– Ball Bearing Turbocharger Technology development Christopher Mitchell

Transcription

– Ball Bearing Turbocharger Technology development Christopher Mitchell
Ball Bearing Turbocharger –
Technology development
Christopher Mitchell
Introduction
Megatrend
CO2 Reduction /
Efficiency Improvement
Drivers
Legislation
95 g/km in 2020
Commercial
Oil price, Cost minimisation
Consumer
Performance and Efficiency
1
Schaeffler Symposium 2014
Christopher Mitchell
Average CO2 Emissions
Development Target
2
Schaeffler Symposium 2014
Christopher Mitchell
Sub-Trends & Main Technologies
Megatrend
CO2 Reduction /
Efficiency Improvement
Drivers
Legislation
95 g/km in 2020
Commercial
Oil price, Cost minimisation
Consumer
Performance and Efficiency
3
Schaeffler Symposium 2014
Christopher Mitchell
Average CO2 Emissions
Sub-Trends & Main Technologies
Megatrend
CO2 Reduction /
Efficiency Improvement
Subtrends
Down-Sizing
Down-Speeding
Driving Resistance
Comprehensive
Measurements
Main Technology
■ Low rpm provision of
power
■ Optimised
Transmission e.g.
■ Forced Induction/
Boosting
■ Stratified DI / HCCI
■ Variable Valve Train
■ Continuously
Variable
Transmission
■ Dual Clutch
Transmission
4
Schaeffler Symposium 2014
Christopher Mitchell
■ Lightweight
Construction
■ Low Friction
Lubrication / Materials
■ Thermal Management
■ Electrification Ancillary
Components
Forced Induction Concepts
5
Schaeffler Symposium 2014
Christopher Mitchell
Forced Induction
Grandfather Clock Design
[Utilising Gear Driven Precompression]
Gottlieb Wilhelm Daimler (1824 – 1900)
6
Schaeffler Symposium 2014
Christopher Mitchell
Patent DRP 34926 1885
Turbocharger - Origin
Exhaust Driven Precompression
Alfred Büchi (1879-1959)
7
Schaeffler Symposium 2014
Christopher Mitchell
Patent CH 35 259A 1905
Ball Bearing Guided Turbo Charger
8
Schaeffler Symposium 2014
Christopher Mitchell
Schaeffler Ball Bearing Cartridge
Anti-Rotation
Slot
Squeeze
Film Land
Oil Jet
Ceramic Balls
Metallic Cage
Turbine
Inner Ring
Compressor
Inner Ring
9
Schaeffler Symposium 2014
Christopher Mitchell
Outer Ring
Stationary Ball Bearing Benefits
Plain bearing
~50% reduction
Ball bearing
400
600
800
1000
Speed [Hz]
10
Schaeffler Symposium 2014
Christopher Mitchell
1200
1400
1600
Source: Honeywell Turbo Technologies
Friction power loss [W]
Operational Power Loss of Bearing System
Source: Honeywell Turbo Technologies
Transient Ball Bearing Benefits
Ball bearing
11
Schaeffler Symposium 2014
Christopher Mitchell
Plain bearing
Ball bearing
Plain bearing
Friction Mechanisms
Film Bearing
12
Schaeffler Symposium 2014
Christopher Mitchell
Rolling Bearing
Flow Regimes
Optimally Flooded
13
Schaeffler Symposium 2014
Christopher Mitchell
Completely Flooded
Optimial Lubricant Flow
Completely Flooded
Power Loss [W]
14
Schaeffler Symposium 2014
Christopher Mitchell
Optimally Flooded
Turbo Charger Cartridge Power Loss
60
viscous friction
circumferrential gap
Power loss [W]
50
load dependent
friction
40
catalogue
supplement for fully
flooded
catalogue speed and
viscocity
30
20
experiment (max)
10
0
min.
max.
measurement measurement
15
Schaeffler Symposium 2014
Christopher Mitchell
analysis
1-D Fluid Dynamics
1-D Simulation Model
Investigated Geometry
Oil Jets into Bearing
Oil Drain
Squeeze Films
 Investigation on Lubricant Availability throughout Operating Conditions
 Optimization of Lubricant Supply Paths
16
Schaeffler Symposium 2014
Christopher Mitchell
Dynamic Bearing Behaviour
17
Contact Forces
Differential Speed
Contact Pressure
Contact Angle
Schaeffler Symposium 2014
Christopher Mitchell
Shaft displacement z
CABA3D – Bearing Interior Dynamic Simulation
Shaft displacement y
 Ball and Cage Dynamic Behavior
 Contact Forces (vs. Race and vs. Cage)
 Spin/Roll; Ball Excursion, …
18
Schaeffler Symposium 2014
Christopher Mitchell
BEARINX – Linear Rotor Dynamics
z
x
Eigenfrequencies
y
 Eigenmodes
 Eigenfrequencies
 Campbell Diagrams
Shaft speed
19
Schaeffler Symposium 2014
Christopher Mitchell
FEA and Multi-Body-Structure
Pre-Tension Force
Axial Contact
Modal Reduction for the Simulation Platform
20
Schaeffler Symposium 2014
Christopher Mitchell
Installation Effects
Contact & Centrifugal Forces
Schaeffler Simulation Platform – System Dynamics
Simulation Platform
Waterfall Diagram
BEARINX®
 Fully Integrated Development Process
■Direct Integration of Nonlinear BEARINX Subsystem into Full System Dynamic Model
■ Component Know-How vs. System Know-How
21
Schaeffler Symposium 2014
Christopher Mitchell
Combined FEM-CFD Analysis
FEM Model
CFD Model
22
Schaeffler Symposium 2014
Christopher Mitchell
Temperature
Temperature of Bearing Parts
23
Schaeffler Symposium 2014
Christopher Mitchell
Real World Data
Fuel Economy
■ Friction power loss - 50% in the bearing system
■ Engine rated power increase + 5%
■ Fuel consumption - 2.5% (dir. cor. to CO2
emission)
■ Engine torque increase + 10% @ ISO soot
Convenience
■ "Kick-down" performance + 2%
Performance
■ Cold start improvement + 80%
■ Applicable to existing hardware
■ Drive away torque improved
■ Compatible with low viscosity
engine oil
■ Transient response - 41%
to boost
@ 1500rpm
Data source: Honeywell
24
Performance
Schaeffler Symposium 2014
Christopher Mitchell
Summary
Megatrend
CO2 Reduction /
Efficiency Improvement
Subtrends
Down-Sizing
Down-Speeding
Turbocharger BallComprehensive
Bearing
Driving Resistance
Measurements
Main Technology
■ Low rpm provision of
power
■ Optimised
Transmission e.g.
■ Forced Induction/
Boosting
■ Stratified DI / HCCI
■ Variable Valve Train
■ Continuously
Variable
Transmission
■ Dual Clutch
Transmission
25
Schaeffler Symposium 2014
Christopher Mitchell
■ Lightweight
■ Thermal Management
Construction
 ~ + 5% Power increase
■ Electrification Ancillary
■ LowFriction
~ + 20% Torque increase
Components
Lubrication
/ Materials
 ~ - 2.5%
CO2 Emission
 Superior cold start behaviour
 Superior transient response
‟
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