Advanced Controls and System Optimization

A new Turbocharger Bearing System as a further step to improve the overall TC Efficiency

Turbochargers are part of the family of high speed rotating machines. They incorporate many technologies that are found in the aerospace industry and run at equivalent tip speeds to aero engines & Auxiliary Power Units (APU’s) at rated power. They are intrinsically capable of power densities much higher that the reciprocating engines that they boost. Like all machines however they must start and idle before accelerating to operating speed. In Passenger Car applications they often operate at very low power and far away from any aerodynamic design point.

This paper focuses on the importance of turbocharger bearing systems at start, idle and part load conditions. As such it deals with the question of low power energy management and efficiency improvement. It then goes on to demonstrate the potential of a low loss bearing system on cold start, transient performance and emission potential as part of an Euro 5 diesel engine packager. It will conclude by showing the fuel economy potential of such as system.

Sequential Boosting Valve and Turbocharger System sets New Standard for Diesel V-Engines

The remarkable performance improvement of the V6 3.0L JLR engine is enabled by Honeywell TwoStage parallel boosting architecture. The system consists of two turbos working sequentially: the primary VNT™ turbo solely provides boost at low engine speeds while the second turbo (in conjunction with the primary turbo) delivers peak power at high engine speeds. In addition, a unique valve technology controls the transition between mono and twin-turbo modes. Multi-stage turbocharging appears as a key enabling technology delivering outstanding performance in terms of low-end torque, high-end power and transient response.

Down-speeding and Upgrading a Product Line for US’07 Tier 2 Bin 5, EU5/6

From 2006 to 2010, the GT20-25 VNT™ product range has undergone a series of advanced changes in order to meet the US’07 Tier 2 Bin 5, EU5 and EU6 requirements. Cutting-edge aerodynamics, upgraded variable geometry mechanism (3rd generation) and new bearing systems are among the critical developments that helped achieve significant improvements in cold start, driveability, reliability, fuel consumption and emission control.

High Volume Production of Ball Bearing Turbochargers

Recent developments at Honeywell have introduced Ball Bearing technology to passenger car diesel. The new “low-friction” turbo, which runs on two rows of ceramic balls, has much lower mechanical losses and hence higher turbo efficiency. The result is an improvement in transient response of between 20-70 percent dependant oil temperature and 2 percent improvement in fuel economy in standard test cycles. The 3.0L V6 diesel application in Europe is an example of the true potential of ball bearing technology.

TwoStage for New Audi V6-TDI Bi-turbo

The first TwoStage serial boosting architecture for V6 diesel engines was recently developed by Honeywell. Its unique architecture combines a high pressure VNT™ turbo that maximizes low-end response with a low pressure turbo for enhanced transition and high-end output. This downsized engine, with its 30 percent displacement reduction, delivers up to 35 percent increased engine power and up to 10 percent improved fuel economy.

New Turbocharger Concept for Boosted Gasoline Engines

Honeywell has designed an innovative turbo system for gasoline engines featuring a new aerodynamic configuration. The new system, which does not use expensive materials such as TiAl, has demonstrated a ≥ 25 percent improvement in torque transient performance at low engin e speeds. This technology enables increased levels of engine downsizing and down-speeding and thus allows further reductions in fuel consumption and CO₂ emissions.