide the improvement of engine fuel supply. The computed engine performance curve coincides with the experiment result well: the low-speed torque, fuel economy, exhaust temperature and boost pressure of the VGT engine are all improved.展开更多
The structure parameters in an actual industrial production have a great influence on the coefficient of supercharger floating bearing dynamic characteristics,but there has been little systematic study so far.In this ...The structure parameters in an actual industrial production have a great influence on the coefficient of supercharger floating bearing dynamic characteristics,but there has been little systematic study so far.In this paper,the influence of structural parameters of the turbocharger floating bearing on its dynamic characteristic coefficientsis systematically investigated based on the theories of hydrodynamic lubrication and tribology.The influence of clearance ratio on eccentricity and the influence of internal to external radius ratios,and Sommerfeld number were analyzed.A new formula of responding characteristics of the oil film force caused by the displacement or velocity disturbance was deduced near an equilibrium in the steady state.Applying the newly developed formula,the dynamic characteristic was studied for floating bearings.Regularity for change of oil film stiffness and damping was analyzed with the structural parameters of floating bearing such as radius ratios and eccentricity.It has been found that the clearance ratio increases with eccentricity when the radius ratio is unchanged.The eccentricity decreases with the internal to external radius ratio of floating rings when the clearance ratio is constant.The absolute value of total principal stiffness and total main damping decrease with the clearance ratio and radius ratio of floating rings when the total cross damping is stable.The results and findings in this paper can contribute to nonlinear dynamics designs of turbocharger rotor-bearing systems.展开更多
The noise prediction of the turbocharger is studied.The broadband noise source model is employed to predict the near-field noise of the turbocharger.The 3D software Solidworks is adopted to establish the model blades ...The noise prediction of the turbocharger is studied.The broadband noise source model is employed to predict the near-field noise of the turbocharger.The 3D software Solidworks is adopted to establish the model blades and inlet of turbocharger compressor,then this 3D model is introduced into the software CFD to calculate the flow-field under different inlet shapes,different blades shapes and different clearances between casing and impeller.On the base of the above simulation,the broadband noise source model is employed to calculate and analyze the near-field noise.The calculation shows that compressor static pressure values and the sound power values near the impeller outlet are the largest.Through the noise calculation by using broadband noise source model under different inlet shapes and blade shapes,we find that the noise level of the inlet of cylindrical and cone types are smaller.Compared with the current widespread used backward skewed or radial blades,there is little difference of the noise value of the inlet of the forward skewed blades.展开更多
A spatial motion mechanism was designed which could make all the nozzle vanes rotate a- round the center of ball with the same radius synchronously to realize control of the variable nozzle mixed-flow turbocharger (V...A spatial motion mechanism was designed which could make all the nozzle vanes rotate a- round the center of ball with the same radius synchronously to realize control of the variable nozzle mixed-flow turbocharger (VN-MT). The back and abdomen of the nozzle vane was designed as arc- shaped. A variable nozzle ring perfectly combined with the mixed-flow turbine was made available. The turbine geometric model of VN-MT was established through the computational fluid dynamics (CFD). Compared with nozzleless mixed-flow turbine, the flow range of variable nozzle mixed-flow turbine was broadened tremendously while the peak turbine efficiency point was lower slightly. Flow field analysis in turbine stage showed that the energy was larger and the blade load of rotor was lower than loss of the VN-MT under designed condition the nozzleless mixed-flow turbocharger.展开更多
