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CHARACTERIZATION of TURBOCHARGER PERFORMANCE and SURGE in a NEW EXPERIMENTAL FACILITY

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CHARACTERIZATION of TURBOCHARGER PERFORMANCE and SURGE in a NEW EXPERIMENTAL FACILITY CHARACTERIZATION of TURBOCHARGER PERFORMANCE and SURGE in a NEW EXPERIMENTAL FACILITY Thesis Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Gregory David Uhlenhake, B.S. Graduate Program in Mechanical Engineering The Ohio State University 2010 Master‟s Examination Committee: Dr. Ahmet Selamet, Advisor Dr. Rajendra Singh Dr. Philip Keller Copyright by Gregory David Uhlenhake 2010 ABSTRACT The primary goal of the present study was to design, develop, and construct a cold turbocharger test facility at The Ohio State University in order to measure performance characteristics under steady state operating conditions and to investigate surge for a variety of automotive turbocharger compression systems. A specific turbocharger is used for a thermodynamic analysis to determine facility capabilities and limitations as well as for the design and construction of the screw compressor, flow control, oil, and compression systems. Two different compression system geometries were incorporated. One system allowed performance measurements left of the compressor surge line, while the second system allowed for a variable plenum volume to change surge frequencies. Temporal behavior, consisting of compressor inlet, outlet, and plenum pressures as well as the turbocharger speed, is analyzed with a full plenum volume and three impeller tip speeds to identify stable operating limits and surge phenomenon. A frequency domain analysis is performed for this temporal behavior as well as for multiple plenum volumes with a constant impeller tip speed. This analysis allows mild and deep surge frequencies to be compared with calculated Helmholtz frequencies as a function of impeller tip speed and plenum volume. ii The steady state performance data was used as an input to a lumped parameter model which was implemented to predict the overall system dynamics during surge with simplified geometry consisting of a compressor, duct, and plenum. In addition to the comparison between the lumped parameter model and experimental results, a parametric study of the time lag constant is performed to examine its effect on the system predictions. Experimental mild surge frequencies were found to be similar to the calculated Helmholtz frequency, while deep surge frequencies were 63-82% of the Helmholtz frequency depending upon the load control valve setting. The model matched the measured plenum pressure amplitudes well; however, the predicted plenum pressure frequencies were slightly higher than the experimental results. Some of the reasons for the deviation from experimental results include map extrapolations, system inputs, and the simplifications in the model geometry relative to the experimental setup. Overall, the primary goal of developing a bench-top capability to measure steady state performance characteristics and unsteady surge was achieved, while also providing a comparison with a lumped parameter model using simplified geometries. iii Dedicated to my family iv ACKNOWLEDGEMENTS I would like to thank my advisor, Prof. Ahmet Selamet, for his assistance and guidance throughout my Master‟s studies. I am in debt to Prof. Selamet for his patience, enthusiasm, and dedication throughout my research and correcting this thesis. I would also like to express thanks to Prof. Rajendra Singh for his time to serve as a member of the examination committee. I am grateful to Rick Renwick, Tom McCarthy, and Dr. Kevin Tallio of the Ford Motor Company along with the College of Engineering for providing support to build the turbocharger test facility at The Ohio State University. Additionally, I would like to thank Dr. Philip Keller at BorgWarner Inc. for providing the turbochargers and technical information used in this study, reviewing this thesis, and serving as a member of the examination committee. For the past two years, I have had the opportunity and privilege of working with an extraordinary group of people at the Center for Automotive Research. I would like to thank Don Williams for his support throughout the project in component design and manufacturing. Additionally, special thanks go to Cam Giang, Ricky Dehner, Asim Iqbal, Hyunsu Lee, Dr. Emel Selamet, and Kevin Fogarty for their help through various stages of the study. I am also grateful to Frank Ohlemacher for his assistance and time interacting with various contractors and the facilities department of the university while v building the turbocharger test facility. Finally, I would like to thank Dr. Shawn Midlam- Mohler for his assistance with LabView and Prof. Michael Dunn and his associates for taking time to discuss certain data acquisition principles. Last, but certainly not least, I would like to thank my family for their constant support and encouragement throughout my entire academic career. vi VITA November 12, 1985……………………….Born - St. Henry, Ohio 2008……………………………………….B.S. Mechanical Engineering, The Ohio State University 2009 – Present…………………………….Graduate Research Associate, The Ohio State University PUBLICATIONS Heydinger, G., Uhlenhake, G. D., Guenther, D., and Dunn, A.L., 2008, “Comparison of Collision and Noncollision Marks on Vehicle Restraint Systems.” SAE Paper 2008-01- 0160. Uhlenhake, G. D., Dunn, A. L., Guenther, D. A., Heydinger, Gary, and Heydinger, Grant, 2009, “Vehicle Coast Analysis: Typical SUV Characteristics,” SAE International Journal of Passenger Cars - Mechanical Systems 1, 526-535. FIELDS OF STUDY Major Field: Mechanical Engineering vii TABLE of CONTENTS ABSTRACT ........................................................................................................................ ii ACKNOWLEDGEMENTS ................................................................................................ v VITA ................................................................................................................................. vii LIST of FIGURES .............................................................................................................. x LIST of TABLES ........................................................................................................... xxiii NOMENCLATURE ...................................................................................................... xxiv 1. INTRODUCTION ....................................................................................................... 1 1.1 Background .......................................................................................................... 1 1.2 Literature Review ................................................................................................. 3 1.3 Objective ............................................................................................................ 15 2. DESIGN of EXPERIMENTAL SETUP .................................................................... 16 2.1 Turbocharger Operating Ranges and Thermodynamic Analysis ........................ 16 2.2 Compressor Selection .......................................................................................... 28 2.3 Control Valve Design .......................................................................................... 31 2.4 Flow Meter Design .............................................................................................. 36 2.5 Oil System Design ............................................................................................... 46 2.6 Data Acquisition and Control System and Instrumentation Selection ................ 48 2.7 Turbine and Compressor System Geometry ....................................................... 52 3. LUMPED PARAMETER MODEL ........................................................................... 58 3.1 Literature Review ................................................................................................ 59 3.2 Selected Model, Assumptions, and Method of Calculation ................................ 69 3.3 Model Results without a Time Lag ..................................................................... 71 viii 3.3.1 Time Step Validation .................................................................................... 72 3.3.2 Comparison of Model Results without a Time Lag with Fink (1988) ......... 76 3.4 Model Results with a Time Lag .......................................................................... 85 3.4.1 Time Step Validation .................................................................................... 85 3.4.2 Time Lag Constant Study and Comparison with Experimental Results ...... 88 4. EXPERIMENTAL RESULTS................................................................................... 94 4.1 Small and Large “B” Compression System Geometries ..................................... 94 4.2 Small and Large “B” Performance Characteristics ............................................. 96 4.3 Mild and Deep Surge Temporal Behavior ........................................................ 101 4.3.1 Temporal Behavior - U 230 m/s, Full Plenum Volume .......................... 107 4.3.2 Temporal Behavior - 310 m/s, Full Plenum Volume .......................... 127 4.3.3 Temporal Behavior - 370 m/s, Full Plenum Volume .......................... 139 4.3.4 Temporal Behavior – Full Volume Summary ............................................ 155 4.3.5 Temporal Behavior – Variable Volume and Speed Study ......................... 156 5. COMPARISON BETWEEN MODEL and EXPERIMENTAL RESULTS ........... 161 5.1 Performance Characteristic
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