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Thesis Submitted for the Degree of Doctor of Philosophy University of Bath PHD Investigation into the Application of Turbo-compounding for Downsized Gasoline engines Lu, Pengfei Award date: 2017 Awarding institution: University of Bath Link to publication Alternative formats If you require this document in an alternative format, please contact: [email protected] General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. • Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal ? Take down policy If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim. Download date: 09. Oct. 2021 Investigation into the Application of Turbo-compounding for Downsized Gasoline engines Pengfei Lu A thesis submitted for the degree of Doctor of Philosophy University of Bath Department of Mechanical Engineering June 2017 COPYRIGHT Attention is drawn that the copyright of this thesis rests with its author. A copy of this thesis has been supplied on condition that anyone who consults it is understood to recognise that its copyright rests with the author and they must not copy it or use material from it except as permitted by law or with the consent of the author. This thesis may be made available for consultation within the University Library and may be photocopied or lent to other libraries for the purposes of consultation. Abstract This thesis sets out to evaluate six novel arrangements of internal combustion engine air path designed to improve the degree of exhaust energy recovery from a practical passenger car engine system. The study was conducted using 1D engine simulation based on two experimentally validated models of modern turbocharged spark ignition engines. Improvements of up to 5% in fuel efficiency are presented, along with reductions of up to 30% in the torque rise time are presented. For at least 7 decades, efforts have been made to recover waste energy from the internal combustion engine. Heat engines, governed by the second law of thermodynamics, inevitably reject a significant proportion of the fuel energy as heat to the environment. Technologies, such as turbo-compounding, (organic) Rankine cycle and thermoelectric generators have been proven effective for waste energy recovery in high load applications. Inverted Brayton cycle is also under investigation currently due to the high exergy availability in exhaust stream and the potential to enhance the overall performance of vehicle engines. However, none of these technologies has been given extensive application in the field of automobiles, especially passenger cars, despite their effectiveness in reducing fuel consumption and CO2 emission. This thesis reviews current and previous studies to summarise the advantages and disadvantages of these technologies as well as the factors that constrain them from wide application. Transient performance, which is rarely considered in the literature, is considered here to allow a more realistic assessment of the technologies merits. Among these approaches, turbo-compounding has the advantage of compact volume, lower complexity and application cost, and is now employed to recover waste heat in heavy duty vehicles, such as mining equipment and road haulage. This thesis reviews the most recent research on turbo-compounding to identify the variables that make the greatest difference to the engine performance. The potential for the augmentation of the fuel economy and power output by a novel implementation of turbo-compounding in light duty vehicles has been demonstrated. The concept of a variable ratio supercharger drive has been studied as part of a novel boosting system to improve the low-speed torque output by up to 55% and overall fuel economy by 3%. After a careful optimisation of the specifications of the variable ratio unit, it is combined with a turbo-compounding system to fully overcome the inherent drawbacks of turbo- i compounding, namely the tendency to reduce the power output and engine efficiency at low speed. Finally, the concept of divided exhaust period has been introduced in a novel turbo- compounded arrangement to regulate the exhaust flow for a better gas exchange process and improve fuel consumption by up to 5% while improving transient response times by 30%. ii Acknowledgements First of all, I would like to express my great appreciation and gratitude to Professor Chris Brace for his consistent supervision, support and guidance. It was his patience, specialised knowledge and vision that helped me to keep direction and proceed effectively towards my goals. And also, I would like to thank Dr Sam Akehurst for the countless helps he provided in technical aspects. Besides, the discussions with Ford, Torotrak and Honeywell have also been greatly appreciated, most notably: Arnd Sommerhoff and Harald Stoffels from Ford; Andrew De Freitas, Dave Burtt and James Shawe from Torotrak and Ludek Pohorelsky from Honeywell. And also, I cannot forget the assistance I received from Calogero Avola and Dr. Andy Lewis in helping me to understand the operation of the test cell. I also must thank my colleagues Dr Bo Hu, Dr. Huayin Tang, Dr. Nic Zhang and Dr. Dai Liu for their considerable assistance in helping me to understand the engine modelling and validation theory. I cannot imagine how tough my works will become without your supports. I also would like to express my sincere thanks to all the colleagues at PVRC for their emotional and technical support throughout my research, Dr. Pin Lu, Dr Dian Liu, Dr Colin Copeland, Dr. Chris Bannister, Dr. Richard Burke, Dr. Pavlos Dimitriou, Dr. Simon Pickering, Dr Ramkumar Vijayakumar, Bingxing Luo, Qiyou Deng, Yuxiang Feng, Zhihang Chen, …Thank you so much for making my experience in these three and half years such an enjoyable one. Finally, I would like to thank my family for their unconditional support and encouragement. I can never finish this study without your love! iii Further Publications The work has led to the publication or peer review of a number of journal and conference articles. A list of these publications is given below and references to these will be provided as necessary within the chapters of this thesis. Refereed journal articles: 1. Analysis and comparison of the performance of an inverted Brayton cycle and turbo- compounding with decoupled turbine and CVT driven compressor for small automotive engines P. Lu et al, Journal of Engineering for Gas Turbines and Power: Transactions of the ASME, 139 (7), 072801. Peer reviewed journal articles: 2. System Validation of the V-charge Variable Drive Supercharger System on a 1.0 L GTDI Engine P. Lu et al Journal: Energy Conversion and Management Refereed conference articles 3. Explore and Extend the Effectiveness of Turbo-Compounding in a 2.0 Litre Gasoline Engine P. Lu, et al, SAE Technical Paper 2015-01-1279, 2015, doi:10.4271/2015-01-1279. 4. Explore and Extend the Effectiveness of Turbo-Compounding in a 2.0 Litre Gasoline Engine (Second report: fuel economy under part load condition, transient performance and effect of pressure ratio) P. Lu, et al, SAE Technical Paper, 2016-01-0564, 2016, doi:10.4271/2016-01-0564. Peer reviewed conference articles: 5. Implementing full electric turbocharging systems on highly boosted gasoline engines P. Lu et al Proceedings of ASME Turbo Expo 2017: Turbomachinery Technical Conference and Exposition. iv Contents Abstract ..................................................................................................................................... i Acknowledgements .................................................................................................................. iii Further Publications ................................................................................................................. iv List of Figures ............................................................................................................................ x List of Tables ........................................................................................................................... xv Abbreviations ......................................................................................................................... xvi Chapter 1 - Introduction ........................................................................................................ 18 1.1. Background ................................................................................................................. 18 1.2. Aim and objectives ...................................................................................................... 24 1.3. Scope of thesis ............................................................................................................ 25 Chapter 2 –Review of research on exhaust energy recovery technologies ............................ 27 2.1. Introduction ................................................................................................................ 27 2.2. Waste energy recovery technologies – a brief overview ...........................................
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