A two stage turbocharging control system was proposed,in which the pressure regulator valve with a close-loop pressure adjusting function instead of a high speed on-off solenoid valve,is used as a driving mechanism of...A two stage turbocharging control system was proposed,in which the pressure regulator valve with a close-loop pressure adjusting function instead of a high speed on-off solenoid valve,is used as a driving mechanism of waste gate.A digital-analog(DA)conversion circuit based on pulse width modulation(PWM)generates one analog voltage signal required by the pressure regulating valve control.The principle of the DA conversion circuit was analyzed,meanwhile,the performance of the conversion circuit was improved by adopting a speed-up capacitor,which helps to increase the stability and responsiveness of the control voltage generated by the conversion circuit;the structure parameters of the circuit was optimized by simulation.After the optimization,the ripple wave of circuit output voltage was kept within16mV under the 12bit conversion accuracy,the conversion time of the circuit could be reduced to 4ms.The engine bench test show that the turbocharging boost pressure control system which adopted the circuit had a rather good stable control accuracy(the steady state within 0.8%)and dynamic response(the regulation time is less than 4s).展开更多
The blade root fatigue is one of important failure modes of turbocharger turbine for vehicle application,and the reliability and life of turbine with blade root fatigue failure mode are studied.Firstly,the stress char...The blade root fatigue is one of important failure modes of turbocharger turbine for vehicle application,and the reliability and life of turbine with blade root fatigue failure mode are studied.Firstly,the stress characteristics of turbine are analyzed,and based on the operating profile of turbocharger corresponding to the endurance test of engine,the stress spectrum of turbine with blade root fatigue failure mode is studied with the simulation method.Then,with the number of endurance test profile cycle as the life parameter,the reliability model and failure rate model of turbine with blade root fatigue failure mode are derived respectively. Finally,the rules that the reliability and failure rate of turbine with the blade root fatigue failure mode changes as life parameters are studied,and the life probabilistic characteristics of turbine are also studied.展开更多
基金supported by the Innovation Team of Complex System Safety and Airworthiness of Aeroengine from the Co-Innovation Center for Advanced Aeroengine of Chinafunded by the National Natural Science Foundation of China and the Civil Aviation Administration of China(No.U1833109)。
文摘Turbocharging is an efficient approach for addressing power reduction and oil consumption increase in aviation piston engines during high-altitude flights.However,a turbocharger significantly increases the complexity of a power system,and its considerably complex matching relation with the engine results in a coupling of failure modes.Conventional analytical methods are hard to identify failure-inducing factors.Consequently,safety issues are becoming increasingly prominent.This study focuses on methods for identifying failure-inducing factors.A whole-machine system model is established and validated through experimentation.The response surface method is employed to further abstract the system simulation model to a surrogate model(average error:~3%)in order to reduce the computational cost while ensuring accuracy.On this basis,an improved Correspondence Analysis(CA)-Polar Angle(PA)-based Classification(PAC)is proposed to identify the key factors affecting the failure mode of turbochargers.This identification method is based on the row profile coordinates G varying with the numerical deviations of the key factors,and is capable of effectively identifying the key factors affecting the failure.In a validation example,this method identifies the diameter of the exhaust valve(e_(2))as the primary factor affecting the safety margin for each work boundary.
文摘Nowadays alternative and innovative energy recovery solutions are adopted on board ships to reduce fuel consumption and harmful emissions.According to this,the present work compares the engine exhaust gas waste heat recovery and hybrid turbocharger technologies,which are used to improve the efficiency of a dual-fuel four-stroke(DF)marine engine.Both solutions aim to satisfy partly or entirely the ship’s electrical and/or thermal loads.For the engine exhaust gas waste heat recovery,two steam plant schemes are considered:the single steam pressure and the variable layout(single or dual steam pressure plant).In both cases,a heat recovery steam generator is used for the electric power energy generation through a steam turbine.The hybrid turbocharger is used to provide a part of the ship’s electric loads as well.The thermodynamic mathematical models of DF engines,integrated with the energy recovery systems,are developed in a Matlab-Simulink environment,allowing the comparison in terms of performance at different engine loads and fuels,which are Natural Gas(NG)and High Fuel Oil(HFO).The use of NG always involves better efficiency of the system for all the engine working conditions.It results that the highest efficiency value achievable is 56%at 50%maximum continuous rating(MCR)engine load.
基金funded by the National Natural Science Foundation of China[Grant Nos.51576129 and 12102298]the China Postdoctoral Science Foundation[Grant No.2021M702443]the State Key Laboratory of Engines(Tianjin University)[Grant No.K2022-09].
