Browse Topic: Turbochargers

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Key Parameters for Turbocharger selection & experimental validation for Off-Highway Applications2026-26-0104To be published on 01/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
KUMAR, HARISH KUMAR, RAWAT, SAURABH, Dogra, DaljitSingh, Singh, Sachleen, Singh, Amarinder
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-0579To be published on 01/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges-such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations-no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
PATRA, SOMNATH, HIBARE, NIKHIL, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Engine Management System Strategies for Mitigating Dual Mass Flywheel Resonance in Gasoline Powertrains2026-26-0052To be published on 01/16/2026
In today's fast paced and competitive automotive market meeting the customers expectations is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajan, viswanatha, Hosur C, Jadhav, Aashish, Jain, Ojase, Jadhav, Marisha
Improving Cold Start and Transient Performance of Medium BMEP CEV Stage V Engines at Low Ambient Temperature and Pressure2026-26-0142To be published on 01/16/2026
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges, particularly concerning cold startability. Low ambient temperatures and pressures intensify the cold start difficulties which are characterized by prolonged cranking, incidences of misfiring, compromised transient response and overall engine performance. This paper highlights the strategies and technologies employed to enhance cold start and transient performance of medium BMEP engines under such demanding environmental conditions. Investigations were conducted up to an altitude of 4500m and ambient temperatures as low as-20°C, utilizing only air heater at intake manifold as the sole cold start aid. This cost effective approach is integrated with an optimized combustion chamber design, along with minimal pilot injection timing and quantity to facilitate smooth ignition and stable combustion during cold start. The paper also explore the techniques to improve the
Saxena, Harshit, Lokare, Prasad, Santhosh, Ajith, Gandhi, Naresh, Shinde, Prashant
Optimization of a Positive Displacement Type Supercharger Using Response Surface Modeling (RSM)2026-26-0429To be published on 01/16/2026
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, in a single or two-cylinder engine, the usage of turbocharger is not recommended, due to the lack of availability of continuous exhaust energy pulses. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model was prepared in Creo, with (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing, being treated as three parameters. The optimum supercharger design was expected to (a) generate a boost pressure of minimum 0.4 bar (gauge), (b
Satre, Santosh Dadasaheb, Mukherjee, Nalini, Rajput, Surendra, Nene, Devendra
Simulation driven design of robust Crank-train systems for elevated In-cylinder combustion pressure2026-26-0400To be published on 01/16/2026
The need for increased in-cylinder pressure to meet the higher engine rating and stringent emissions norms requires special attention on the Main moving components torsional behaviour and the bearing performance. The work presented in this paper utilizes the 1D and 3D simulation potential of AVL EXCITE for the assessment of design changes required in Crank-Train system for the increased in-cylinder pressure from 170bar to 220bar. The key feature of the executed work was that all the design changes were accommodated with minimal changes in packaging / layout interfaces. The given work was executed on 6-Cylinder Turbocharged In-cylinder with Type V valve-train configurations. Initial brain storming & 0d calculation helped in understanding the design optimization required in each and every crank-train parts. Considering the guidelines available in terms of L/d ratio for the bearing, connecting rod length, the overall linkage specification was set up for starting with design work for
Khandelwal, Meha
EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION2026-26-0322To be published on 01/16/2026
Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine
JOSHI, ATUL KAMALAKARRAO, Subramanian, MANOJ
Computational Fluid Dynamics (CFD) Analysis of Turbocharger Aerodynamics and Thermal Behaviour in Automotive Applications2025-28-022911/06/2025
Turbocharging is a vital technology for enhancing internal combustion engine (ICE) performance and efficiency while enabling engine downsizing to reduce fuel consumption and emissions. This research analyzes turbocharger systems by examining their components—turbine, compressor, intercooler, and waste-gate—and their roles in boosting engine efficiency. It explores how exhaust energy drives the turbine to compress intake air, improving power output. The study evaluates turbocharger impact on fuel economy, emissions, and engine response under various driving conditions. It also considers wheel design, material selection, and durability under high temperatures and speeds. Advanced simulations using CFD and FEA analyze airflow, pressure, and thermal behavior to optimize performance. This research affirms turbocharging’s role in creating high-performance, fuel-efficient, and environmentally sustainable engines, offering insights that support the design of next-generation automotive
Chandrashekar, B. Aditya, Bhaduria, Abhishek
Effective Power Management on Diesel Engine Using Electrified Turbocharger2025-28-024211/06/2025
The growing demand for improved fuel efficiency and reduced emissions in diesel engines has led to significant advancements in power management technologies. This paper presents a dual-mode functional strategy that integrates electrified turbochargers to enhance engine performance, provide boost and generate electrical power. This helps in optimizing the overall engine efficiency. The engine performance is enhanced with boosting mode where the electric motor accelerates the turbocharger independent of exhaust flow, effectively reducing turbo lag and provides immediate boost at low engine speeds. This feature also improves high altitude performance of the engine. Conversely, in generating mode, the electric turbocharger recovers or harvest energy from exhaust gases depending on engine operating conditions, converting it into electrical energy for battery recharging purpose. Advanced control systems enable real-time adjustments to boost pressure and airflow in response to dynamic driving
Borle, Shraddha, Prasad, Lakshmi, Couvret, Sebastien, Fournier, Hugo, Chenuet, Laurent
Influence of Twin-Scroll Turbocharging on the Performance of Direct Injection Gasoline Engine2025-01-507010/16/2025
