1

Simulation and Implementation of

Turbocharging a 600cc Engine for Formula

SAEMario Farrugia

Nicholas Grech

Marlon Chircop

Jean Paul Azzopardi

2

Introduction

•FSAE restrictor

•Turbocharging PST vs CPT

•Garrett Honeywell GT 15V vs GT 12

•Kawasaki 600cc engine

3

Objectives

•Simulations in Wave of Turbocharged engine

•Implementation of turbocharger

• Dynamometer testing of turbocharged engine

4

Choice of Turbocharger

•Garrett donate GT 12 fixed geometry

•And also GT15V variable geometry

•Choice of GT 15 V because some experience was gathered at Oakland University (Michigan) on GT 12, so now took the variable geometry challenge

5

Variable Geometry Turbine

•

6

The vane mechanism

•

7

1D engine Simulation

Wave®

8

Simulations

•Simulations in Wave of Turbocharged engine

•Started from naturally aspirated simulations SAE papers 2005-01-0025and 2006-01-3651

9

Compressor Map

GT 15V donated by

Garrett Honeywell

10

The Variable Geometry Turbine Map

FULL RANGE TURBINE MAP - ISOWORKLINE N°4TURBINE: GT15V (7.9 mm shaft) - T109(39) - 58 Trim - 0,42 A/R

0.4

0.4

0.45

0.45

0.5

0.5

0.55

0.55

0.6

0.6

Open

4/5 open

3/5 open

2/5 open

1/5 open

1/10 open

Closed

122550rpm at 0,9 %

0

1

2

3

4

5

6

7

8

1 1.5 2 2.5 3 3.5Turbine Expansion Ratio

corr

ecte

d m

ass

flow

(lb/

min

)

open 4/5open 3/5open 2/5open 1/5open 1/10open closed

WW T

PT

T

* /

/ . 1

1

519

2992N

N

TT

phy

T

1 519/

11

Wave Model

12

Effect of Compression Ratio on Knock

13

Effect of Compression Ratio on Torque

Kawasaki 600cc engine with GT 15V

14

Various PST turbocharging setups

15

25

35

45

55

65

75

3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

Engine Speed (rpm)

Torq

ue (N

m)

Boost 1.5bar

Boost 1.5bar, intercooled

Boost 1.5bar, intercooled, modified valve timing

Boost 1.5bar, intercooled, modified valve timing, tuned exhaust length

Final model, CR 7

Naturally Aspirated

15

Exhaust Setup

16

Inlet Manifold

17

Throttle Body and Restrictor

18

Timing Chain Length Inspection

19

Machined Decompression Plate

CNC machined decompression plate, 3mm aluminium sheet

20

Mechanical Seal on Compressor Side

CNC machined compressor back plate and mechanical seal components

21

Scavenge Oil Pump and Breaking Oil Siphon

•.

•.Oil Pump Photos

•.Jean Paul ‘s Photos

Turbo

Oil Pan

Turbo

Oil Pan

22

Cam Sensor Novel Implementation

•.A strong, 250gr rated, magnet was inserted into a bolt and swage locked in the bolt.•Magnet has north and south on the axis

•.The bolt was installed in one of the cam sprocket OEM holes Ol ump Photos

•Cam signal is trace 1, crank signal is trace 2

23

Scavenge Oil Pump and Breaking Oil Siphon

•.Oil supply taken from highest point, and also a point that has connection to atmosphere when engine is stopped so that siphon is broken

24

Dynamometer Testing

25

Exhaust Gas Temperature variation with Spark Timing

• EGT drops with more advanced timing

26

Air Temperature and Manifold Absolute Pressure

• Air temperature increase with rise in boost pressure as expected

27

Charge Air Cooler

•Direction 1 is shorter than direction 2 , so direction 2 was used to have more effectiveness of the heat exchanger.

28

TPS Compensation On Fuel Quantity

•Engine was with MAP as the load parameter but due to large cam overlap high exhaust residuals exist at idle which result in high MAP Values at idle as discussed in SAE 2005-01-0025 .

TPS % Compensation

0 45

5 45

15 50

25 55

50 100

75 100

100 100

•The TPS compensation effectively generates a low throttle map or sometimes called zero throttle map.

29

Toruqe measurements

•Maesurement of Torque on dynamometer with increase in RPM and resulting boost pressures

30

Steady State: Variation of Electrical Power Input with Frequency

• Limited capability to control rpm and MAP

31

Conclusion

32

Concluding Remarks

•Engine was successfully run

•Oil problems solved by mechanical seal and breaking of siphon

•Charge air cooler controlled temperature well

•TPS compensation to counteract High MAP values at idle

•External Wastegate implemented in ongoing project to have a stable system on dyno.

Thank you Questions ?