文摘Power deterioration is a major problem for diesel engines operating at high altitudes.This problem stems from the limited availability of turbocharger energy,which is not enough to increase the boost pressure to the required level.In this study,a control strategy is introduced in order to achieve engine power recovery at different altitudes.It is shown that as the altitude increases from 0 to 4500 m,the required boost pressure ratio increases from 2.4 to 4.3.The needed turbocharger energy should be increased accordingly by 240%,and the TCC(turbine characterization coefficient)should be adjusted within wide ranges.A 12%decrease in the TCC can lead to a rise of the intake air pressure,which can compensate the pressure decrease due to a 1000 m altitude increase.The fluctuation range of boost pressure was within 14.5 kPa for variations in altitude from 0 to 4500 m.
基金Supported by National Natural Science Foundation of China(Grant Nos.51205121,51375162)Scientific Research Foundation of Hunan Provincial Education Department of China(Grant No.13A023)Postgraduate Innovation Foundation of Hunan University of Science and Technology,China(Grant No.S140020)
文摘The inner and outer oil film dynamic characteristic coefficients of floating ring bearings(FRBs) change due to the manufacturing tolerance of the floating ring, journal and intermediate, which leads to high-speed turbocharger's vibration too large and even causes nonlinear vibration accident. However, the investigation of floating ring bearing manufacturing tolerance clearance on the rotordynamic characteristics is less at present. In order to study the influence law of inner and outer clearance on turbocharger vibration, the rotor dynamic motion equations of turbocharger supported in FRBs are derived by analyzing the size relations between floating ring, journal and intermediate for the inner and outer oil film clearances, the time transient response analysis for combination of FRBs clearance are developed. A realistic turbocharger is taken as a research object, the FE model of the turbocharger with FRBs is modeled. Under the conditions of four kinds of limit state bearing clearances for inner and outer oil film, the nonlinear transient analyses are performed based on the established FE dynamic models of the nonlinear rotor-FRBs system applied incentive combinations of gravity and unbalance force, respectively. From the waterfall, the simulation results show that the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different under the four kinds of bearing manufacturing tolerance limit clearances, and fractional frequency does not appear in the turbocharger and the amplitude is minimum under the ODMin/IDMax bearing manufacturing tolerance clearances. The turbocharger vibration is reduced by controlling the manufacturing tolerance clearance combinations of FRBs, which is helpful for the dynamic design and production-manufacturing of high-speed turbocharger.
基金supported by National Natural Science Foundation of China(Grant Nos.51375465,50905007)
文摘Blade vibration failure is one of the main failure modes of compressor wheel of turbocharger for vehicle application. The existing models for evaluating the reliability of blade vibration of compressor wheel are static, and can not reflect the relationship between the reliability of compressor wheel with blade vibration failure mode and the life parameter. For the blade vibration failure mode of compressor wheel of turbocharger, the reliability evaluation method is studied. Taking a compressor wheel of turbocharger for vehicle application as an example, the blade vibration characteristics and how they change with the operating parameters of turbocharger are analyzed. The failure criterion for blade vibration mode of compressor wheel is built with the Campbell diagram, and taking the effect of the dispersity of blade natural vibration frequency and randomness of turbocharger operating speed into account, time-dependent reliability models of compressor wheel with blade vibration failure mode are derived, which embody the parameters of blade natural vibration frequency, turbocharger operating speed, the blade number of compressor wheel, life index and minimum number of resonance, etc. Finally, the rule governing the reliability and failure rate of compressor wheel and the method for determining the reliable life of compressor with blade vibration is presented. A method is proposed to evaluate the reliability of compressor wheel with blade vibration failure mode time-dependently.
基金Supported by National Natural Science Foundation of China(Grant No51506108)
文摘Semi-floating ring bearing(SFRB) is developed to control the vibration of turbocharger rotor. The outer clearance of SFRB affects the magnitude and frequency of nonlinear whirl motion, which is significant for the design of turbocharger. In order to explore the effects of outer clearance, a transient finite element analysis program for rotor and oil film bearing is built and validated by a published experimental case. The nonlinear dynamic behaviors ofrotor-SFRB system are simulated. According to the simulation results, two representative subsynchronous oscillations excited by the two hearings respectively are discovered. As the outer clearance of SFRB increases from 24 ~tm to 60 pro, the low-frequency subsynchronous oscillation experiences three steps, including a strong start, a gradual recession and a combination with the other one. At the same time, the high-frequency subsynchronous oscillation starts to appear gradually, then strengthens, and finally combines. If gravity and unbalance are neglected, the combination will start starts from high rotor speed and extents to low rotor speed, just like a "zipper". It is found from the quantitative analysis that when the outer clearance increases, the vibration amplitude experiences large value firstly, then reduction, and suddenly increasing after combination. A useful design principle of SFRB outer clearance for minimum vibration amplitude is proposed: the outer clearance value should be chosen to keep the frequency of two subsynchronous oscillations clearly separated and their amplitudes close.
