Trends and Limits of Two-Stage Boosting Systems for Automotive ...

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3 Analytical study of two-stage turbocharging performance 115 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3.2 Governing Equations . . . . . . . . . . . . . . . . . . . . . . . . 116 3.2.1 Relation between Compression and Expansion Ratio . . 117 3.2.2 Model Validation . . . . . . . . . . . . . . . . . . . . . . 125 3.3 Main Variables Influences on Two-Stage Architectures . . . . . 126 3.3.1 HP and LP Expansion Ratio . . . . . . . . . . . . . . . 127 3.3.2 Coolers Performance . . . . . . . . . . . . . . . . . . . . 129 3.3.3 Exhaust Temperature and Turbochargers Efficiencies . . 131 3.3.4 Comparison between Single-Stage and Two-Stage Performance . . . . . . . . . . . . . . . . . . . . . . . . . . 134 3.4 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 4 Experimental engine and turbocharger characterization 139 4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 4.2 Experimental Facilities . . . . . . . . . . . . . . . . . . . . . . . 141 4.2.1 Flow Test Rig . . . . . . . . . . . . . . . . . . . . . . . . 141 4.2.2 Injection Rig . . . . . . . . . . . . . . . . . . . . . . . . 144 4.2.3 Turbocharger Test Bench . . . . . . . . . . . . . . . . . 146 4.2.4 Engine Test Bench . . . . . . . . . . . . . . . . . . . . . 148 4.3 Turbocharger Characteristic Maps . . . . . . . . . . . . . . . . 151 4.3.1 Standard Characteristic Maps . . . . . . . . . . . . . . . 151 4.3.2 Adapted Characteristic Maps . . . . . . . . . . . . . . . 153 4.4 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 5 0D Diesel Engine Modeling 169 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 5.2 Mean Value Based Gas-Path Description . . . . . . . . . . . . . 174 5.2.1 Intake Line . . . . . . . . . . . . . . . . . . . . . . . . . 174 5.2.2 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . 180 5.3 Crank Angle Resolved Model . . . . . . . . . . . . . . . . . . . 184 5.3.1 Filling & Emptying Modeling . . . . . . . . . . . . . . . 184 5.3.2 Cylinder Model . . . . . . . . . . . . . . . . . . . . . . . 189 5.3.3 Combustion Model . . . . . . . . . . . . . . . . . . . . . 194 5.4 A Fully Integrated 0D Engine Model . . . . . . . . . . . . . . . 197 5.4.1 0D Engine Model Structure . . . . . . . . . . . . . . . . 197 5.4.2 Algorithm Resolution and Control . . . . . . . . . . . . 198 xvi
5.5 Experimental Calibration and Validation . . . . . . . . . . . . . 203 5.5.1 Combustion Model . . . . . . . . . . . . . . . . . . . . . 204 5.5.2 Engine Model in Steady State Operations . . . . . . . . 207 5.5.3 Engine Model in Transient Operations . . . . . . . . . . 212 5.6 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 6 Synthesis of Two-Stage Boosting Systems Performance 225 6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 6.2 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 6.2.1 Engine Similarities . . . . . . . . . . . . . . . . . . . . . 227 6.2.2 Boosting Architectures . . . . . . . . . . . . . . . . . . . 231 6.2.3 Turbochargers Data . . . . . . . . . . . . . . . . . . . . 232 6.2.4 Engine and Intake/Exhaust Lines Constraints . . . . . . 235 6.3 Steady-State Results . . . . . . . . . . . . . . . . . . . . . . . . 237 6.3.1 Main-Stage Operations . . . . . . . . . . . . . . . . . . 238 6.3.2 Two-Stage Operations . . . . . . . . . . . . . . . . . . . 250 6.4 Matching Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 258 6.4.1 Current Characteristic Maps . . . . . . . . . . . . . . . 258 6.4.2 Future Turbocharger Maps Requirements . . . . . . . . 261 6.5 Transients Results . . . . . . . . . . . . . . . . . . . . . . . . . 265 6.5.1 Turbochargers Response . . . . . . . . . . . . . . . . . . 265 6.5.2 Two-Stage Performance . . . . . . . . . . . . . . . . . . 269 6.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 7 Conclusions 281 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 7.2 Boosting Technologies . . . . . . . . . . . . . . . . . . . . . . . 282 7.3 Modeling Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 7.4 Trends and Limits of Two-Stage Systems . . . . . . . . . . . . 287 Bibliography 293 xvii
Page 1: Departamento de Máquinas y Motores
Page 5 and 6: Abstract Internal combustion engine
Page 7 and 8: Résumé Le développement des mote
Page 9 and 10: Acknowledgments Many people have co
Page 11 and 12: “Research is to see what everybod
Page 13 and 14: xiii à mes parents et à Coralie.
