Confidential

AVL List GmbH

Romain Lardet

FLOWSONIX – TURBOCHARGER APPLICATION

DETECTION OF THE SURGE LIMIT USING FLOWSONIX

Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden

Romain Lardet | Consumption Measurement | 21 May 2015 | 2Confidential

ambient air, conditioned air

TURBO CHARGER APPLICATION

Check and detect the pumping limit of turbo chargers with a high-resolution air mass flow meter

Having an appropriate device the pumping limit of the turbocharger will be visible via the air mass flow

pumping limit

Measurement setup

Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden

Romain Lardet | Consumption Measurement | 21 May 2015 | 3Confidential

CONTEXT OF TURBOCHARGER NEW DEVELOPMENTS

3

67000

88000

106000

120000

134000

0.78

0.76

0.76

0.74

0.74

0.72

0.72

0.7

0.7

0.68

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.04 0.12 0.20 0.28 0.36 0.44 0.52

Dru

ckve

rhä

ltn

is p

2t/p

1t[-

]

Massenstrom [kg/s]

Pumping

high torque

EGR

Asym. cycle

low

speed

air mass flow rate

pre

ssu

re r

ati

o

For a given design of

turbocharger, getting the most

benefit out of it requires to get

closer to the surge limit after

which the performances of the

turbocharger fully deteriorate.

We must stay inside the “Normal

Operation” zone in all conditions

(cold, hot, altitude, transient...etc).

this can generally not be fully

tested or optimized at the

turbocharger testbed, only on the

engine testbed.

Normal

Operation

Being able to model and predict the behavior of the turbocharger

in combination with a given engine in different conditions leads to

efficiently use the capabilities of the entire system.

Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden

Romain Lardet | Consumption Measurement | 21 May 2015 | 4Confidential

67000

88000

106000

120000

134000

0.78

0.76

0.76

0.74

0.74

0.72

0.72

0.7

0.7

0.68

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.04 0.12 0.20 0.28 0.36 0.44 0.52

Dru

ckve

rhä

ltn

is p

2t/p

1t[-

]

Massenstrom [kg/s]

4

Pumping

operating range

DETECTION OF THE SURGE MARGIN

0.14

0.16

0.18

0.20

0.22

0.00 0.12 0.24 0.36 0.48 0.60air

mas

s fl

ow

rat

e [

kg/s

]

time [s]

air mass flow rate [kg/s]

pre

ssu

re r

ati

o

Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden

Romain Lardet | Consumption Measurement | 21 May 2015 | 5Confidential

67000

88000

106000

120000

134000

0.78

0.76

0.76

0.74

0.74

0.72

0.72

0.7

0.7

0.68

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.04 0.12 0.20 0.28 0.36 0.44 0.52

Dru

ckve

rhä

ltn

is p

2t/p

1t[-

]

Massenstrom [kg/s]

5

Pumping

operating range

DETECTION OF THE SURGE MARGIN

0.14

0.16

0.18

0.20

0.22

0.00 0.12 0.24 0.36 0.48 0.60[air

mas

s fl

ow

rat

e k

g/s]

time [s]

air mass flow rate [kg/s]

pre

ssu

re r

ati

o

Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden

Romain Lardet | Consumption Measurement | 21 May 2015 | 6Confidential

67000

88000

106000

120000

134000

0.78

0.76

0.76

0.74

0.74

0.72

0.72

0.7

0.7

0.68

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.04 0.12 0.20 0.28 0.36 0.44 0.52

Dru

ckve

rhä

ltn

is p

2t/p

1t[-

]

Massenstrom [kg/s]

6

Pumping

0.14

0.16

0.18

0.20

0.22

0.00 0.12 0.24 0.36 0.48 0.60

Mas

sen

stro

m [

kg/s

]

Zeit [s]

DETECTION OF THE SURGE MARGIN

time [s]air

mass f

low

rate

[kg

/s]

air mass flow rate [kg/s]

pre

ssu

re r

ati

o

Turbocharger – surge margin recognized and documented

Turbocharger - operating maps under real operating conditions of the engine.Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden

Romain Lardet | Consumption Measurement | 21 May 2015 | 7Confidential

BENEFITS & POSSIBLE APPLICATIONS

RELIABLE & FAST DETECTION of the Surge Limit (light surge / Hard Surge) thanks to:

The 1kHz fast sampling rate of the Flowsonix

The bidirectional measurement principle

NON-INVASIVE METHOD OF DETECTION (there is no need to adapt temperature or pressure sensors at the intake/exhaust of the turbocharger) –easy and fast installation

METHOD APPLICABLE TO

ENGINE TESTBEDS : Possibility to optimize the Engine + Turbocharger combination and in different conditions of ambient temperature, ambient pressure, …etc

VALIDATION OF TURBOCHARGER SIMULATION (e.g AVL BOOSTTM Model)

METHOD VALIDATED BY A LARGE TURBOCHARGER OEM

Any unauthorized copying, disclosure or distribution of the presentation is strictly forbidden