文摘The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achieving cost and durability performance somewhere between that of cast and machined from solid(MFS) aluminium alloy wheels.Experimental results show SSM material has a superior microstructure and mechanical properties over cast and comparable to MFS materials.Component testing including durability testing,using accelerated speed cycle tests,proves SSM compressor wheels emerge as being significantly more durable than cast equivalents and approaching that of MFS impellers.Further challenges for semi-solid processing in manufacture of other complex components and other materials in automotive industry in terms of both cost and durability are also discussed.
基金financially supported by the Liaoning Natural Science Foundation ( Grant No.20170540888)the Liaoning Science and Technology Project (Grant No.2017221006)
文摘Casting technology of thin-wall TiAl alloy turbochargers was studied by investment casting and numerical simulation.Misruns and gas holes were the main defects observed in preliminary work due to the poor fluidity of alloy,and to gas entrapment.In order to eliminate these defects,cast parameters,such as centrifugal rotation rate and mould preheating temperature,were optimized by numerical simulation,meanwhile,the structure of the shell mould was optimized to improve the filling capacity of TiAl alloy.Pouring experiments were carried out by vacuum induction melting furnace equipped with a water-cooled copper crucible based on the above optimization.The quality of the TiAl alloy casting was analyzed by fluorescent penetrant inspection and X-ray detection.The results show that a centrifugal rotation rate of 200 rpm,mould preheating temperature of 600°C,shell preparation through organic fiber addition can dramatically improve the mould filling capacity,and integrated turbochargers were finally prepared.
基金Supported by Turbocharging Laboratory of Beijing Institute of Technology(1030040610016)
文摘The critical speed and unbalance response of a small vehicle gasoline turbocharger in semi-floating bearing are analyzed.The dynamical characters of semi-floating bush bearing used in small vehicle gasoline turbocharger were summarized by comparing the structure and shaft rigid mode of semi-floating bush bearings with those of floating bush bearings.The rotor model was built.The first,second and third mode of critical speeds of rotor system were computed,and the changes in the compressor or turbine bushing bearing clearances were analyzed.Compared with the experiment data,the accuracy and the rationality of computation model were verified.The unbalance response and time transient rotor response were also computed.
文摘The critical speeds for a vehicle turbocharger with hybrid ceramic ball bearing are researched. The ball bearing-rotor system produces resonance when it working in critical speed and that makes the turbocharger injury working for a long time. The calculation and analysis methods of the critical speed for the vehicle turbocharger are described. The critical speed is computed by two methods including Riccati transfer matrix and DyRoBeS finite element method for a vehicle turbocharger with hybrid ceramic ball bearing. The vibration experiment had been taken to validate the calculating result, Comparison between the results by two calculation methods and the test results show that the first critical speed differences are 6.47 % and 5.66 %, the second critical speed differences are 2.87 % and 2.94 % respectively. And then, the primary factors which influence the critical speed are analyzed, the conclusions will be helpful for the vehicle turbocharger bearing-rotor system design.