In order to further understand the effect of twin-scroll turbocharging on the engine performance, this paper adopts a combination of one-dimensional numerical simulation and experimental research methods to compare the effects of two-scroll and single-scroll turbocharging on the power and fuel economy of direct injection gasoline engine. The research results show that, compared with the single-scroll turbocharger, twin-scroll turbocharger increased the low-end torque for 16% and 32% at 1000 r/min and 1500 r/min, respectively. However, the average fuel consumption has increased 1.3% at part load with twin-scroll turbocharger due to the pumping loss. Compared with a turbocharged port injection engine with a displacement 1.2 times that of the former, the twin-scroll turbocharged engine saved 11% fuel economy at part loads. The fuel consumption is saved 11% at part loads with twin-scroll turbocharger. This research first establishes the 1D simulation capability in twin-scroll turbocharger
Yu, Xiaocao
An Investigation into the Impact of Cylinder Count on the Efficiency of Opposed Piston Two-Stroke Compression Ignition Engines03-18-06-003710/09/2025
The gas exchange process of opposed piston two-stroke (OP2S) diesel engines is primarily driven by the pressure differential between the intake and exhaust, making them susceptible to cylinder-to-cylinder crosstalk, and therefore to cylinder count. This study examined how cylinder count influences brake efficiency in OP2S engines. Using an experimentally validated 1D engine model, three architectures, ranging from two to four cylinders, were created and simulated across their full operating ranges. To isolate the impact of cylinder count, all configurations employed identical cylinder and port geometries, and identical but scaled electrically assisted turbocharger based airpaths. The engines were also controlled to consistent trapped conditions at a given operating condition, resulting in comparable closed-cycle efficiencies. Comparisons were then made using both scaled electrified airpaths and by assuming isentropic airpath work, to assess the impact of airpath efficiency on the
Vorwerk, Erik Scott, Prucka, Robert, Lawler, Benjamin, Huo, Ming
Flexible an Low Cost Fuel Consumption Prediction in Heavy-Duty Vehicles Using Machine Learning2025-24-012109/07/2025
This study presents a novel approach for predicting fuel consumption in heavy-duty vehicles using a Machine Learning-based model, which is based on feedforward neural network (FFNN). The model is designed to enhance real-time vehicle monitoring, optimize route planning, and reduce both operational costs and environmental impact, making it particularly suitable for fleet management applications. Unlike traditional physics-based approaches, the FFNN relies solely on a refined selection of input variables, including vehicle speed, acceleration, altitude, road slope, ambient temperature, and engine power. Additionally, vehicle mass is estimated using a methodology presented elsewhere and is included as an input for a better generalization of the consumption model. This parameter significantly impacts fuel consumption and is particularly challenging to obtain for heavy-duty vehicles. Engine power is derived from both engine torque and speed (RPM), ensuring a direct relationship with fuel
Vicinanza, Matteo, Pandolfi, Alfonso, Arsie, Ivan, Giannetti, Flavio, Polverino, Pierpaolo, Esposito, Alfonso, Paolino, Antonio, Adinolfi, Ennio Andrea, Pianese, Cesare, Frasci, Valentino
Influence of Crankcase Ventilation on Oil-Derived Emissions in a Hydrogen-Fueled Internal Combustion Engine2025-24-009409/07/2025
Crankcase ventilation has a dual influence over hydrogen accumulation in the crankcase and lubricant-derived emissions in hydrogen-fueled internal-combustion engines (H₂-ICEs), yet the magnitude of that influence is still poorly quantified. The present investigation addresses this gap by systematically varying crankcase ventilation flow rate and testing the influence of blowby routing on the emissions of a 2.3 L turbocharged, direct-injection H₂-ICE equipped with a variable-speed sump pump and two oil separators. The engine was held at four steady-state operating points spanning 2 500–3 500 rpm and 5–10 bar brake mean effective pressure, all under ultra-lean mixtures with global excess-air ratios between 2.6 and 3.2. At each point the crankcase ventilation system outlet mass flow was incremented from 6 to 20 kg/h. Elevating the flow diluted the in-crankcase hydrogen concentration from roughly 25 000 ppm to below 10 000 ppm, reducing the mixture to less than one-quarter of the lower
Bahhar, Anas, Berthome, Vincent, Mura, Ernesto, Chesse, Pascal, Perrot, Nicolas
Experimental Measurement of Dynamometer Homologation Cycles in a Dual-Fuel Medium-Duty Engine2025-24-003609/07/2025
Dual-fuel engines employing alternative combustion concepts have shown promising results in meeting significant emission reductions while maintaining engine performance. In the medium and heavy-duty transport sectors, where electrification remains challenging, developing low-temperature combustion is still a technological solution for reducing carbon impact. However, most of the results in this research field have been presented under stationary conditions, which still positions the transient operation as a challenge. One of the main reasons has been the lack of a dedicated control system to manage the load transitions and the inoperability of stock turbochargers to satisfy the EGR dilution ratios and boost pressure to sustain dual-fuel combustion. This study employs a modified 7.7 L dual-fuel engine for its operation in transient conditions by incorporating a prototype turbocharger system. The study addresses the recalibration of the engine to introduce modifications to the injection
Garcia, Antonio, Monsalve-Serrano, Javier, Marco-Gimeno, Javier, Iñiguez, Erasmo
Using Turbogenerators for Energy Recovery in Turbocharged Hybrid Powertrains2025-24-010009/07/2025
The widespread adoption of battery electric vehicles (BEVs) is progressing more slowly than anticipated, making hybridization crucial for improving efficiency through load point shifting, running the engine at its most efficient operating points and kinetic energy recovery. As the world continues to use fossil fuels, enhancing powertrain efficiency is critical to reducing CO2 emissions. Improved efficiency will also increase the share of renewable e-fuels in the energy mix, supporting the transition to low-carbon mobility. A significant portion of energy in ICEs is lost through exhaust heat, which is a high-grate energy source that can be converted into electricity in hybrid systems. Conventional turbochargers, widely used to enhance volumetric efficiency and drivability, typically incorporate a wastegate (WG) to regulate boost pressure. However, this results in the intentional dumping of excess valuable exhaust energy leading to energy loss. This paper investigates the replacement of
Kodaboina, Raghu Vamsi, Vorraro, Giovanni, Turner, James W. G.
