Martin Seiler

Comparison Between Steady and Unsteady Double-Entry Turbine Performance Using the Quasi-Steady Assumption

The experimental performance evaluation of a circumferentially divided, double-entry turbocharger turbine is presented in this paper with the aim of understanding the influence of pulsating flow. By maintaining a constant speed but varying the frequency of the pulses, the influence of frequency was shown to play an important role in the performance of the turbine. A trend of decreasing cycle-averaged efficiency at lower frequencies was measured. One of the principal objectives was to assess the degree to which the unsteady performance differs from the quasi-steady assumption. In order to make the steady-unsteady comparison for a multiple entry turbine, a wide set of steady equal and unequal admission flow conditions were tested. The steady state data was then interpolated as a function of three, non-dimensional parameters in order to allow a point-by-point comparison with the instantaneous unsteady operation. As an average, the quasi-steady assumption generally under-predicted the mass flow and efficiency loss through the turbine, albeit the differences were reduced as the frequency increased. Out-of-phase pulsations produced unsteady operating orbits that corresponded to a significant steady state, partial admission loss, and this was reflected as a drop in the quasi-steady efficiency. However, these differences between quasi-steady in-phase and out-of-phase predictions were not replicated in the measured results, suggesting that the unequal admission loss is not as significant in pulsating flow as it is in steady flow.

Unsteady Performance of a Double Entry Turbocharger Turbine With a Comparison to Steady Flow Conditions

Circumferentially divided, double entry turbocharger turbines are designed with a dividing wall parallel to the machine axis such that each entry feeds a separate 180 deg section of the nozzle circumference prior to entry into the rotor. This allows the exhaust pulses originating from the internal combustion exhaust to be preserved. Since the turbine is fed by two separate unsteady flows, the phase difference between the exhaust pulses entering the turbine rotor will produce a momentary imbalance in the flow conditions around the periphery of the turbine rotor. This research seeks to provide new insight into the impact of unsteadiness on turbine performance. The discrepancy between the pulsed flow behavior and that predicted by a typical steady flow performance map is a central issue considered in this work. In order to assess the performance deficit attributable to unequal admission, the steady flow conditions introduced in one inlet were varied with respect to the other. The results from these tests were then compared with unsteady, in-phase and out-of-phase pulsed flows most representative of the actual engine operating condition.

Comparison between the steady performance of double-entry and twin-entry turbocharger turbines

Most boosting systems in internal combustion engines utilize ‘pulse turbocharging’ to maximize the energy extraction by the turbine. An internal combustion engine with more than four cylinders has a significant overlap between the exhaust pulses which, unless isolated, can decrease the overall pulse energy and increase the engine pumping loss. Thus, it is advantageous to isolate a set of cylinders and introduce the exhaust gases into two or more turbine entries separately. There are two main types of multiple entry turbines depending on the method of flow division: the twin-entry and the double-entry turbine. In the twin-entry design, each inlet feeds the entire circumference of the rotor leading edge regardless of inlet conditions. In contrast, the double-entry design introduces the flow from each gas inlet into the rotor leading edge through two distinct sectors of the nozzle. This paper compares the performance of a twin and double-entry mixed flow turbine. The turbines were tested at Imperial College for a range of steady-state flow conditions under equal and unequal admission conditions. The performance of the turbines was then evaluated and compared to one another. Based on experimental data, a method to calculate the mass flow under unequal admission from the full admission maps was also developed and validated against the test results.Copyright

The Effect of Unequal Admission on the Performance and Loss Generation in a Double-Entry Turbocharger Turbine

The current work investigates a circumferentially divided turbine volute designed such that each gas inlet feeds a separate section of the turbine wheel. Although there is a small connecting interspace formed between the nozzle and the mixed-flow rotor inlet, this design does well to preserve the exhaust gas energy in a pulsed-charged application by largely isolating the two streams entering the turbine. However, this type of volute design produces some interesting flow features as a result of unequal flows driving the turbine wheel. To investigate the influence of unequal flows, experimental data from the turbocharger facility at Imperial College have been gathered over a wide range of steady-state, unequal admission conditions. These test results show a significant drop in turbine performance with increasing pressure difference between inlets. In addition, the swallowing capacities of each gas inlet are interdependent, thus indicating some flow interaction between entries. To understand the flow physics driving the observed performance, a full 3D computational fluid dynamics (CFD) model of the turbine was created. Results show a highly disturbed flow field as a consequence of the nonuniform admission. From these results, it is possible to identify the regions of aerodynamic loss responsible for the measured performance decrease. Given the unequal flows present in a double-entry design, each rotor passage sees an abrupt change in flow conditions as it rotates spanning the two feeding sectors. This operation introduces a high degree of unsteady flow into the rotor passage even when it operates in steady conditions. The amplitude and frequency of this unsteadiness will depend both on the level of unequal admission and the speed of rotor rotation. The reduced frequency associated with this disturbance supports the evidence that the flow in the rotor passage is unsteady. Furthermore, the CFD model indicates that the blade passage flow is unable to fully develop in the time available to travel between the two different sectors (entries).