基金Supported by National Natural Science Foundation of Chin(Grant No.51375465)
文摘As turbocharging diesel engines for vehicle application are applied in plateau area, the environmental adaptability of engines has drawn more attention. For the environmental adaptability problem of turbocharging diesel engines for vehicle application, the present studies almost focus on the optimization of performance match between turbocharger and engine, and the reliability problem of turbocharger is almost ignored. The reliability problem of compressor impeller of turhocharger for vehicle application when diesel engines operate in plateau area is studied. Firstly, the rule that the rotational speed of turbocharger changes with the altitude height is presented, and the potential failure modes of compressor impeller are analyzed. Then, the failure behavior models of compressor impeller are built, and the reliability models of compressor impeller operating in plateau area are developed. Finally, the rule that the reliability of compressor impeller changes with the altitude height is studied, the measurements for improving the reliability of the compressor impellers of turbocharger operating in plateau area are given. The results indicate that when the operating speed of diesel engine is certain, the rotational speed of turbocharger increases with the increase of altitude height, and the failure risk of compressor impeller with the failure modes of hub fatigue and blade resonance increases. The reliability of compressor impeller decreases with the increase of altitude height, and it also decreases as the increase of number of the mission profile cycle of engine. The method proposed can not only be used to evaluating the reliability of compressor impeller when diesel engines operate in plateau area but also be applied to direct the structural optimization of compressor impeller.
基金Supported by National Natural Science Foundation of China(Grant Nos.51575176,51375162)Scientific Research Foundation of Hunan Provincial Education Department of China(Grant No.15B085)Postgraduate Innovation Foundation of Hunan University of Science and Technology,China(Grant No.S140020)
文摘For the high-speed gasoline engine turbocharger rotor, due to the heterogeneity of multiple parts material, manufacturing and assembly errors, running wear in impeller and uneven carbon of turbine, the random unbalance usually can be developed which will induce excessive rotor vibration, and even lead to nonlinear vibration accidents. However, the investigation of unbalance location on the nonlinear high-speed turbocharger rotordynamic characteristics is less. In order to discuss the rotor unbalance location effects of turbocharger with nonlinear floating ring bearings(FRBs), the realistic turbocharger of gasoline engine is taken as a research object. The rotordynamic equations of motion under the condition of unbalance are derived by applied unbalance force and nonlinear oil film force of FRBs. The FE model of turbocharger rotor-bearing system is modeled which includes the unbalance excitation and nonlinear FRBs. Under the conditions of four different applied locations of unbalance, the nonlinear transient analyses are performed based on the rotor FEM. The differences of dynamic behavior are obvious to the turbocharger rotor systems for four conditions, and the bifurcation phenomena are different. From the results of waterfall and transient response analysis, the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different from the different unbalance locations, and the non-synchronous vibration does not occur in the turbocharger and the amplitude is relative stable and minimum under the condition 4. The turbocharger vibration and non-synchronous components could be reduced or suppressed by controlling the applied location of unbalance, which is helpful for the dynamic design, fault diagnosis and vibration control of the high-speed gasoline engine turbochargers.
基金Sponsored by the Ministerial Advanced Research Foundation (C2002AA002)
文摘A variable nozzle turbocharger (VNT) was applied to a 2.2-liter L4 natural gas engine,and a VNT control system was designed to operate it.Based on VNT matching test results,a VNT control strategy was studied,in which VNT adjustment is carried out through pre-calibrated VNT handling rod position,combined with a closed-loop target boost pressure feedback using proportional-integral-derivative(PID) algorithm.Experimental results showed that the VNT control system presented in this thesis can lead to optimized performance of VNT,increase engine volumetric efficiency over a wide speed range,improve engine dynamic characteristics and upgrade economic performance.
基金the Ministerial Level Advanced Research Foundation (37256)
文摘To compute the matching performance of diesel engine with variable geometry turboeharger(VGT), the formerly used program is improved through adjustment of turbine mass flow rate and efficiency characteristics. The calculation result is applied to forecast the performance of J6110Z diesel engine with rotary-vaned VGT70, and to guide the improvement of engine fuel supply. The computed engine performance curve coincides with the experiment result well: the low-speed torque, fuel economy, exhaust temperature and boost pressure of the VGT engine are all improved.