Experimental Study of the Lubricating Oil Impact on the Unsteady Performance of an Automotive Turbocharger2025-24-007809/07/2025
Turbocharging technique is a key technology for the development of hydrogen engines, allowing high lambda values to reach low NOx emissions. In ultra-lean mixture conditions, the thermal management of the lubricating oil and its cold condition becomes a crucial aspect that cannot be neglected. Accordingly, the impact of different lubricating oils and different lubricant thermal conditions is highlighted referring to the performance of a turbocharging system for automotive application. To this aim, an experimental campaign is conducted at the test bench for components of propulsion systems of the University of Genoa. Tests are performed on a turbocharger equipped with a variable geometry turbine under both steady and unsteady flow conditions, considering different positions of the turbine regulating device. A 4-cylinder engine head was coupled to the turbocharger in order to reproduce the pulsating flow related to the opening and closing of the engine valves. The influence of the
Marelli, Silvia, Usai, Vittorio, Cordalonga, Carla
High Lambda Boosting for Hydrogen Internal Combustion Engine02-18-03-002308/29/2025
The commercial vehicle industry continues to move in the direction of lower emissions while reducing its carbon footprint. This study focuses on hydrogen internal combustion engines (H2-ICE) since it offers a zero-carbon solution to the industry while showing very low NOx emissions when coupled to a conventionally sized aftertreatment SCR system. This work highlights modeling efforts for analyzing key boosting configurations to operate a hydrogen engine at high lambda (relative air–fuel ratio) for lowering NOx, maintain the aftertreatment system reasonable in size, and improving brake thermal efficiency (BTE). GT-Power was used to model H2-ICE engines from 13L to 19L in displacement with different boosting architectures. Key configurations include a variable geometry turbine (VGT) turbocharger coupled with a supercharger (SC), a VGT with higher engine displacement, and a VGT coupled in series with a fixed geometry turbine (FGT) turbocharger. An exhaustive study comparing these boosting
Gurjar, Shubham, McCarthy, Jr., James E., Manickavasagan, Thirumoolan, Chaudhari, Amol S., Nimeshkumar, Parmar, Bachu, Pruthvi, Bitsis, Christopher
Methodology for Selection of Gasoline Catalytic Convertor & Oxygen Sensor Position, Study on Oxygen Storage Capacity for 1.2L Turbocharger MPFI Engine2025-01-502205/16/2025
The results published in this paper emphasize on the study of three-way catalytic convertor for a 1.2 L turbocharged multi-point fuel injection gasoline engine. This paper takes us through the findings on methodology used for finalizing the brick configuration for catalytic convertor along with downstream oxygen sensor placement for emission control and methods applied for catalytic convertor selection with actual testing. The advantages of dual brick configuration over single brick with downstream sensor placed in between the bricks to enable faster dew point of sensor is explained using water splash test and design confirmation of better exhaust gas flow vortices concentration at the sensor tip for better sensing. Selection of catalytic convertor loading by testing its emission conversion capability and light-off behavior. NOx conversion capability across stoichiometric ratio (14.7:1 for petrol) on selected most operational zone was tested (±5% lambda) for the design-finalized
Arun Selvan, S. A., Paul, Arun Augustine, Selvaraj, Manimaran
Optimization of HEV Vehicle’s Engine Modulated Noise2025-01-008405/05/2025
One 1.5L Miller-cycle turbocharged four cylinder gasoline hybrid engine is installed on a certain hybrid vehicle. When accelerating at low to medium speeds with a small throttle, there is a "da da" knocking noise inside the car, which seriously affects the overall sound quality of the vehicle. By analyzing the vibration and noise data of the engine, it was found that the frequency of the abnormal knocking sound is 200-2000Hz, which presents a half order characteristic in the time domain, that is, one knocking occurs when the engine crankshaft rotates twice. Through Hilbert demodulation analysis of the vibration data in the problem frequency range, it was found that the knocking noise was modulated in the frequency domain, with a modulation frequency of half of the crankshaft rotation frequency. By building a fully flexible multi-body dynamic model of a hybrid powertrain and inputting the engine's cylinder pressure excitation, the combustion excitation is coupled with mechanical
Dan, Kong
Theoretical Study of Electrically Assisted Two-Stage Turbocharger Boost System Applied to Large-Bore Gas SI ICE2025-01-835404/01/2025
Large-bore gas SI ICEs are supposed to operate under more strict conditions in terms of NOx level and potentially using new generation of fuels (e.g., hydrogen, ammonia) in the near future. Currently, the TA Luft norm is being considered while typical BMEP levels are between 22-28 bar. It is expected that NOx will have to drop significantly (down to 20% or even below 10% of the amount based on TA Luft) while engine BMEP is supposed to be increased above 30 bar. The paper is based on 0-D/1-D simulations while using the experience gained from older research projects concerning similar engines. The main goal is to study the influence of different operating conditions (e.g., NOx level, BMEP level, control means, ambient conditions) on both ICE performance and turbocharger operation while comparing classical 2-stage system with 2 electrically assisted ones (e-turbo, e-booster) – steady state performance is of the main focus while transient one is also considered. Complex optimizations were
Vitek, Oldrich, Macek, Jan, Mares, Bohumil, Klima, Jiri, Vacek, Martin
Assessment of a Heavy-Duty Diesel Engine Retrofitted to Dual-Fuel and Neat Methanol SI Operation2025-01-844004/01/2025
This paper explores the potential of leveraging methanol's knock-resistant properties to facilitate both dual fuel (DF) and spark ignition (SI) operation in retrofitted heavy-duty (HD), high-speed marine engines. The study involves retrofitting an original 6-cylinder 7.15L CI diesel engine with port fuel injection (PFI) of methanol to enable DF operation. Later, the diesel injectors were replaced with six spark plugs allowing SI operation. Notably, efforts were made to minimize adaptations to the existing diesel engine, maintaining the compression ratio (CR) at 17.6:1 and retaining the same turbocharging pressure. This research aims to assess the feasibility of retrofitting conventional HD diesel engines (high CR, large bore) for dual-fuel and SI operation on methanol, with a focus on optimizing engine performance, while preserving key characteristics for HD applications, e.g. high torque and high power density. The high CR required spark retarding to prevent knock at higher loads in
Dejaegere, Quinten, Ballerini, Alberto, Demiddeleer, Sheldon, Vanderbeken, Thomas, Bracke, Kwinten, Gyselinck, Ben, D'Errico, Gianluca, Verhelst, Sebastian
WITHDRAWAL NOTICE2025-01-8253.0104/01/2025
Enhanced High-Temperature Performance of NH 3 -SCR Catalysts for Lean-Burn Engines2025-01-704301/31/2025
