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Thesis Template for Researchers University of Huddersfield Repository Latif, Raja An Investigation into The Development of an Electrically Assisted Turbocharger with Energy Recovery Original Citation Latif, Raja (2019) An Investigation into The Development of an Electrically Assisted Turbocharger with Energy Recovery. Masters thesis, University of Huddersfield. This version is available at http://eprints.hud.ac.uk/id/eprint/35035/ The University Repository is a digital collection of the research output of the University, available on Open Access. Copyright and Moral Rights for the items on this site are retained by the individual author and/or other copyright owners. Users may access full items free of charge; copies of full text items generally can be reproduced, displayed or performed and given to third parties in any format or medium for personal research or study, educational or not-for-profit purposes without prior permission or charge, provided: • The authors, title and full bibliographic details is credited in any copy; • A hyperlink and/or URL is included for the original metadata page; and • The content is not changed in any way. For more information, including our policy and submission procedure, please contact the Repository Team at: [email protected]. http://eprints.hud.ac.uk/ AN INVESTIGATION INTO THE DEVELOPMENT OF AN ELECTRICALLY ASSISTED TURBOCHARGER WITH ENERGY RECOVERY. RAJA SUBHAN LATIF A thesis submitted to the University of Huddersfield in partial fulfilment of the requirements for the degree of MSc By Research The University of Huddersfield Submission date – June 2019 Copyright statement i. The author of this thesis (including any appendices and/or schedules to this thesis) owns any copyright in it (the “Copyright”) and s/he has given The University of Huddersfield the right to use such copyright for any administrative, promotional, educational and/or teaching purposes. ii. Copies of this thesis, either in full or in extracts, may be made only in accordance with the regulations of the University Library. Details of these regulations may be obtained from the Librarian. This page must form part of any such copies made. iii. The ownership of any patents, designs, trademarks and any and all other intellectual property rights except for the Copyright (the “Intellectual Property Rights”) and any reproductions of copyright works, for example graphs and tables (“Reproductions”), which may be described in this thesis, may not be owned by the author and may be owned by third parties. Such Intellectual Property Rights and Reproductions cannot and must not be made available for use without the prior written permission of the owner(s) of the relevant Intellectual Property Rights and/or Reproductions Statement of Publications Arising from this Thesis The following publications have arisen from my research detailed in this thesis: “An electrically assisted turbocharger system for Formula Student” Latif, R., & Allport, J. An electrically assisted turbocharger system for Formula Student. In Proceedings of the 4th Biennial International Conference on Powertrain Modelling and Control, Testing, Mapping and Calibration, Loughborough University, 10 – 11 September 2018 Contribution of the candidate: I performed all the research and wrote the entire manuscript with minor input and editorial changes from my co-author. It is indicated where text from this publication has been reproduced in this thesis. 2 Abstract An experimental electrically boosted turbocharger system has been developed for a small motorcycle engine intended for use in Formula Student competitions. The system was developed and tested to produce elevated levels of torque at low engine speeds through the use of computer simulations validated by dynamometer testing. This research took a standard inline two-cylinder engine with a displacement of 471cc and improved its torque output throughout the speed range. The engine was considered as originally designed, in a naturally aspirated state, then modified to be turbocharged, both the NA and the turbocharged engine being simulated and tested. There was less than 5% error between the simulation and test, therefore the simulation was considered suitable as a basis for further development and the turbocharger was modified to accommodate for a 9kW electric motor. Results from the simulation show that there is a 25% increase in torque at engine idle for the electrically boosted turbo system. Furthermore, the electro-turbocharger engine starts to produce boost pressure at 5500rpm, with the system producing 0.19 bar of gauge boost pressure at engine idle. The same amount of pressure is not produced by the standard turbocharged engine until 6800rpm. The electrically boosted turbocharger system was used to overcome design issues such as turbo-lag and torque levelling. The optimised design demonstrates significant improvements in engine torque and driveability. 3 Table of Contents Abstract ......................................................................................................................................................................... 3 Table of Contents .......................................................................................................................................................... 4 List of Tables ................................................................................................................................................................. 6 List of Figures ................................................................................................................................................................ 7 Dedications and Acknowledgements .......................................................................................................................... 10 Introduction ................................................................................................................................................................ 11 Research problem ................................................................................................................................................... 12 What we aim for ..................................................................................................................................................... 15 Formula Student rules ............................................................................................................................................ 16 ICE theory ............................................................................................................................................................... 17 Turbo Compressor Theory ...................................................................................................................................... 19 Academic Aim ............................................................................................................................................................. 23 Objectives ............................................................................................................................................................... 23 Chapter 1 Literature review ........................................................................................................................................ 24 Literature review conclusion .................................................................................................................................. 34 Chapter 2 Generating Electricity ................................................................................................................................. 35 Generating power from turbochargers .................................................................................................................. 35 Generation simulation ............................................................................................................................................ 37 Boundary conditions and Plan ................................................................................................................................ 38 Chapter 3 Electrical drive ............................................................................................................................................ 42 Difference between ESC and Generator controllers .............................................................................................. 42 What is the difference between electric motors and generators .......................................................................... 43 AC and DC motors .............................................................................................................................................. 43 Motor capabilities .............................................................................................................................................. 44 Chapter 4 ECU tuning .................................................................................................................................................. 46 Fuel & Ignition Maps ............................................................................................................................................... 47 Turbocharging the petrol engine ............................................................................................................................ 51 Turbo sizing ............................................................................................................................................................
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