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Turbomachinery Laboratory

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Last revised: Nov. 01, 2020

DME6035 Automotive Turbochargers

1. Class information
 • Class Year and semester: 2020, FALL semester
 • Course No. : DME6035
 • Course title: Automotive Turbochargers
 • Credit-Lecture Hour-Practice Training: 3.00-3.00-0.00
 • Course outline: One Three-hour lecture/week
 • Organizing Department: Mechanical Design Engineering

2. Instructor information
 • Name: Dr. Keun Ryu
 • Department: Mechanical Design Engineering
 • Email: kryu@hanyang.ac.r
 • Web: http://turbolab.hanyang.ac.kr/DME6035.html

 • Office hours: By scheduled appointment (E-mail in advance required)
 • About office hours: This is to encourage individual interaction between the students and the instructor. Students should prepare by organizing questions in advance.

3. Course objective
 This course will provide the fundamentals of turbochargers for automotive applications.

Prerequisites: Vibrations, Fluid Dynamics, Dynamics

4. Textbook
No textbook. The instructor will provide the class material.

5. Grading
Final Project (30%), Mid-term Project (30%), Final Exam (30%), Attendance (5%), Class participation (5%)

For full credit, homework should be presented in a professional way, including the problem(s) statement and objective, the steps in the modeling and procedure of solution, including a nomenclature and a sound discussion of the results obtained.
Attendance to the lectures is a must for success.

6. References

 - BorgWarner Turbo Systems Knowledge Library: http://www.turbos.bwauto.com/press/knowledgeLibrary.aspx

 - BorgWarner Turbo Systems Turbo Facts: http://www.turbos.bwauto.com/products/turbofacts.aspx


7. Lecture material and topics

　

• Week 1

  Introduction to class
  http://www.cstt.in/pdf/81462_probe.pdf

　

References

  How a Turbocharger Works: https://youtu.be/JJ2U1GeLzS8

  Turbo Teardown - How a Turbocharger Works https://youtu.be/3ge8dPkvG-o
  https://www.dieselnet.com/tech/air_turbocharger.php


  5 Why --> https://youtu.be/U3w_eIa7Eq0 ;  https://en.wikipedia.org/wiki/5_Whys


• Week 2

  Introduction to Turbochargers and Turbocharging: Note 1
　

References

ABB Turbocharging Operating turbochargers by ABB:

  https://library.e.abb.com/public/77547b9dbf02d66ec1257880005681d3/ABB%20Turbocharging_Operating%20turbochargers.pdf

  http://www.swiss-ships.ch/berichte-buecher/berichte/ABB_Turbo_Systems/TM_2005_100Y_EN.pdf

ABB Turbocharging We multiply power by ABB:

  https://library.e.abb.com/public/3a8a405f56da7489c1257b360029260b/ABBTC_BRO1000_WEMULTIPLYPOWER.pdf


• Week 3

  Turbocharger Core Assembly (Compressor Wheels): Note 2-1
  Turbocharger Core Assembly (Bearing Housing and Bearing Systems): Note 2-2

　

References

  How a turbocharger is made: https://youtu.be/G_139qEGXks

  http://www.turbos.borgwarner.com/files/pdf/efr_turbo_technical_brief.pdf
  https://www.youtube.com/user/GcgTurbos/videos

　

Notice: Announcement of Mid-term and Final Group Projects

1. Mid-term Project

 1) Group 1  (due on Week 8)

   Dr. Ryu will provide a small turbocharger (supported on fully floating ring bearings) for passenger car applications.

   Student will report the followings:

    - Procedure of teardown (with pictures)

    - Measurement of dimensions, mass, inertias (see Ref. 1 and Ref. 2), and C.G. for major turbocharger core components (as accurate as possible)

    - Model rotor structural FE model and validate with measurements (See Ref. 3, pp. 28-29)

    - Prepare the NVH and rotordynamic test setup for run-up/run-down/coastdown tests

   Important: GUIDELINES FOR MOUNTING TEST ACCELEROMETERS https://www.pcb.com/resources/technical-information/mounting

                          Piezoelectric Accelerometers and Vibration Preamplifiers: https://www.bksv.com/media/doc/bb0694.pdf

 2) Group 2  (due on Week 8)

  Study the technical papers below and present the summary of each paper.