Page 15: Contents 1 Introduction 1 1.1 Backg
Page 19 and 20: Nomenclature Acronyms 0D Zero Dimen
Page 21 and 22: cu tangential velocity [m�s]. D d
Page 23 and 24: 0 stagnation conditions. 1 LP compr
Page 25 and 26: Chapter 1 Introduction Contents 1.1
Page 27 and 28: Chapter 1 Section 1.1 Particulaate
Page 29 and 30: Chapter 1 Section 1.1 CO2 C g/KKm 2
Page 31 and 32: Chapter 1 Section 1.1 Important pro
Page 33 and 34: Chapter 1 Section 1.2 arrive now to
Page 35 and 36: Chapter 1 Section 1.3 intercooler v
Page 37 and 38: Chapter 1 References the inherent u
Page 39 and 40: Chapter 1 References [109] U. Flaig
Page 41 and 42: Chapter 2 Literature Review of Boos
Page 43 and 44: Chapter 2 Section 2.1 components of
Page 45 and 46: Chapter 2 Section 2.2 meanwhile on
Page 47 and 48: Chapter 2 Section 2.2 than a larger
Page 49 and 50: Chapter 2 Section 2.2 A control sys
Page 51 and 52: Chapter 2 Section 2.2 In this arran
Page 53 and 54: Chapter 2 Section 2.2 and packaging
Page 55 and 56: Chapter 2 Section 2.2 across the LP
Page 57 and 58: Chapter 2 Section 2.2 low HP turbin
Page 59 and 60: Chapter 2 Section 2.2 In 2009, in o
Page 61 and 62: Chapter 2 Section 2.2 turbocharger
Page 63 and 64: Chapter 2 Section 2.2 after-treatme
Page 65 and 66: Chapter 2 Section 2.3 Overall compr
Page 67 and 68:
Chapter 2 Section 2.3 studies are v
Page 69 and 70:
Chapter 2 Section 2.3 for the turbo
Page 71 and 72:
Chapter 2 Section 2.3 Pressure Rati
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Chapter 2 Section 2.3 Then at highe
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Chapter 2 Section 2.3 ifold. They r
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Chapter 2 Section 2.4 204], and the
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Chapter 2 Section 2.4 less electric
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Chapter 2 Section 2.4 whereas the E
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Chapter 2 Section 2.4 kW EAT system
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Chapter 2 Section 2.4 electrical en
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Chapter 2 Section 2.5 etc. . . ). T
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Chapter 2 Section 2.5 to improve th
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Chapter 2 Section 2.5 pipe arrangem
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Chapter 2 Section 2.5 Figure 2.42:
Page 95 and 96:
Chapter 2 Section 2.5 axial and rad
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Chapter 2 Section 2.5 the AFR by hi
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Chapter 2 Section 2.5 Numbers of al
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Chapter 2 Section 2.5 theses result
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Chapter 2 Section 2.5 which the pea
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Chapter 2 Section 2.6 able centripe
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Chapter 2 Section 2.6 [52] designin
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Chapter 2 Section 2.6 BSFC (g/kWh)
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Chapter 2 Section 2.6 significant c
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Chapter 2 Section 2.6 engine cranks
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Chapter 2 Section 2.7 Vuk [338, 339
Page 117 and 118:
Chapter 2 Section 2.7 When one comp
Page 119 and 120:
Chapter 2 Section 2.8 prove the mai
Page 121 and 122:
Chapter 2 References [24] S. Arnold
Page 123 and 124:
Chapter 2 References [69] C.J Chadw
Page 125 and 126:
Chapter 2 References [121] J. Galin