NOx after-treatment has greatly limited the development of lean-burn technology for gasoline engines. NH3-Selective Catalytic Reduction (SCR) technology has been successfully applied to NOx conversion in diesel engines. For gasoline engines, SCR catalyst is required to maintain high activity over a higher temperature window. In this study, we utilized a turbocharged and intercooled 2.0 L petrol engine to investigate the NOx conversion of two zeolite-based SCR catalysts, Cu-SSZ-13 and Fe/Cu-SSZ-13, at exhaust flows ranging from 80 to 300 kg/h and exhaust temperatures between 550 to 600°C. The catalysts were characterized using SEM, ICP, XRD, H2-TPR, NH3-TPD, and other methods. The selected Fe/Cu-SSZ-13 catalyst showed higher NOx conversion (>80%) in the temperature range of 550~600oC and 80~300 kg/h exhaust gas flow. NOx output could be controlled below 10ppm. The characterization results showed that although the specific surface area and acidic sites decreased after the aging treatment
Pan, Shiyi, Wang, Ruwen, Zhang, Nan, Xu, Zhiqin, Hu, Jiangtao, Liao, Xiuke, Duan, Pingping, Chen, Ruilian
Vibration Measurement on Diesel Engine Components under Adverse Conditions in Brazilian Application2024-36-002112/20/2024
The objective of this study is to investigate the root cause of cracks detected in the Turbocharger bracket belonging to the engine Mercedes-Benz OM471 (Power: 390kW, Torque: 2600Nm) from Vehicle Truck Mercedes-Benz Actros 2651LS 6x4 Euro V. The investigation started with the instrumentation of every related component (besides the bracket itself, the charge air pipe, the exhaust pipe and also the crankcase for reference) in order to perform a vibration measurement. The necessary equipment to execute this procedure, included accelerometers, temperature sensors, strain gages and an inductive engine speed sensor. All data had to be acquired directly from real application conditions in vehicle, maximum load of 74 ton in a previously defined mountain road track, due to the impossibility to generate similar results in comparison to the ones detected on road through bench tests (or any other in-door experiment). The bracket position is located on the right side of a diesel combustion engine
Feijó, Igor Sommerfeld, Gonçalves, Carlos Aurélio Bustamante
Large-Bore HFO Engine Gas Conversion for Power Plants – Part A: Numerical Assessment2024-36-016012/20/2024
In the global scenario marked by the increasing environmental awareness and the necessity on reducing pollutant emission to achieve the decarbonization goals, action plans are being proposed by policy makers to reduce the impact of the climate change, mainly affecting the sectors that most contribute to CO2 emissions such as transportation and power generation. In this sense, by virtue of the National Energy Plan 2050, the Brazilian market will undergo the decommissioning of thermal power plants fueled by diesel and heavy fuel oil (HFO) by 2030, compromising about 6.7 GW of power capacity according to the Brazilian Electricity Regulatory Agency (ANEEL) database. An alternative to the scrapping of these engine power plants is their conversion to operate with fuels with a lower carbon footprint, such as the natural gas. This work, therefore, aims to numerically assess the conversion feasibility of a HFO large bore four-stroke turbocharged engine to operate with natural gas by means of a
Gonçalves, Vinícius Fernandez, Zabeu, Clayton Barcelos, Antolini, Jácson, Salvador, Roberto, Almeida, Rogério, Valiati, Allan Soares, Filho, Guenther Carlos Krieger
Fuel Efficiency Evaluation of an Off-Road Diesel Engine with an EGR Pump and High-Efficiency Turbocharger across Various Drive Cycles02-17-04-002312/10/2024
As regulations become more stringent, engine manufacturers are adopting innovative technologies to reduce emissions while maintaining durability and reliability. One approach involves optimizing air handling systems. Eaton developed a 48 V electric exhaust gas recirculation pump (EGRP) to reduce NOx and CO2 emissions while improving fuel efficiency when paired with a high-efficiency turbocharger. This study integrates an electric EGRP and a high-efficiency turbocharger onto a 13.6L John Deere off-road diesel engine to evaluate the impact on fuel efficiency and NOx emissions across various drive cycles including the nonroad transient cycle (NRTC), the low load application cycle (LLAC), the constant speed–load acceptance (CSLA) test, and the ramped modal cycle (RMC). The study highlights the benefits and limitations of the prototype EGRP on an off-road engine. Since the setup did not include aftertreatment systems, engine-out emissions were analyzed. Experiments were conducted at
Willoughby, Audrey, Adekanbi, Michael, Kakani, Raghav, Ahmad, Zar Nigar, Shaver, Greg, Holloway, Eric, Haaland, Eric, Evers, Matthew, Loesch, Adam, McClurg, Josiah, Bagal, Nilesh, McCarthy, James, Coates, Michael
Investigating Methods to Generate Models for Turbine Maps Using Machine Learning02-17-04-001910/09/2024
For turbocharged engine design, manufacturer-provided turbocharger maps are typically used in simulation analysis to understand key engine performance metrics. Each data point in the turbocharger map is generated by physically testing the hardware or through CFD analysis—both of which are time-consuming and expensive. As such, only a modest set of data can be generated, and each data map must be interpolated and extrapolated to create a smooth surface, which can then be used for engine simulation analysis. In this article, five different machine learning algorithms are described and compared to experimental data for the prediction of Cummins Turbo Technologies (CTT) fixed geometry turbines within and outside of the experimental data range. The results were validated against xxx-provided test data. The results demonstrate that the Bayesian neural networks performed the best, realizing a 0.5%–1% error band. In addition, it is extrapolatable when suitable manually created extra data
Supe, Shreyas, Natarajan, Bharath, Shaver, Greg
Variable Geometry Turbine Turbocharger Optimization Using Machine Learning for On-Highway Fuel Cell Applications02-17-04-002010/07/2024
Turbocharger design involves adjustment of various geometric parameters to improve the performance and suit mechanical constraints, depending on the application-specific requirements. In designing the turbine stage, these parameters are optimized to maximize durability and efficiencies at the required operating points. For a heavy-duty class eight truck, “road load” and “rated power” are generally considered the two most important operating points. The objective of this article is to improve the efficiencies of these two operating points. The common challenge in the development of a turbine wheel design is the large number and interdependence of parameters to optimize. For example, increasing the blade thickness improves structural strength but reduces the mass flow capacity, thus influencing its performance. It is general practice to optimize the wheel geometry using iterative CFD analysis. However, running simulations for every single change in geometry involves significant
Wichlinski, Joseph, Gonser, Lukas, Naik, Pavan, Taylor, Alexander H., Al-Hasan, Nisar S.
