Professional Documents
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Author/s:
Attard, Mr William; Watson, Professor Harry; Konidaris, Mr Steven
Title:
Highly Turbocharging a Restricted Two Cylinder Small Engine - Turbocharger Development
2007-01-1562
Date:
2007
Citation:
Attard, Mr William and Watson, Professor Harry and Konidaris, Mr Steven (2007) Highly
Turbocharging a Restricted Two Cylinder Small Engine - Turbocharger Development 2007-
01-1562, in Proceedings, SAE International World Congress, Detroit, Michigan, USA.
Publication Status:
Published
Persistent Link:
http://hdl.handle.net/11343/34523
File Description:
Highly Turbocharging a Restricted Two Cylinder Small Engine - Turbocharger Development
2007-01-1562
TEST ENGINE
The test engine used in experiments was specifically
designed and developed at the University of Melbourne
for use in Formula SAE. The 434 cm3 twin cylinder in-
line arrangement features double overhead camshafts
and four valves per cylinder, along with a three speed
transmission and dry sump lubrication. Further
specifications are given in Table 1. Figure 2 highlights a
Figure 2: Engine sectional view, highlighting the cylinder
sectional view of the engine design and Figure 3 head, barrel and reciprocating assembly.
displays the final TC version.
Figure 4: Externally driven Rootes type supercharger setup.
ROTATING ASSEMBLY
Dual ring seals Seal housing
55
45
(A) Log Plenum (4L volume)
(B) Log Plenum (2L volume)
Figure 6: Method 10 - Components used to overcome the oil (C) Log Plenum (0.7L volume)
control issue (Upper): Modified centre bearing housing with 35
(D) Sphere Plenum (1L volume)
silver soldered insert and vent orifice. (Lower): Rotating (E) 2 into 1 Pulse type (equal lengths)
assembly with new compressor seal assembly.
25
EXHAUST MANIFOLD GEOMETRY 5000 6000 7000 8000 9000 10000 11000
Speed
Engine (rev/min)
Speed (rev/min)
Exhaust manifold design was heavily influenced by the
unequal pulse effects, attributed to the uneven firing Figure 7: (Upper): WAVE® model used for optimisation.
order of this engine. The unequal pulsing caused (Lower): Simulated results with constant pressure and pulse
problems ranging from exhaust turbine velocity type turbocharging.
Simulation results from Figure 7 show significant brake BMEP (kPa)
power improvements when employing constant pressure Expt. Plenum (Constant press)
Pred. Plenum (Constant press)
type turbocharging to this particular odd firing engine. 2400 Expt. 2 into 1 (Pulse type)
The reduced performance of the equal length pulse type Pred. 2 into 1 (Pulse type)
setup is evident across all speeds, as the increased
residual gas content reduces air consumption. It is also 2000
noted that as a consequence of the engine design, all
experimental and simulated data presented corresponds
to the performance at the gearbox output shaft and not
1600
at the crankshaft. Performance at the crankshaft is
expected to be marginally higher, due to the reduction in
losses associated with driving the transmission
1200
components.
Performance increases are associated with increasing
the exhaust manifold volume, as this reduces the pulsing 800
effect thus reducing the exhaust turbine velocity 4000 5000 6000 7000 8000 9000 10000
fluctuations and increasing delivered boost. This effect
Engine Speed (rev/min)
is most dominant at lower engine speeds, prior to the
intake restriction limiting airflow. The odd pulsing effects Figure 9: BMEP experimental and simulation results for
decrease with increasing engine speed, due to the constant pressure and pulse type turbocharging, highlighting
reduced time intervals. From the simulation results, an the performance differences due to exhaust manifolding for an
exhaust manifold geometry with a volume of four liters odd firing engine.
was selected. Larger volumes provided small gains in
output but are coupled with increased heat losses and
transport times and thus were not used. In order to avoid the DL for the given CR for the two into
The most efficient plenum geometry was thought to be a one pulse manifold, boost levels and spark timing were
sphere, as this has the minimum surface area to volume reduced and thus performance suffered, with
ratio, reducing heat losses. However, simulation results experimental results for a fixed speed shown in Figure
showed that the log style plenum had reduced flow 10. To improve engine performance and reliability, the
losses for similar volumes and so was employed. The initial plenum design was further developed to prevent
log style plenum also permitted the adoption of Watson’s thermal cracking and was later implemented. This was
KEC rolling flow design, which had been used achieved by changing the material specification from
successfully in intake manifolds [1,2,5], but as yet had 316 stainless steel to a low carbon mild steel and by
not been implemented to exhaust manifold designs. increasing the manifold wall thickness.
600 23
400 17
200 11
0 5
100 120 140 160 180
MAP (kPa)
Figure 10: BMEP and spark timing versus MAP for constant
pressure and pulse type turbocharging. Experimental results
highlight the reduced performance of the two into one pulse
Figure 8: Varying exhaust manifold geometry, (Left) two into type system. (5000 rev/min, 10:1 CR)
one pulse system (model E), (Right) Watson’s KEC plenum
system (model A) optimized through WAVE®.
OPERATING LIMITS audible noise associated with the heavy knocking
condition was closer to a high frequency crackle at the
The oil jet cooled, custom forged pistons received elevated engine speeds, quite different to knock in low
considerable development. In order to achieve the final speed conventional engines.
design objectives while operating on 98-RON pump
gasoline, the final design featured a reduced
compression ratio of 10:1 and an increase in the number
of rings from two to three. This reduced blow-by and
improved heat rejection to reduce knock intensities to 100
20
0
-200 -100 0 100 200
-10
-20
-30
Crank Angle (deg.)