A comparison of timescales within a pulsed flow turbocharger turbine

Most modern turbocharger turbines are driven by a highly pulsating flow generated at the exhaust valve of an internal combustion engine. The amplitude and frequency of the exhaust pulses can influence the performance of the turbine when compared to steady state operation. It is useful to seek to simplify the problem of unsteadiness such that greater understanding may result. This paper uses a combination of experimental and computational results to study the various timescales associated with pulsed turbine operation. The effect of pulse amplitude and frequency on the unsteady flow in the volute and rotor is discussed.

A Three-Dimensional Computational Study of Pulsating Flow Inside a Double Entry Turbine

The double entry turbine contains two different gas entries, each feeding 180 deg of a single rotor wheel. This geometry can be beneficial for use in turbocharging and is uniquely found in this application. The nature of the turbocharging process means that the double entry turbine will be fed by a highly pulsating flow from the exhaust of an internal combustion engine, most often with out-of-phase pulsations in each of the two entries. Until now research on the double entry turbine under pulsating flow conditions has been limited to experimental work. Although this is of great value in showing how pulsating flow will affect the performance of the double entry turbine, the level of detail with which this can be studied is limited. This paper is the first to use a three-dimensional computational analysis to study the flow structures within a double entry turbine under conditions of pulsating flow. The analysis looks at one condition of pulsating flow with out-of-phase pulsations. The computational results are validated against experimental data taken from the turbocharger test facility at Imperial College and a good agreement is found. The analysis first looks at the degree of mass flow storage within different components of the turbine and discusses the effect on the performance of the turbine. Each of the volute limbs is found to be subject to a large degree of mass storage throughout a pulse cycle demonstrating a definite impact of the unsteady flow. The rotor wheel shows a much smaller degree of mass flow storage overall due to the pulsating flow; however, each rotor passage is subject to a much larger degree of mass flow storage due to the instantaneous flow inequality between the two volute inlets. This is a direct consequence of the double entry geometry. The following part of the analysis studies the loss profile within the turbine under pulsating flow using the concept of entropy generation rate. A significant change in the loss profile of the turbine is found throughout the period of a pulse cycle showing a highly changing flow regime. The major areas of loss are found to be due to tip leakage flow and mixing within the blade passage.

Blade Excitation in Pulse-Charged Mixed-Flow Turbocharger Turbines

In this article, a fully three-dimensional computational modeling approach in the time and frequency domain is presented, which allows to accurately predicting fluid-structure interactions in pulse-charged mixed-flow turbocharger turbines. As part of the approach, a transient computational fluid mechanics analysis is performed based on the compressible inviscid Euler equations covering an entire engine cycle. The resulting harmonic orders of aerodynamic excitation are imposed in a forced response analysis of the respective eigenvector to determine effective stress amplitudes. The modeling approach is validated with experimental results based on various mixed-flow turbine designs. It is shown that the numerical results accurately predict the measured stress levels. The numerical approach can be used in the turbine design and optimization process. Aerodynamic excitation forces are the main reason for high cycle fatigue in turbocharger turbines and therefore a fundamental understanding is of key importance.

A 3-Dimensional Computational Study of Pulsating Flow Inside a Double Entry Turbine

The double entry turbine contains two different gas entries, each feeding 180° of a single rotor wheel. This geometry can be beneficial for use in turbocharging and is uniquely found in this application. The nature of the turbocharging process means that the double entry turbine will be fed by a highly pulsating flow from the exhaust of an internal combustion engine, most often with out of phase pulsations in each of the two entries.Until now research on the double entry turbine under pulsating flow conditions has been limited to experimental work. Although this is of great value in showing how pulsating flow will affect the performance of the double entry turbine, the level of detail with which this can be studied is limited. This paper is the first to use a 3 dimensional computational analysis to study the flow structures within a double entry turbine under conditions of pulsating flow. The analysis looks at one condition of pulsating flow with out of phase pulsations. The computational results are validated against experimental data taken from the turbocharger test facility at Imperial College and a good agreement is found.The analysis first looks at the degree of mass flow storage within different components of the turbine and discusses the effect on the performance of the turbine. Each of the volute limbs is found to be subject to a large degree of mass storage throughout a pulse cycle demonstrating a definite impact of the unsteady flow. The rotor wheel shows a much smaller degree of mass flow storage overall due to the pulsating flow, however each rotor passage is subject to a much larger degree of mass flow storage due to the instantaneous flow inequality between the two volute inlets. This is a direct consequence of the double entry geometry.The following part of the analysis studies the loss profile within the turbine under pulsating flow using the concept of entropy generation rate. A significant change in the loss profile of the turbine is found throughout the period of a pulse cycle showing a highly changing flow regime. The major areas of loss are found to be due to tip leakage flow and mixing within the blade passage.Copyright