Advanced Laser Cleaning Robotic Work Cells Turbocharge Industrial ProcessesTBMG-5140309/01/2024
Today, advancements in industrial laser cleaning automation show great promise in boosting productivity and safety when rust and contaminant removal or surface preparation is required for higher volumes of components and equipment.
An Investigation on Exhaust Pulse Characteristics of Asymmetric Twin-Scroll Turbocharged Heavy-Duty Diesel Engine03-17-06-004807/24/2024
The shape and energy distribution characteristics of exhaust pulse of an asymmetric twin-scroll turbocharged engine have a significant impact on the matching between asymmetric twin-scroll turbines and engines, as well as the matching between asymmetric twin scrolls and turbine wheels. In this article, the exhaust pulse characteristics of an asymmetric twin-scroll turbocharged engine was studied. Experiments were conducted on a turbine test rig and an engine performance stand to determine the operation rules of exhaust pulse strength, turbine flow parameters, turbine isentropic energy, and turbine efficiency. The results showed that the exhaust pulse strength at the inlets of both the small and large scrolls continuously decreased with the increase of engine speed. And the flow parameters at the inlets of the small and large scrolls exhibited a “ring” or “butterfly” shape with the change of expansion ratio depending on the pressure deviation of the extreme points at the troughs on both
Wu, Liangqin, Jin, Jianjiao, Wang, Jie, Zhang, Chenyun
Turbocharging System Selection for a Hydrogen-Fuelled Spark-Ignition Internal Combustion Engine for Heavy-Duty Applications2024-01-301907/02/2024
Nowadays, green hydrogen can play a crucial role in a successful clean energy transition, thus reaching net zero emissions in the transport sector. Moreover, hydrogen exploitation in internal combustion engines is favored by its suitable combustion properties and quasi-zero pollutant emissions. High flame speeds enable a lean combustion approach, which provides high efficiency and reduces NOx emissions. However, high airflow rates are required to achieve the load levels typical of heavy-duty applications. In this framework, the present study aims at investigating the required boosting system of a 6-cylinder, 13-litre heavy-duty spark ignition engine through 1D numerical simulation. A comparison among various architectures of the turbocharging system and the size of each component is presented, thus highlighting the limitations and potentialities of each architecture and providing important insights for the selection of the best turbocharging system.
Pucillo, Francesco, Millo, Federico, Piano, Andrea, Giordana, Sergio, Rapetto, Nicola, Paulicelli, Fabio
Numerical Study of Application of Gas Foil Bearings in High-Speed Drivelines2024-01-294106/12/2024
The commitment to environmentally friendly transportation calls for efficient solutions with the evolution of automotive industry. Turbochargers are an important part of this development. The application of Gas or Air Foil Bearings (GFB) instead of traditional hydrodynamic bearings is recently very noticed, with which the fuel consumption, and emissions can be minimized as well as decreasing the maintenance costs and increasing the reliability. However, low viscosity of gas leads to lower dynamic stiffness and damping characteristics resulting in low load carrying capacity and instability at higher speeds. Gas bearings can be enhanced by adding a foil structure commonly known as gas foil bearings whose dynamic stiffness can be tailored by modifying the geometry and the material properties resulting in better stability and higher load carrying capacity. A detailed study is required to assess the performance of high-speed rotor systems supported on GFBs, therefore in this study a bump
Mandapalli, Prithvi Raju, Hoefler, Dieter, Rohani, Rezvan
Influences of High-Pressure Pump and Injector Nozzle Geometry on Hydraulics Characteristics of a Mechanical Diesel Direct-Injection System2024-01-506106/04/2024
The geometry of high-pressure pump and injector nozzles crucially influences hydraulic behaviors (e.g., the start of injection, the pressure profiles developed in the high-pressure line, needle lift, and injection rates) in diesel engines. These factors, in turn, significantly impact fuel atomization, fuel–air mixing, combustion quality, and the formation of emissions. The main geometry parameters such as plunger diameter and the number and diameter of nozzles lead to the system complexity, requiring careful analysis, design, and calibration. In this study, a high-speed shadowgraph system and a high-resolution pressure recording system were developed to capture the start of injection, spray structure, and pressure profiles in the high-pressure line. Additionally, a model was developed using GT-Fuel package built within the GT-Suite of simulation tools to explore different plunger diameters and numbers and diameters of injector nozzles. These models were validated using the pressure
Nguyen, Quan Q., Vu, Manh D., Phung, Duoc V., Nguyen, Kien T., Vu*, Tuan N., Pham, Phuong X.