KNOCK
180 P
COMPENSATION L
160 RETARD AND OR ENRICH Dynamometer and competition results have highlighted
the success of the turbocharger development program.
140
The TC engine package resulted in the Formula vehicle
120 being very competitive in competition, achieving
100 exceptional fuel economy while maintaining excellent
80 power and drivability. The engine was installed into
successive MUR Motorsport vehicles in 2003 and 2004
60
and became the first prototype engine to successfully
4000 5000 6000 7000 8000 9000 10000 compete in the competition’s 25 year history. In 2004,
Speed (rev/min) the engine and car were very competitive, finishing first
in the fuel economy event.
Operating(A) HUCR at WOT
at Performance Limits (PL)
10000
P Dynamometer results also emphasize the significance of
9000 L KNOCK the turbocharger development for the highly TC engine
COMPENSATION package. Peak BMEP values of 25 bar were observed
RETARD AND OR ENRICH
and are believed to be the highest specific output
Speed (rev/min)
8000
recorded for small engines operating on pump gasoline
7000 [1,4]. This surpasses the 22 bar, achieved by GM’s TC
DAMAGE Ecotec engine [14]. Final brake performance is
LIMIT
displayed in Figure 14 and is compared to simulation
6000
results and the team’s previous powerplant.
Performance results show improved brake power output
5000 when compared to the Suzuki GSX-R600 due to the
reduced frictional losses associated with the downsized
4000 capacity. Also evident is the near constant power
9 10 11 12 13 achieved over half the speed range as the power is
CR limited by sonic flow through the restriction. Excellent
Figure 13: Knock and airflow limitations versus MAP, engine agreement between simulation results from WAVE® is
speed and CR. Cross hatched areas indicate operation with also evident, with GSX-R600 experimental results used
spark retard and/or fuel enrichment to compensate for knock. for initial model validation [1,3].
Shaded areas indicate non operation due to knock levels
above the DL or limited airflow. PL is the performance limit line
defined at WOT.
P ower (kW) CFD vs EXPERIMENTAL
70
Turbocharger development for a restricted 430 cm3 odd The authors are thankful for the patience, support and
firing two cylinder engine has been described. The understanding of family and friends as days would go by
downsized test engine used for development was where the team would not leave the thermodynamics
specifically designed and configured for Formula SAE, lab. The authors would also like to thank the Australian
SAE’s student Formula race-car competition. division of Garrett Turbochargers for the components
supplied together with technical drawings and
As a result of the design objectives, high pressure ratio information. Thanks are also due to Elisa Toulson for
turbocharging was implemented, with MAP values her efforts in reviewing the technical writing of this
reaching 270 kPa at mid range speeds. However, as a paper. The team is also grateful, to all academic,
result of the Formula regulated upstream intake postgraduate, and technical staff involved for their
restrictor and throttle location, oil consumption issues persistence, patience and support during the most trying
arose due to compressor throttling. times. Who said engine development was easy?
This problem was compounded as modern turbocharger To the generous sponsors that made the UniMelb
designs feature piston ring type oil seals on the ‘WATTARD’ engine possible, we offer our sincere
compressor side. The research and development steps thanks for supporting the excellent learning activity at
to overcome this oil control issue are outlined, together the University of Melbourne.
with a final solution. This development has significant
relevance, as it allows the continual use of compressor ¾ ACL Bearing Company - Tas, Australia
side piston ring seals, while also allowing the ¾ APEP Pistons - Vic, Australia
turbocharger to be placed downstream of the throttle. ¾ Argo Engineering - NSW, Australia
This layout has additional benefits in reducing turbo-lag ¾ Bishop Innovation - NSW, Australia
and increasing spool rates during engine transience. ¾ Bohler Uddeholm - Vic, Australia
¾ CadCore Pty Ltd - Vic, Australia
The TC development methodology has been outlined, ¾ Concentric Asia Pacific - SA, Australia
together with the importance of simulation as an aid in ¾ Cosway Motorcycles - Vic, Australia
accelerating engine development. These tools have ¾ Davies Craig - Vic, Australia
enabled improved performance and understanding at ¾ Electromold - Vic, Australia
reduced costs and lead times. ¾ Farley Laserlab - Vic, Australia
¾ Garrett Honeywell - NSW, Australia
Exhaust manifold effects on turbocharger ¾ Kawasaki Australia - NSW, Australia
implementation are investigated for both pulse and
¾ Magnesium Technologies - Vic, Australia
constant pressure type systems. Results from
¾ MAME Centre for Manufacturing - Vic, Australia
simulation and experimentation show significant brake
¾ M&W Ignitions - NSW, Australia
power improvements when employing constant pressure
type turbocharging to this particular odd firing engine. ¾ Penrite Lubricants - Vic, Australia
¾ QMI Solutions - Qld, Australia
Operating limits are also outlined in order to achieve 25 ¾ Ricardo - Sussex, UK
bar BMEP, believed to be the highest recorded for small ¾ Robert Bosch - Vic, Australia
engines operating on pump gasoline. Knock has been ¾ Siemans VDO - Vic, Australia
highlighted as being the most important limiting factor in ¾ Southside Cylinder Heads - Vic, Australia
defining the performance for small highly TC engines. ¾ University of Melbourne - Vic, Australia
Testing demonstrated that spark retard and/or fuel ¾ Wade Camshafts - Vic, Australia
enrichment can be used as a method of knock control ¾ Whitehorse Industries - Vic, Australia
for up to 1-2 CR points depending on the knock severity.
CONSTANT
PRESSURE
PULSE
TYPE
COMPONENT INDEX
13:1 CR
SINGLE COMPRESSION RING
11:1 CR
SINGLE COMPRESSION RING
10:1 CR
DUAL COMPRESSION RINGS