    - Turbocharger Nonlinear Response with Engine-Induced Excitations: Predictions and Test Data
    - A Virtual Tool for Prediction of Turbocharger Nonlinear Dynamic Response: Validation Against Test Data
    - Rotordynamics of Small Turbochargers Supported on Floating Ring Bearings – Highlights in Bearing Analysis and Experimental Validation
    - Nonlinear Rotordynamics of Automotive Turbochargers – Predictions and Comparisons to Test Data
    - Test Response and Nonlinear Analysis of a Turbocharger Supported on Floating Ring Bearings
　

2. Final Project

 1) Group 1 (due on Week 15)

   Dr. Ryu will provide a small turbocharger for passenger car applications.

   Student will report the followings:

    - Conduct rotordynamic measurements during run-up/run-down/coastdown for various oil pressures and temperatures with two triaxial accelerometers on the bearing housing (only for baseline imbalance condition, i.e., no added imbalance condition): DO NOT exceed the turbo speed over 200 krpm!

    - In particular, set the supply oil pressure as low as possible (~1 bar) and report the results

    - Present waterfall plots of bearing housing accelerations for each test conditions

    - Present overall and synchronous (1X) accelerations of bearing housing for each test conditions

    - Predict the nonlinear rotordynamic response and compare with the measurements

 2) Group 2 (due on Week 14)

  Study the technical papers below and present the summary of each paper.

    - On the Effect of Thermal Energy Transport to the Performance of (Semi) Floating Ring Bearing Systems for Automotive Turbochargers

    - On the Influence of Lubricant Supply Conditions and Bearing Configuration to the Performance of (Semi) Floating Ring Bearing Systems for Turbochargers

    - A thermo-hydrodynamic model for thermal energy flow management in a (semi) floating ring bearing system for automotive turbochargers


• Week 4

  Turbocharger Core Assembly (Squeeze Film Dampers): Note 2-3
　

References

  BorgWarner Build EFR 7163 Turbocharger - Full Video: https://youtu.be/s87LbgxKEPQ


• Week 5

  Turbocharger Core Assembly (Seals, Turbine Wheels, Thrust Bearings, Heat Shield): Note 2-4

  Turbocharger Core Assembly (Development Case Study): Note 2-5

　

References

   Dual Volute Turbocharger https://youtu.be/r4RyEQGxyWI

　

• Week 6
  Turbocharger Architecture: Note 3-1

　

References

  Borg Warner K Series Turbo Animation https://youtu.be/PB8FjZEXPrQ
  Variable Turbine Geometry (VTG) https://youtu.be/AuQor-YnbZ8
  Regulated 2-Stage Turbocharging (R2S∝) https://youtu.be/zRdPq-cT8Ys
  Electric Wastegate featuring Patented Twin Port Wastegate Technology https://youtu.be/s-vfCKfJub4
  Technology eBooster∝ - Electrically Driven Compressor for Light Vehicles https://youtu.be/iEGisoOnewg
  Technology eBooster∝ - Electrically Driven Compressor for Commercial Vehicles https://youtu.be/hpSIsLj3OwE
  48V eTurbocompound https://youtu.be/72Kt0WUfBFU
  eTurbo(TM) https://youtu.be/8OwswYe69_E
  ORC Waste Heat Recovery System https://youtu.be/rEH18JnPvqA

• Week 7

  Oil-Free Automotive Turbochargers: Drag Friction and On-Engine Performance Comparisons to Oil-Lubricated Commercial Turbochargers