Auto-Ignited Combustion Control in an Engine Equipped with Multiple Boosting Devices03-17-06-004306/03/2024
The combustion timing of auto-ignited combustion is determined by composition, temperature, and pressure of cylinder charge. Thus, for a successful auto-ignition, those key variables must be controlled within tight target ranges, which is challenging due to (i) nature of coupling between those variables, and (ii) complexity of managing multiple actuators in the engine. In this article, a control strategy that manages multiple actuators of a boosted homogeneous charge compression ignition (HCCI) engine is developed to maintain robust auto-ignited combustion. The HCCI engine being considered is equipped with multiple boosting devices including a supercharger and a turbocharger in addition to conventional actuators and sensors. Since each boosting device has its own pros and cons, harmonizing those boosting devices is crucial for successful transient operation. To address the multi-variable transient control problem, speed-gradient control methodology is applied to minimize coupling
Kang, Jun-Mo
Centrifugal Compressor Map Prediction Based on Geometrical Parameters with Invariant Coefficients2024-01-505604/24/2024
In the present work, a new methodology for predicting the performance of centrifugal compressors is developed. The proposed method differs from existing methods found in literature by gathering principal losses in three parameters: two constants and one variable, which is a function of the compressor wheel geometrical characteristics. As those parameters are constants for a given centrifugal compressor, there is no need for additional corrective parameters in order to obtain coherent results. Indeed, the proposed methodology does not depend on the choice of the slip factor correlation for the prediction of the correct pressure ratio. However, the choice of slip factor influences the efficiency computation. The prediction of the compressor maps for two full stage centrifugal compressors is presented and they show good agreement while compared with manufacturer’s data obtained from gas stand measurements. In addition, a method to obtain the surge line based on this methodology is
Martinez Alvarado, Luis Enrique, Milosavljevic, Misa
Evaluating the Effects of an Electrically Assisted Turbocharger on Scavenging Control for an Opposed Piston Two Stroke (OP2S) Compression Ignition Engine2024-01-238804/09/2024
Opposed piston two-stroke (OP2S) diesel engines have demonstrated a reduction in engine-out emissions and increased efficiency compared to conventional four-stroke diesel engines. Due to the higher stroke-to-bore ratio and the absence of a cylinder head, the heat transfer loss to the coolant is lower near ‘Top Dead Center.’ The selection and design of the air path is critical to realizing the benefits of the OP2S engine architecture. Like any two-stroke diesel engine, the scavenging process and the composition of the internal residuals are predominantly governed by the pressure differential between the intake and the exhaust ports. Without dedicated pumping strokes, the two-stroke engine architecture requires external devices to breathe. In the unique OP2S engine architecture studied in this work, the external pumping devices present in the air path include an electrically assisted turbocharger (EAT), an electrified EGR pump, and a back-pressure valve (BPv) located downstream of the
Bhatt, Ankur, Gandolfo, John, Huo, Ming, Gainey, Brian, Lawler, Benjamin
Post-Oxidation Phenomena as a Thermal Management Strategy for Automotive After-Treatment Systems: Assessment by Means of 3D-CFD Virtual Developmen t2024-01-262904/09/2024
The target of the upcoming automotive emission regulations is to promote a fast transition to near-zero emission vehicles. As such, the range of ambient and operating conditions tested in the homologation cycles is broadening. In this context, the proposed work aims to thoroughly investigate the potential of post-oxidation phenomena in reducing the light-off time of a conventional three-way catalyst. The study is carried out on a turbocharged four-cylinder gasoline engine by means of experimental and numerical activities. Post oxidation is achieved through the oxidation of unburned fuel in the exhaust line, exploiting a rich combustion and a secondary air injection dedicated strategy. The CFD methodology consists of two different approaches: the former relies on a full-engine mesh, the latter on a detailed analysis of the chemical reactions occurring in the exhaust line. The coupling between experimental data and simulation results provides a complete assessment of the investigated
Barillari, Loris, Pipolo, Mario, Della Torre, Augusto, Montenegro, Gianluca, Onorati, Angelo, Vacca, Antonino, Chiodi, Marco, Kulzer, André
3-Dimentional Numerical Transient Simulation and Research on Flow Distribution Unevenness in Intake Manifold for a Turbocharged Diesel Engine2024-01-242004/09/2024
The design of engine intake system affects the intake uniformity of each cylinder of the engine, which in turn has an important impact on the engine performance, the uniform distribution of EGR exhaust gas and the combustion process of each cylinder. In this paper, the constant-pressure supercharged diesel engine intake pipe is used as the research model to study the intake air flow unevenness of the intake pipe of the supercharged diesel engine. The pressure boundary condition at the outlet of each intake manifold is set as the dynamic pressure change condition. The three-dimensional numerical simulation of the transient flow process in the intake manifold of diesel engine is simulated and analyzed by using numerical method, and the change of the Intake air flow field in the intake manifold under different working conditions during the intake overlapping period is discussed. The dynamic effects of diesel engine intake boost pressure, rotated speed, and intake pipe geometrical
Yang, Shuai, Yan, Kai, Liu, Haifeng, Fu, Yahao, Liu, Hairan, Li, Tong
Assessing the Effects of Computational Model Parameters on Aerodynamic Noise Characteristics of a Heavy-Duty Diesel Engine Turbocharger Compressor at Full Operating Conditions2024-01-235204/09/2024