基金Supported by the Natural Science Foundation of Shanxi Province Project(2012011023-2)
文摘The structure parameters in an actual industrial production have a great influence on the coefficient of supercharger floating bearing dynamic characteristics,but there has been little systematic study so far.In this paper,the influence of structural parameters of the turbocharger floating bearing on its dynamic characteristic coefficientsis systematically investigated based on the theories of hydrodynamic lubrication and tribology.The influence of clearance ratio on eccentricity and the influence of internal to external radius ratios,and Sommerfeld number were analyzed.A new formula of responding characteristics of the oil film force caused by the displacement or velocity disturbance was deduced near an equilibrium in the steady state.Applying the newly developed formula,the dynamic characteristic was studied for floating bearings.Regularity for change of oil film stiffness and damping was analyzed with the structural parameters of floating bearing such as radius ratios and eccentricity.It has been found that the clearance ratio increases with eccentricity when the radius ratio is unchanged.The eccentricity decreases with the internal to external radius ratio of floating rings when the clearance ratio is constant.The absolute value of total principal stiffness and total main damping decrease with the clearance ratio and radius ratio of floating rings when the total cross damping is stable.The results and findings in this paper can contribute to nonlinear dynamics designs of turbocharger rotor-bearing systems.
基金Sponsored by the National Natural Science Foundation of China (50875022)Research Foundation of Beijing Institute of Technology(20070342012)
文摘The noise prediction of the turbocharger is studied.The broadband noise source model is employed to predict the near-field noise of the turbocharger.The 3D software Solidworks is adopted to establish the model blades and inlet of turbocharger compressor,then this 3D model is introduced into the software CFD to calculate the flow-field under different inlet shapes,different blades shapes and different clearances between casing and impeller.On the base of the above simulation,the broadband noise source model is employed to calculate and analyze the near-field noise.The calculation shows that compressor static pressure values and the sound power values near the impeller outlet are the largest.Through the noise calculation by using broadband noise source model under different inlet shapes and blade shapes,we find that the noise level of the inlet of cylindrical and cone types are smaller.Compared with the current widespread used backward skewed or radial blades,there is little difference of the noise value of the inlet of the forward skewed blades.
基金Supported by the National Natural Science Foundation of China(51009003)
文摘A spatial motion mechanism was designed which could make all the nozzle vanes rotate a- round the center of ball with the same radius synchronously to realize control of the variable nozzle mixed-flow turbocharger (VN-MT). The back and abdomen of the nozzle vane was designed as arc- shaped. A variable nozzle ring perfectly combined with the mixed-flow turbine was made available. The turbine geometric model of VN-MT was established through the computational fluid dynamics (CFD). Compared with nozzleless mixed-flow turbine, the flow range of variable nozzle mixed-flow turbine was broadened tremendously while the peak turbine efficiency point was lower slightly. Flow field analysis in turbine stage showed that the energy was larger and the blade load of rotor was lower than loss of the VN-MT under designed condition the nozzleless mixed-flow turbocharger.
基金Supported by the Ministerial Level Research Project of China(D2220112901)
文摘A two stage turbocharging control system was proposed,in which the pressure regulator valve with a close-loop pressure adjusting function instead of a high speed on-off solenoid valve,is used as a driving mechanism of waste gate.A digital-analog(DA)conversion circuit based on pulse width modulation(PWM)generates one analog voltage signal required by the pressure regulating valve control.The principle of the DA conversion circuit was analyzed,meanwhile,the performance of the conversion circuit was improved by adopting a speed-up capacitor,which helps to increase the stability and responsiveness of the control voltage generated by the conversion circuit;the structure parameters of the circuit was optimized by simulation.After the optimization,the ripple wave of circuit output voltage was kept within16mV under the 12bit conversion accuracy,the conversion time of the circuit could be reduced to 4ms.The engine bench test show that the turbocharging boost pressure control system which adopted the circuit had a rather good stable control accuracy(the steady state within 0.8%)and dynamic response(the regulation time is less than 4s).
基金National Natural Science Foundation of China(No.51375465)
文摘The blade root fatigue is one of important failure modes of turbocharger turbine for vehicle application,and the reliability and life of turbine with blade root fatigue failure mode are studied.Firstly,the stress characteristics of turbine are analyzed,and based on the operating profile of turbocharger corresponding to the endurance test of engine,the stress spectrum of turbine with blade root fatigue failure mode is studied with the simulation method.Then,with the number of endurance test profile cycle as the life parameter,the reliability model and failure rate model of turbine with blade root fatigue failure mode are derived respectively. Finally,the rules that the reliability and failure rate of turbine with the blade root fatigue failure mode changes as life parameters are studied,and the life probabilistic characteristics of turbine are also studied.