Ball Bearing Turbocharger – Technology development · Shaft displacement y Shaft displacement z....

transcript

Ball Bearing Turbocharger –

Technology development

Christopher Mitchell

Schaeffler Symposium 2014 Christopher Mitchell 1

Introduction

Megatrend

Legislation

95 g/km in 2020

Commercial

Oil price, Cost minimisation

Consumer

Performance and Efficiency

Average CO2 Emissions Drivers

CO2 Reduction /

Efficiency Improvement

Development Target

Sub-Trends & Main Technologies

Megatrend

CO2 Reduction /

Legislation

95 g/km in 2020

Commercial

Oil price, Cost minimisation

Consumer

Performance and Efficiency

Drivers Average CO2 Emissions

Sub-Trends & Main Technologies

Main Technology

Down-Sizing Down-Speeding Driving Resistance Comprehensive

Measurements

Subtrends

￭ Thermal Management

￭ Electrification Ancillary

Components

￭ Lightweight

Construction

￭ Low Friction

Lubrication / Materials

￭ Low rpm provision of

￭ Optimised

Transmission e.g.

￭ Continuously

Variable

Transmission

￭ Dual Clutch

Transmission

￭ Forced Induction/

Boosting

￭ Stratified DI / HCCI

￭ Variable Valve Train

Megatrend

CO2 Reduction /

Forced Induction Concepts

Forced Induction

Gottlieb Wilhelm Daimler (1824 – 1900) Patent DRP 34926 1885

Grandfather Clock Design

[Utilising Gear Driven Precompression]

Turbocharger - Origin

Alfred Büchi (1879-1959) Patent CH 35 259A 1905

Exhaust Driven Precompression

Ball Bearing Guided Turbo Charger

Schaeffler Ball Bearing Cartridge

Anti-Rotation Slot

Squeeze Film Land

Oil Jet

Ceramic Balls

Metallic Cage

Turbine Inner Ring

Outer Ring Compressor Inner Ring

Stationary Ball Bearing Benefits F

riction p

loss [

Speed [Hz]

Operational Power Loss of Bearing System

400 600 800 1000 1200 1400 1600 Sourc

echnolo

Plain bearing

Ball bearing

~50% reduction

Transient Ball Bearing Benefits

echnolo

Plain bearing Ball bearing Plain bearing Ball bearing

Friction Mechanisms

Film Bearing Rolling Bearing

Flow Regimes

Optimally Flooded Completely Flooded

Optimial Lubricant Flow

Completely Flooded

Optimally Flooded Power Loss [W]

Turbo Charger Cartridge Power Loss

measurement

analysis

loss [

viscous friction

circumferrential gap

load dependent

friction

catalogue

supplement for fully

floodedcatalogue speed and

viscocity

experiment (max)

1-D Fluid Dynamics

Investigation on Lubricant Availability throughout Operating Conditions

Optimization of Lubricant Supply Paths

Oil Jets into Bearing

Squeeze Films

Oil Drain

1-D Simulation Model Investigated Geometry

Dynamic Bearing Behaviour

Contact Forces Differential Speed

Contact Pressure Contact Angle

CABA3D – Bearing Interior Dynamic Simulation

Ball and Cage Dynamic Behavior

Contact Forces (vs. Race and vs. Cage)

Spin/Roll; Ball Excursion, …

Shaft displacement y

Shaft d

BEARINX – Linear Rotor Dynamics

Eigenmodes

Eigenfrequencies

Campbell Diagrams Shaft speed

FEA and Multi-Body-Structure

Modal Reduction for the Simulation Platform

Pre-Tension Force

Axial Contact

Installation Effects

Contact & Centrifugal Forces

Schaeffler Simulation Platform – System Dynamics

Fully Integrated Development Process

￭Direct Integration of Nonlinear BEARINX Subsystem into Full System Dynamic Model

￭ Component Know-How vs. System Know-How

BEARINX®

Waterfall Diagram Simulation Platform

Combined FEM-CFD Analysis

CFD Model

FEM Model

Temperature of Bearing Parts

Real World Data

￭ Applicable to existing hardware

￭ Compatible with low viscosity

engine oil

￭ Cold start improvement + 80%

￭ Drive away torque improved

￭ Transient response - 41%

to boost

@ 1500rpm

￭ Engine rated power increase + 5%

￭ Engine torque increase + 10% @ ISO soot

￭ "Kick-down" performance + 2%

Data source: Honeywell

Fuel Economy Performance

Performance Convenience

￭ Friction power loss - 50% in the bearing system

￭ Fuel consumption - 2.5% (dir. cor. to CO2

emission)

Summary

Main Technology

Down-Sizing Down-Speeding Driving Resistance Comprehensive

Measurements

Subtrends

￭ Thermal Management

￭ Electrification Ancillary

Components

￭ Lightweight

Construction

￭ Low Friction

Lubrication / Materials

￭ Low rpm provision of

￭ Optimised

Transmission e.g.

￭ Continuously

Variable

Transmission

￭ Dual Clutch

Transmission

￭ Forced Induction/

Boosting

￭ Stratified DI / HCCI

￭ Variable Valve Train

Megatrend

CO2 Reduction /

~ + 5% Power increase

~ + 20% Torque increase

~ - 2.5% CO2 Emission

Superior cold start behaviour

Superior transient response

Turbocharger Ball Bearing

We can't solve problems by using the same kind of thinking

we used when we created them.

” ‟

Albert Einstein

1879-1955

[Turbo charging is,] briefly spoken,

open the throttle today, are ready to go tomorrow.

” ‟

Walter Röhrl

Rallye Champion

1980 and 1982

Ball Bearing Turbocharger – Technology development · Shaft displacement y Shaft displacement z....

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