BorgWarner_ChargingSystems

FuturePassengerCarR2SChiStiVTGChargingSystems-usingVTGandLowPressureEGR?GT-SUITEConference2008DrFrankSchmittDr.FrankSchmittSebastianHowePhilippWilkensOctober20,2008Contents•StatusonRegulated2-Stage(R2S)ChargingSystem•ComparisonofengineperformanceandfuelconsumptionofR2SSystemvs.VTG(Downsizing)•UseofVariableTurbineGeometryinR2SApplications•HighPressureEGRvs.LowPressureEGR•ConclusionsConclusionsProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt2StatusinR2S™-Regulated-2-StageEGRValveEGRCoolerChargeAirCoolerRegulatingValveHPstageTurbineCompressorHPstageTurbo-gCompressorBypassHPstageTurbochargerLPstageTurbo-chargerwithBypassProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt3R2S™:CompressorMapOverallpressureratioProductDevelopmentCalculationsandSimulationsDr.FrankSchmittR2S™-2.0LPassengerCarApplicationComparisonofengineperformanceandfuelpgpconsumption27LV6DieselwithMonoVTGversus20LDieselI42.7LV6DieselwithMonoVTGversus2.0LDieselI4withTwoStageSystemR2SProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt5Downsizing:R2S2.0Lvs.VTG2.7LPower12014016080100wer[kW]VTG27L204060PowVTG2.7LR2S2.0L0200100020003000400050006000enginespeed[rpm]ProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt6enginespeed[rpm]Downsizing:R2S2.0Lvs.VTG2.7LBrakespec.Fuelconsumption270280290g/kWh]VTG2.7L240250260nsumption[gR2S2.0L210220230spec.fuelcon2002100100020003000400050006000enginespeed[rpm]sProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt7enginespeed[rpm]VTGinR2SApplicationsR2S™ChargingSystemswithVariableTurbineGeometry:Geometry:Driver:•EmissionConcepttofulfillfutureEmissionLegislation•HigherEGRrates•HigherAir-FuelRatio•HigherAir-FuelRatio•FuelConsumptionProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt8VTGinR2SApplications30200220N/L2025bar]70-100kW/L200-220Nm/L150-180Nm/LR2SwithVTG2-stage1stage15bmep[bVTGSerialSequential(R2S)50-70kW/L50-70kW/L1-stage510010002000300040005000q()FixedGeometryTurbine(FGT)ParallelSequentialSerialSequential(R2S)withVTG010002000300040005000enginespeed[rpm]ProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt9R2SChargingSystemsVTGinHighPressureStageorVTGinLowPressureStage:ProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt10R2SChargingSystems:VariableTurbineinHP-StageBV40MassFLowChartKP39MassFlowimprovedtransition1-stage↔2-stagereducedPressurep3→improvedbeHighPressureStage:FixGeometryTurbine+Bypass34039080%430/210280340max.uredT=390m/s1.21.41.6kg/s*√K/KPa*102]1.21.41.6kg/s*√K/KPa*102]therm.-min.21128134020%uredT=390m/s14021028034038940%uredT=430m/s14021028034039060%uredT=430m/s140210280uredT=430m/s1400.60.81.0turbineflowparameter[210280340390uredT=430m/sKP39-240.82ACAAD,017231vt10.60.81.0turbineflowparameter[ktest-no.024795t1024796t1024797t1024798t1024799t1024800t1024801t1resp.dated5symbolXWSV08.02.0638.5testdate06.02.200601.02.200602.02.200603.02.200603.02.200603.02.200602.02.2006turbine340.18AVAXK340.18AVAXK340.18AVAXK340.18AVAXK340.18AVAXK340.18AVAXK340.18AVAXKsh&hass54391208501/154391208501/154391208501/154391208501/154391208501/154391208501/154391208501/1340.18AVAXK170220260mech.-min.uredT=310m/s140210280uredT=340m/s1410.20.41.001.201.401.601.802.002.202.402.602.803.003.203.403.603.804.00expansionratiop3t/p4[-]test-no.017230vt1017231vt1017232vt1021419t1resp.dated5symbolXSFR03.11.0638.5testdate27.01.200428.01.200427.01.200419.02.2005turbine200.82ACAAD240.82ACAAD280.82ACAAD310.12ACCXKXXX.8XACAAD1400.20.41.001.201.401.601.802.002.202.402.602.803.003.203.403.603.804.00expansionratiop3t/p4[-]sh&whassy54391208501/154391208501/154391208501/154391208501/154391208501/154391208501/154391208501/1hous.mach.54409107801/154409107801/154409107801/154409107801/154409107801/154409107801/154409107801/1BV40sh&whassy54391205008/254391205008/254391205008/254391205013/1hous.mach.54399108003/154399108004/154399108005/154391016302/1KP39improvedLowEndTorqueimprovedPartLoad(EGR,AFR)ProductDevelopmentCalculationsandSimulationsDr.FrankSchmitt11R2SChargingSystems:VariableTurbineinLP-StageChartLowPressureStage:FixGeometryTurbineLowPressureStage:VTG340390100%,031435t1uredT=430m/s80%,031441t12.22.63.0kg/s*√K/KPa*102]2.22.63.0kg/s*√K/KPa*102]140210280140210280340390uredT=430m/s14021028034038960%,031440t1uredT=431m/s21028034039040%,031439t1uredT=430m/s28034039120%,031438t1uredT=431m/sThermodynMin031436t11.01.41.8turbineflowparameter[140210280340390023767t1uredT=430m/s1.01.41.8turbineflowparameter[ktest-no.031435t1031441t1031440t1031439t1031438t1031436t1031437t1resp.dated5symbolXSFR18.09.0750testdate12.09.200714.09.200714.09.200714.09.200713.09.200712.09.200713.09.2007turbine380.18BVAXK380.18BVAXK380.18BVAXK380.18BVAXK380.18BVAXK380.18BVAXK380.18BVAXK380.18P9VAXK140141210140140210210281Thermodyn.Min,031436t1uredT=340m/s140210Min,031437t1uredT=280m/s0.20.61.001.201.401.601.802.002.202.402.602.803.003.203.403.603.804.00expansionratiop3t/p4[-]test-no.Tref[K]responsibledatedrawingnumberremark023767t1873SCG01.08.2006250.88AAAXKA0=6.53cm²0.20.61.01.21.41.61.82.02.22.42.62.83.03.23.43.6