Pressure increase
In the automotive world, boost refers to the increase in pressure that is generated by the turbocharger in the intake manifold that exceeds normal atmospheric pressure. Atmospheric pressure is approximately 14.5 psi or 1.0 bar, and anything above this level is considered to be boost. The level of boost may be shown on a pressure gauge, usually in bar, psi or possibly kPa. This is representative of the extra air pressure that is achieved over what would be achieved without the forced induction. Manifold pressure should not be confused with the volume of air that a turbo can flow.
In contrast, the instruments on aircraft engines measure absolute pressure in inches of mercury. Absolute pressure is the amount of pressure above a total vacuum. The ICAO standard atmospheric pressure is 29.92 inches (760 mm) of mercury at sea level. Most modern aviation turbochargers are not designed to increase manifold pressures above this level, as aircraft engines are commonly air-cooled and excessive pressures increase the risk of overheating, preignition, and detonation. Instead, the turbo is only designed to hold a pressure in the intake manifold equal to sea-level pressure as the altitude increases and air pressure drops. This is called turbo-normalizing.
Boost pressure is limited to keep the entire engine system, including the turbo, inside its thermal and mechanical design operating range. The speed and thus the output pressure of the turbo is controlled by the wastegate, a bypass which shunts the gases from the cylinders around the turbine directly to the exhaust pipe.
The maximum possible boost depends on the fuel's octane rating and the inherent tendency of any particular engine towards detonation. Premium gasoline or racing gasoline can be used to prevent detonation within reasonable limits. Ethanol, methanol, liquefied petroleum gas (LPG) and diesel fuels allow higher boost than gasoline, because of these fuels' combustion characteristics.
To obtain more power from higher boost levels and maintain reliability, many engine components have to be replaced or upgraded such as the fuel pump, fuel injectors, pistons, valves, head-gasket, and head bolts.
Wastegate
Main article: Wastegate
By spinning at a relatively high speed, the compressor turbine draws in a large volume of air and forces it into the engine. As the turbocharger's output flow volume exceeds the engine's volumetric flow, air pressure in the intake system begins to build. The speed at which the assembly spins is proportional to the pressure of the compressed air and total mass of air flow being moved. Since a turbo can spin to RPMs far beyond what is needed, or of what it is safely capable of, the speed must be controlled. A wastegate is the most common mechanical speed control system, and is often further augmented by an electronic or manual boost controller. The main function of a wastegate is to allow some of the exhaust to bypass the turbine when the set intake pressure is achieved.
Passenger cars have wastegates that are integral to the turbocharger.
Anti-Surge/Dump/Blow Off Valves
Main article: Blowoff valve
Turbocharged engines operating at wide open throttle and high rpm require a large volume of air to flow between the turbo and the inlet of the engine. When the throttle is closed compressed air will flow to the throttle valve without an exit (i.e. the air has nowhere to go).
This causes a surge which can raise the pressure of the air to a level which can damage the turbo. If the pressure rises high enough, a compressor stall will occur, where the stored pressurized air decompresses backwards across the impeller and out the inlet. The reverse flow back across the turbocharger causes the turbine shaft to reduce in speed quicker than it would naturally, possibly damaging the turbocharger. In order to prevent this from happening, a valve is fitted between the turbo and inlet which vents off the excess air pressure. These are known as an anti-surge, bypass, blow-off valve(BOV) or dump valve. It is basically a pressure relief valve, and is normally operated by the excess pressure in the intake manifold.
The prima, ry use of this valve is to maintain the turbo spinning at a high speed. The air is usually recycled back into the turbo inlet but can also be vented to the atmosphere. Recycling back into the turbocharger inlet is required on an engine that uses a mass-airflow fuel injection system, because dumping the exc, essive air overboard downstream of the mass airflow sensor will cause an excessively rich fuel mixture. A dump valve will also shorten the time needed to re-spool the turbo after sudden engine deceleration.
Charge cooling
Compressing air in the turbocharger increases its temperature, which can cause a number of problems. Excessive charge air temperature can lead to detonation, which is extremely destructive to engines. When a turbocharger is installed on an engine, it is common practice to fit the engine with an intercooler, a type of heat exchanger which gives up heat energy in the charge to the ambientair. In cases where an intercooler is not a desirable solution, it is common practice to introduce extra fuel into the charge for the sole purpose of cooling. The extra fuel is not burned. Instead, it absorbs and carries away heat when it changes phase from liquid to vapor. The evaporated fuel holds this heat until it is released in the exhaust stream. This thermodynamic property allows manufacturers to achieve good power output by using extra fuel at the expense of economy and emissions.
Multiple Turbochargers
Main article: Twin-turbo
Parallel
Some engines, such as V-type engines, utilize two identically-sized but smaller turbos, each fed by a separate set of exhaust streams from the engine. The two smaller turbos produce the same (or more) aggregate amount of boost as a larger single turbo, but since they are smaller they reach their optimal RPM, and thus optimal boost delivery, faster. Such an arrangement of turbos is typically referred to as a parallel twin-turbo system. The first production automobile with parallel twin turbochargers was the Maserati Biturbo of the early 1980s. Later such installations include the Dodge Stealth R/T Twin Turbo, Mitsubishi 3000GT VR-4, the Nissan 300ZX, and the BMW twin-turbo 3.0 liter I6 cars (E90, E81, E60).