  Bump-Type Foil Bearings and Flexure Pivot Tilting Pad Bearings for Automotive Oil-Free Turbochargers: Highlights in Rotordynamic Performance

  Turbocharger Performance Measurements: Note 3-2


• Week 8

  Mid-term Project Presentation (Group 1)


• Week 9

  Mid-term Project Presentation (Group 2)


• Week 10

  Review of Mid-term Projects

  2018 Fall: Turbocharger Rotordynamics Nonlinearity -Texas A&M

  Turbocharger Rotordynamics: Note 3-3

　

• Week 11

  Balancing: Turbocharger CHRA balancing machine: https://youtu.be/Ecb9WZnhtos

　

• Week 12

 Compressor Map

References

  Compressor Map

  Selecting a Centrifugal Compressor

  Practical Approach to Surge and Surge Control Systems

  Principles Of Operation And Performance Estimation Of Centrifugal Compressors

  Aerodynamic Design of Centrifugal Compressor for AT14 Turbocharger

  http://www.turboneticsinc.com/performance/sites/default/files/TN_2014_Catalog_MED_6.pdf


• Week 13

  Matching the Engine and the Turbocharger
  www.turbos.bwauto.com/aftermarket/matchbot/

  Thermodynamics of turbochargers

  Analysis and Methodology to Characterize Heat Transfer Phenomena in Automotive Turbochargers: http://gasturbinespower.asmedigitalcollection.asme.org/article.aspx?articleid=1897016
  Heat Transfer Correction Methods for Turbocharger Performance Measurements: http://gasturbinespower.asmedigitalcollection.asme.org/article.aspx?articleID=2538215
  Impact of Measurement Uncertainty in the Characteristic Maps of a Turbocharger on Engine Performance: http://gasturbinespower.asmedigitalcollection.asme.org/article.aspx?articleid=1743128

References

  http://standards.sae.org/j1723_199508/  --> http://autoparts-standard.org/index/images/userfiles/media/SAE%20J1723-1995.pdf

  http://digitalcommons.calpoly.edu/cgi/viewcontent.cgi?article=1028&context=aerosp

  http://www.vortechsuperchargers.com/pdf/papers/efficiency_paper.pdf

  http://papers.sae.org/2007-01-2205/


• Week 14

  Final Project Presentation (Group 2)


• Week 15

  Final Project Presentation (Group 1)


• Week 16

  Final exam
　

-------------------------------
Review for the final exam (2018 FALL)

Probs. 1 & 2. Turbocharger fundamentals

Prob. 3 Function and design of the exhaust-gas turbocharger

Prob. 4

Brief History of Turbocharging
Turbocharger Performance Basics

Prob. 5~6 Ball Bearings + SFDs
Bearing Systems pg.33 – 41
(+ Additional handout)

Probs. 7~9 Vibration and Noise of Automotive Turbochargers
∙ Noise Types
∙ Turbocharger NVH test methods
∙ Slow roll vibrations (+ Additional handout)
∙ Future Directions: Bearings to improve stability

Probs. 10~11
Turbocharger Components

Probs. 12 Turbocharger Rotordynamics: Modeling and Experimental Validation (Nonlinear Rotordynamics of Automotive Turbochargers –Predictions and Comparisons to Test Data)

Probs. 13
Balancing

Probs. 14 High pressure supercharging with an electrically driven supercharger

　

-------------------------------

  2018 Fall:  Personal Homework - About Electrically Assisted Turbochargers

 Q1) What are the-state-of-the-art configurations of electrically assisted turbochargers?

  Tips: Search patents (min. 3) & Search technical papers from ASME or SAE (min. 3) --> You MUST include comprehensive references!!!

 Q2) What are the benefits of electric turbocharging systems?

 Q3) What are their major technical hurdles for development process?

 Electrically Assisted Turbochargers
 Five Groups: 60 min/each group
Example) https://www.mhi.co.jp/technology/review/pdf/e474/e474007.pdf

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