Page 127 and 128:
Chapter 2 References [166] Y. Iwaki
Page 129 and 130:
Chapter 2 References [204] R. Krebs
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Chapter 2 References [248] P. Nefis
Page 133 and 134:
Chapter 2 References [293] M. Schwa
Page 135 and 136:
Chapter 2 References [332] H. Uchid
Page 137 and 138:
Chapter 2 References [360] A. Whitf
Page 139 and 140:
Chapter 3 Analytical study of two-s
Page 141 and 142:
Chapter 3 Section 3.2 figure 3.1 wi
Page 143 and 144:
Chapter 3 Section 3.2 turbines. The
Page 145 and 146:
Chapter 3 Section 3.2 Replacing the
Page 147 and 148:
Chapter 3 Section 3.2 The analysis
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Chapter 3 Section 3.2 Engine load a
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Chapter 3 Section 3.3 ratios and ex
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Chapter 3 Section 3.3 Figure 3.4: O
Page 155 and 156:
Chapter 3 Section 3.3 decreases for
Page 157 and 158:
Chapter 3 Section 3.3 Figure 3.7: E
Page 159 and 160:
Chapter 3 Section 3.4 the difficult
Page 161 and 162:
Chapter 3 References [242] P. Moraa
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Chapter 4 Experimental engine and t
Page 165 and 166:
Chapter 4 Section 4.2 and more reli
Page 167 and 168:
Chapter 4 Section 4.2 ∆p element
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Chapter 4 Section 4.2 correspond to
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Chapter 4 Section 4.2 by an electri
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Chapter 4 Section 4.2 They are all
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Chapter 4 Section 4.3 Regarding fue
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Chapter 4 Section 4.3 on the speed
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Chapter 4 Section 4.3 where Cpt is
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Chapter 4 Section 4.3 (W/K) Power T
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Chapter 4 Section 4.3 Turbine Addap
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Chapter 4 Section 4.3 Turbine T e A
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Chapter 4 Section 4.4 Power (W/K) (
Page 189 and 190:
Chapter 4 References [76] H. Chen,
Page 191 and 192:
Chapter 4 References [266] R. Payri
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Chapter 5 0D Diesel Engine Modeling
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Chapter 5 Section 5.1 CPU Peerforma
Page 197 and 198:
Chapter 5 Section 5.1 tions, lookup
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Chapter 5 Section 5.2 the air filte
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Chapter 5 Section 5.2 Fuel mass fra
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Chapter 5 Section 5.2 Taking into a
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Chapter 5 Section 5.2 Air Filter Ou
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Chapter 5 Section 5.3 and the waste
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Chapter 5 Section 5.3 as the HP EGR
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Chapter 5 Section 5.3 α 720 Cdim
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Chapter 5 Section 5.3 Nuinneropen
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Chapter 5 Section 5.3 Diesel engine
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Chapter 5 Section 5.3 Short Circuit
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Chapter 5 Section 5.3 1306 J. Arreg
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Chapter 5 Section 5.4 where i repre