Sequential
Some car makers combat lag by using two small turbos. A typical arrangement for this is to have one turbo active across the entire rev range of the engine and one coming on-line at higher RPM. Early designs would have one turbocharger active up to a certain RPM, after which both turbochargers are active. Below this RPM, both exhaust and air inlet of the secondary turbo are closed. Being individually smaller they do not suffer from excessive lag and having the second turbo operating at a higher RPM range allows it to get to full rotational speed before it is required. Such combinations are referred to as a sequential twin-turbo. Porsche 959 first used this technology back in 1985. Sequential twin-turbos are usually much more complicated than a single or parallel twin-turbo systems because they require what amounts to three sets of pipes-intake and wastegate pipes for the two turbochargers as well as valves to control the direction of the exhaust gases. Many new diesel engines use this technology to not only eliminate lag but also to reduce fuel consumption and reduce emissions.
Remote installations
Turbochargers are sometimes mounted well away from the engine, in the tailpipe of the exhaust system. Such remote turbochargers require a smaller aspect ratio due to the slower, lower-volume, denser exhaust gas passing through them. For low-boost applications, an intercooler is not required; often the air charge will cool to near-ambient temperature en route to the engine. A remote turbo can run 300 to 600 degrees cooler than a close-coupled turbocharger, so oil coking in the bearings is of much less concern. Remote turbo systems can incorporate multiple turbochargers in series or parallel.
Automotive applications
To manage the upper-deck air pressure, the turbocharger's exhaust gas flow is regulated with a wastegate that bypasses excess exhaust gas entering the turbocharger's turbine. This regulates the rotational speed of the turbine and thus the output of the compressor. The wastegate is opened and closed by the compressed air from turbo (the upper-deck pressure) and can be raised by using a solenoid to regulate the pressure fed to the wastegate membrane. This solenoid can be controlled by Automatic Performance Control, the engine's electronic control unit or an after market boost control computer. Another method of raising the boost pressure is through the use of check and bleed valves to keep the pressure at the membrane lower than the pressure within the system.
Turbocharging is very common on diesel engines in automobiles, trucks, locomotives, boats and ships, and heavy machinery. For current automotive applications, non-turbocharged diesel engines are becoming increasingly rare.[9] Diesels are particularly suitable for turbocharging for several reasons:
Turbocharging can dramatically improve an engine's specific power and power-to-weight ratio, performance characteristics which are normally poor in non-turbocharged diesel engines.
Truck and industrial Diesel engines run mostly at their maximum power reducing problems with turbo lag and compressor stall caused by sudden accelerations and decelerations.
Diesel engines have no detonation because diesel fuel is injected at the end of the compression stroke, ignited by compression heat. Because of this, diesel engines can use much higher boost pressures than spark ignition engines, limited only by the engine's ability to withstand that pressure.
The turbocharger's small size and low weight have production and marketing advantage to vehicle manufacturers. By providing naturally-aspirated and turbocharged versions of one engine, the manufacturer can offer two different power outputs with only a fraction of the development and production costs of designing and installing a different engine. Usually increased piston cooling is provided by spraying more lubrication oil on the bottom of the piston. The compact nature of a turbocharger mean that bodywork and engine compartment layout changes to accommodate the more powerful engine are not needed . Parts common to the two versions of the same engine reduces production and servicing costs.
Temperature considerations
One disadvantage of turbocharging is that compressing the air increases its temperature, which is true for any method of forced induction. This causes multiple problems. Increased temperatures can lead to detonation and excessive cylinder head temperatures. In addition, hotter air is less dense, so fewer air molecules enter the cylinders on each intake stroke, resulting in an effective drop in volumetric efficiency which works against the efforts of the turbocharger to increase volumetric efficiency.
Aircraft engines generally cope with this problem in one of several ways. The most common one is to add an intercooler or aftercooler somewhere in the air stream between the compressor outlet of the turbocharger and the engine intake manifold. Intercoolers and aftercoolers are types of heat exchangers which cause the compressed air to give up some of its heat energy to the ambient air. In the past, some aircraft featured anti-detonant injection for takeoff and climb phases of flight, which performs the function of cooling the fuel/air charge before it reaches the cylinders.
In contrast, modern turbocharged aircraft usually forego any kind of temperature compensation, because the turbochargers are generally small and the manifold pressures created by the turbocharger are not very high. Thus the added weight, cost, and complexity of a charge cooling system are considered to be unnecessary penalties. In those cases the turbocharger is limited by the temperature at the compressor outlet, and the turbocharger and its controls are designed to prevent a large enough temperature rise to cause detonation. Even so, in many cases the engines are designed to run rich in order to use the evaporating fuel for charge cooling.
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