In recent years, with the development of computing infrastructure and methods, the potential of numerical methods to reasonably predict aerodynamic noise in turbocharger compressors of heavy-duty diesel engines has increased. However, aerodynamic acoustic modeling of complex geometries and flow systems is currently immature, mainly due to the greater challenges in accurately characterizing turbulent viscous flows. Therefore, recent advances in aerodynamic noise calculations for automotive turbocharger compressors were reviewed and a quantitative study of the effects for turbulence models (Shear-Stress Transport (SST) and Detached Eddy Simulation (DES)) and time-steps (2° and 4°) in numerical simulations on the performance and acoustic prediction of a compressor under various conditions were investigated. The results showed that for the compressor performance, the turbulence models and time-step parameters selection were within 3% error of the simulated and experimental values for
Huang, Rong, Ni, Jimin, Wang, Qiwei, Yin, Qi
Water Droplet Collison and Erosion on High-Speed Spinning Wheels03-17-05-003704/04/2024
The water droplet erosion (WDE) on high-speed rotating wheels appears in several engineering fields such as wind turbines, stationary steam turbines, fuel cell turbines, and turbochargers. The main reasons for this phenomenon are the high relative velocity difference between the colliding particles and the rotor, as well as the presence of inadequate material structure and surface parameters. One of the latest challenges in this area is the compressor wheels used in turbochargers, which has a speed up to 300,000 rpm and have typically been made of aluminum alloy for decades, to achieve the lowest possible rotor inertia. However, while in the past this component was only encountered with filtered air, nowadays, due to developments in compliance with tightening emission standards, various fluids also collide with the spinning blades, which can cause mechanical damage. One such fluid is the condensed water in the low-pressure exhaust gas recirculation channel (LP-EGR) formulated at cold
Takács, Richárd, Zsoldos, Ibolya, Szentendrei, Dániel
2025 Kia Carnival MPV Hybrid brings unplugged PHEV power24AUTP04_1204/01/2024
The 2025 Kia Carnival MPV is acquiring a hybrid powertrain as part of the minivan's model year update that debuted at the Chicago Auto Show. The internal-combustion engine option remains the 3.5-L V6 GDI seen in the current Carnival and produces 287 hp and 260 lb-ft (353 Nm) that powers the front wheels through an 8-speed automatic transmission. Engine power is down slightly from the output of the V6 in the 2024 model (290 hp and 262 lb-ft [355 Nm]). It's the addition of an electric motor to the new hybrid model where things get interesting. The hybrid Carnival uses a 1.6-L turbocharged 4-cyl. and a 54 kW motor that produce a combined 242 hp and 271 lb-ft (367 Nm). The Carnival Hybrid MPV uses a 6-speed automatic transmission. Improved fuel economy is one reason for the new hybrid option. While Kia doesn't yet have official EPA estimates, a spokesperson told SAE Media that the target is 32 mpg combined. The current ICE-only Carnival gets 22 mpg.
Blanco, Sebastian
Sea-Level Characterization of Electrically Assisted Turbocharger for Use on Aviation Diesel Engine2024-01-191403/05/2024
Airborne compression-ignition engine operations differ significantly from those in ground vehicles, both in mission requirements and in operating conditions. Unique challenges exist in the aviation space, and electrification technologies originally developed for ground applications may be leveraged to address these considerations. One such technology, electrically assisted turbochargers (EATs), have the potential to address the following: increase the maximum system power output, directly control intake manifold air pressure, and reignite the engine at altitude conditions in the event of an engine flame-out. Sea-level experiments were carried out on a two-liter, four-cylinder compression-ignition engine with a commercial-off-the-shelf EAT that replaced the original turbocharger. The objective of these experiments was to demonstrate the technology, assess the performance, and evaluate control methods at sea level prior to altitude experimentation. This work covers the baseline
Pope, Aaron, Kim, Kenneth, Schroen, Erik, Clerkin, Peter, Musser, Marshall, Mattson, Jonathan, Meininger, Rik, Gibson, Joseph, Kang, Sang-Guk, Kruger, Kurt, Hepp, Kyle, Kweon, Chol-Bum
Effect of Turbine Speed Parameter on Exhaust Pulse Energy Matching of an Asymmetric Twin-Scroll Turbocharged Heavy-Duty Engine02-17-02-001003/04/2024
The two-branch exhaust of an asymmetric twin-scroll turbocharged engine are asymmetrically and periodically complicated, which has great impact on turbine matching. In this article, a matching effect of turbine speed parameter on asymmetric twin-scroll turbines based on the exhaust pulse energy weight distribution of a heavy-duty diesel engine was introduced. First, it was built as an asymmetric twin-scroll turbine matching based on exhaust pulse energy distribution. Then, by comparing the average matching point and energy matching points on the corresponding turbine performance map, it is revealed that the turbine speed parameter of energy matching points was a significant deviation from the turbine speed parameter under peak efficiency, which leads to the actual turbine operating efficiency lower than the optimal state. In addition, a turbine speed parameter adjustment strategy was proposed by changing compressor impeller diameters to reveal the effect on turbine matching based on
Jin, Jianjiao, Zhang, Chenyun, Wu, Liangqin, Zhu, Hongping, Qian, Yuanping
Review of Research on Asymmetric Twin-Scroll Turbocharging for Heavy-Duty Diesel Engines02-17-02-000902/21/2024
Asymmetric twin-scroll turbocharging technology, as one of the effective technologies for balancing fuel economy and nitrogen oxide emissions, has been widely studied in the past decade. In response to the ever-increasing demands for improved fuel efficiency and reduced exhaust emissions, extensive research efforts have been dedicated to investigating various aspects of this technology. Researchers have conducted both experimental and simulation studies to delve into the intricate flow mechanism of asymmetric twin-scroll turbines. Furthermore, considerable attention has been given to exploring the optimal matching between asymmetric twin-scroll turbines and engines, as well as devising innovative flow control methods for these turbines. Additionally, researchers have sought to comprehend the impact of exhaust pulse flow on the performance of asymmetric twin-scroll turbines. Drawing on a comprehensive review of prior research endeavors, this study presents a meticulous summary of the
Jin, Jianjiao, Wang, Jie, Zhang, Chenyun, Cao, Tianyi
Optimised Air Management System for Heavy Duty Hydrogen Engines2024-26-017101/16/2024