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Chapter 5 Section 5.4 parameters. A
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Chapter 5 Section 5.4 significantly
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Chapter 5 Section 5.5 MVEM’s, mos
Page 229 and 230:
Chapter 5 Section 5.5 RoHR’s calc
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Chapter 5 Section 5.5 5.5.2 Engine
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Chapter 5 Section 5.5 achieving air
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Chapter 5 Section 5.5 simulated by
Page 237 and 238:
Chapter 5 Section 5.5 ues of therma
Page 239 and 240:
Chapter 5 Section 5.6 A hot transie
Page 241 and 242:
Chapter 5 References [14] A. Albrec
Page 243 and 244:
Chapter 5 References [110] J.W. Fox
Page 245 and 246:
Chapter 5 References [201] P.A. Kon
Page 247 and 248:
Chapter 5 References [283] C. Romer
Page 249 and 250:
Chapter 6 Synthesis of Two-Stage Bo
Page 251 and 252:
Chapter 6 Section 6.2 the boosting
Page 253 and 254:
Chapter 6 Section 6.2 Table 6.2: Pa
Page 255 and 256:
Chapter 6 Section 6.2 6.2 that the
Page 257 and 258:
Chapter 6 Section 6.2 in the steady
Page 259 and 260:
Chapter 6 Section 6.2 5 points decr
Page 261 and 262:
Chapter 6 Section 6.3 retained to l
Page 263 and 264:
Chapter 6 Section 6.3 second stage
Page 265 and 266:
Chapter 6 Section 6.3 tion timings
Page 267 and 268:
Chapter 6 Section 6.3 levels before
Page 269 and 270:
Chapter 6 Section 6.3 These results
Page 271 and 272:
Chapter 6 Section 6.3 tion delays a
Page 273 and 274:
Chapter 6 Section 6.3 At 3000 rpm,
Page 275 and 276:
Chapter 6 Section 6.3 is provided b
Page 277 and 278:
Chapter 6 Section 6.3 brake power i
Page 279 and 280:
Chapter 6 Section 6.3 Fuel consumpt
Page 281 and 282:
Chapter 6 Section 6.3 For the turbo
Page 283 and 284:
Chapter 6 Section 6.4 to current ch
Page 285 and 286:
Chapter 6 Section 6.4 technological
Page 287 and 288:
Chapter 6 Section 6.4 are strongly
Page 289 and 290:
Chapter 6 Section 6.5 6.5 Transient
Page 291 and 292:
Chapter 6 Section 6.5 BMEP [bbar] 4
Page 293 and 294:
Chapter 6 Section 6.5 effect can al
Page 295 and 296:
Chapter 6 Section 6.5 power [kW/K]
Page 297 and 298:
Chapter 6 Section 6.5 Pressure rati
Page 299 and 300:
Chapter 6 Section 6.5 been retained
Page 301 and 302:
Chapter 6 Section 6.6 observed with
Page 303 and 304:
Chapter 6 References In this chapte
Page 305 and 306:
Chapter 7 Conclusions Contents 7.1
Page 307 and 308:
Chapter 7 Section 7.2 specific powe
Page 309 and 310:
Chapter 7 Section 7.3 � Very fast
Page 311 and 312:
Chapter 7 Section 7.4 uncertainties
Page 313 and 314:
Chapter 7 Section 7.4 intermediate
Page 315 and 316:
Chapter 7 Section 7.4 justify its u
Page 317 and 318:
Bibliography [1] “ Council Direct
Page 319 and 320:
Bibliography [22] O. Armas. “Diag
Page 321 and 322:
Bibliography [47] Y. Borila. “A S
Page 323 and 324:
Bibliography [71] C.C. Chan. “The
Page 325 and 326:
Bibliography [95] A. Dhand, J. Baek
Page 327 and 328:
Bibliography [119] J. Galindo, J.R.
Page 329 and 330:
Bibliography [143] E. Hendricks, A.
Page 331 and 332:
Bibliography [168] W. Jansen, A.F.
Page 333 and 334:
Bibliography [193] W. Knecht. “Di
Page 335 and 336:
Bibliography [216] B. Lee, Z. Filip
Page 337 and 338:
Bibliography [243] T. Morel and R.
Page 339 and 340:
Bibliography [266] R. Payri, V. Ber
Page 341 and 342:
Bibliography [290] F. Schmitt and B
Page 343 and 344:
Bibliography [313] N. Stosic, I.K.
Page 345 and 346:
Bibliography [339] C.T. Vuk. “Ele
Page 347 and 348:
Bibliography [363] P.R. Williams.
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