Many Indian cities are amongst the most polluted cities in the world. Transport sector is identified as one of the major contributors to air pollution. Following the global trend, Government of India is also promoting near zero emission fuels with zero CO2 emissions as a way forward to solve the emission problems. With its policies like Green Hydrogen Mission, government of India plans to accelerate the adoption of Hydrogen as a fuel in the country. These initiatives have created a breakthrough in development of Hydrogen ICEs by the Indian OEM’s. Hydrogen ICE have only NOx emissions as the most prominent engine out emissions. NOx emission in Hydrogen engines is very sensitive to operating lambda, where in, after a certain threshold lambda the emissions rise significantly. Therefore, the air management system plays a very important role in the hydrogen engine performance & NOx emissions. This study evaluates various air management system options for a heavy-duty Hydrogen engine
Emran, Ashraf, Paranjape, Sumeet, Sreedharan, Sajil N, Jagodzinski, Bartosch, Garg, Shivam, Sharma, Vijay, Wagh, Sachin
Oil Aerosol Emission Optimization Using Deflectors in Turbo Charger Oil Drain Circuit2024-26-004701/16/2024
Closed crankcase ventilation prevent harmful gases from entering atmosphere thereby reducing hydrocarbon emissions. Ventilation system usually carries blowby gases along with oil mist generated from Engine to Air intake system. Major sources of blowby occurs from leak in combustion chamber through piston rings, leakage from turbocharger shafts & leakage from valve guides. Oil mist carried by these blowby gases gets separated using separation media before passing to Air Intake. Fleece separation media has high separation efficiency with lower pressure loss for oil aerosol particles having size above 10 microns. However, efficiency of fleece media drops drastically if size of aerosol particles are below 10 microns. Aerosol mist of lower particle size (>10 microns) generally forms due to flash boiling on piston under crown area and from shafts of turbo charger due to high speeds combined with elevated temperatures. High power density diesel engine is taken for our study. It produces
M, Velshankar, Dharan R, Bharani, Dhadse, Ashish, Permude, Ashok, Loganathan, Sekar
Model Based Charge Control for 3-Cylinder TGDI Miller Engine Containing Variable Geometry Turbocharger2024-26-004301/16/2024
For ensuring environmental safety, strong emphasis on CO2 pollution reduction is mandated which led to evolution of miller cycle engines. However, the inherent Miller engine characteristic is the lower volumetric efficiency when compared to otto engines because of which small turbo chargers with variable geometry turbines are used to induct air into the engine. With miller engine and VGT turbo charger combination arises the challenges of charge controllability because of lower inertia and reduced vane control area. With conventional turbo charger control methods, the response time is slow thereby leading to turbo lag or severe over boosting, this is overcome by accurate engine modelling and using the same as input for charger control. In this study, model-based calibration approach was performed on a 3-cylinder Miller GDI 1.2L engine to model the charge exchange of the engine and use the same for determination required turbine vane positions to achieve the desired airflow induction
Veeramani, Vivekanand, Karthi, Ramanathan, Shanmugam Ramakrishnan, Muthu
PERKINS bets big on SMALLER ENGINE23TOFHP12_0112/01/2023
The new 2600 Series 13-liter engine for off-highway machines will do more with less thanks to variable geometry turbocharging. Perkins announced in September its all-new engine series for off-highway applications, launching the 2600 Series 13-liter engine at a press event in London where Truck & Off-Highway Engineering was in attendance. Perkins states that the 2600 Series is intended for a wide array of off-highway applications including agricultural tractors, materials handling, construction, mining, aircraft ground support and other use cases. “As the off-highway industry advances toward a lower-carbon future, equipment manufacturers still face expectations for long-term productivity and reliability in the world's most-demanding work environments,” said Jaz Gill, vice president of global sales, marketing, service and parts. “The new Perkins 2600 Series engine platform demonstrates how we're leveraging our experience, intelligence and commitment to help OEMs navigate the energy
Wolfe, Matt
Cummins' new mid-displacement turbos quieter, more efficient23TOFHP12_0812/01/2023
Cummins announced its seventh-generation series HE250 and HE300 waste-gate turbochargers for medium displacement on- and off-highway commercial engines. The turbos are sized for 5.5- to 8-liter medium-duty diesel engines and 8- to 11-liter natural-gas engines. Cummins states that the HE250 and 300 were designed to meet the global emissions regulations from 2024 onwards including the upcoming China Stage IV FE 2024, NSVII 2026 and Euro VII 2027. Cummins claims significant improvements in performance and durability compared to the outgoing models. Both turbos reportedly offer a 6-7% gain in overall efficiency as well as enhanced low-speed performance, which translates to additional low-end torque and better compatibility with engine start/stop systems.
Wolfe, Matt
Hybrid Experimental-CFD Mapping Approach for Twin-Entry Turbo Turbine2023-01-160410/31/2023
The steady flow hot-gas stand test is a widely used method for experimentally characterising turbocharger turbines to produce maps for use in 1D engine simulations. However, for twin entry turbine stages with two volutes, measuring multiple maps at different ratios of mass flow in each volute is time-consuming. This study investigated how computational fluid dynamics (CFD) simulation could reduce the experimental effort for mapping twin-entry turbines, especially for unequal admission conditions. The study is based on a case study of a medium-duty twin-entry turbine, characterising its performance both experimentally and using 3D simulations with ANSYS CFX®. In total, nine maps were produced: one at equal admission, two single admissions, and six unequal admissions conditions. The unequal admission maps were recorded at constant pressure ratios between the two scrolls; the scroll pressure ratio varied from 0.58 to 1.75. Each map contains 24 data points, comprising four constant
Boye, ThankGod E., Adamou, Adamos, Esposito, Stefania, Burke, Richard
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