the new comprex - gamma technologies...comprex pws how does it work: advantages: • very fast...

The new ComprexPressure Wave Superchargerin GT-SUITE

Comprex PWS how does it generally look like:

Frischgasgehäuse

Rotorgehäuse

Exhaustgas Casing Rotor Casing

Air Casing

Rotor

Comprex PWS how does it work:

Advantages:

• Very fast transient response

• High boost pressure at low engine speed up to 300% more Torque compared to Turbo.

• Load control over HX in a wide engine operating range

• Nearly powerless Drive system – only needed for synchronisation to engine speed

• Lifetime lubrication on bearings, no water cooling


Advantages:

• High altitude capability

• Engine noise absorbing due to multi cell rotor design -> low weight / muffler system size and cost (Acoustics!!)

• High reliability due to low stress on parts

• No influence on oil consumption or oil change periods (blow by, oil cooking)

Comprex PWS New Technology:

• Aluminium hot gas casing water cooled

• Two Part Rotor

• Switchable working Cycle (on / off)

New Technology: Watercooled Exhaust Gas Casing

EGCAir Casing

AluminiumWater cooledNew!: WithRotorBearing

Aluminium

DWL New Technology:


• Two Part Rotor


New Technology: Two Part Rotor

EGCAir Casing

Old Version:large Gap, 0.6mmhuge Leakageless charging airless boost press.EG Temp. up to1050°C

Old Version:Both Bearings inAir Casing

Rotor (one piece) Expands onlytowards EGC.

New Technologie: Two Part Rotor

EGC Air Casing

New Version:One Bearing inEGCConst. small Gaplow Leakagehuge charging airhuge boost press.

New Version:One Bearing inAir Casing

Rotor (two pieces) Expands to middleGap inbetweenBoth parts

New Technologie: Two Part Rotor

EGCAir Casing

Gap with relativeSpeed.0.10 mm or less(New:Independent fromRotor Temp.)

Gap with relativeSpeed0.10 mm or less

New: Gap = 0.0 (high Temp.) to0.3 mm (coldTemp.) noRelative Speed


0102030405060708090

100

1

Pressure waves

time (sec)0.062 sec0.062 sec

Rotorlength (mm)

Mass flow from cell tocell (shift)

Gap Area

Turning direction

Question: Gap inbetween Rotor halfs is gas tight?Regarding Rotorcell to Rotorcell: F.e. at 18000 RPM and 54 Cells the pressure waves have an offset by 0.062 sec, there is only a mass flow shift from cell to cell during this period but no loss. This overall “loss” can be neglected.


EGCAir Casing

Sealing on theouter Edge:«Injectoreffect» due to fast flowMeasured avrg. negative pressure:delta p = - 55 kPa

Middle Gap hasneglectable impacton performance

DWL New Technologie:


• Two Part Rotor


New Technologie: Cycle switching

EGCAir Casing

Old Version:Always bothCycles arerunning

New Technology: Cycle switching

EGCAir Casing

New Verision:One Cycle canbe closedSimilar toSequential orRegister-Charging

1

1.2

1.4

1.6

1.8

2

2.2

2.4

2.6

2.8

0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16

Impact of Cycle switching

2 Cycles 1 and 2 Cycles

DWL NT: 1 cycle working

Switch Point

Old Hyprex: with always 2 cycles working

Improvedpressureratio

New Technology: Cycle shut on and off

Switchable working Cycle Picture 1

p2 [bar] p2 [bar]

Mass flow [kg/s]

New Technology: Cycle switching

• Ratio of Exhaustgasflow (EGF) and Rotor-Casing Gap (RCG): Example

0.6mm (RCGold) /0.10mm (RCGnew)= 6 times smaller

2 LAold / 1 LAnew = 2 (only one Leakage Area instead of two)

2x EGFnew / 1x EGFold = 2 (twice as much EGF in working Cycle)

• Means EGF/Gap = 6*2*2= Factor 24 times better Ratio as old Version (very important for cold start and running with lower flows).

New Technology: Cycle switching measurements

• Impact of Ratio of Exhaustgasflow (EGF) and R Rotor-Casing Gap (RCG): With T3=100°C !! Apr. 1.2 bar Boost pressure are available even at low flow.

1.19

1.34

1.5

0.424

0.6890.8

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

0.018 0.023 0.028 0.033 0.038 0.043

piV etatot

Pressure ratio pi_C

Source: Antrova AG measurements with new Comprex Prototype at KTI 2016

New Technology: Cycle switchingWhy is the Ratio of Exhaust gas flow (EGF) and Rotor-Casing Gap (RCG) so important? See this measurements!

That happened with the olderHyprex Version, and large Gap. This no go is eliminated now!

Diss: Emanuel Binder, TU Braunschweig 2015

New Technology: Cycle switchingWhy is the Ratio of Exhaust gas flow (EGF) and Rotor-Casing Gap (RCG) so important?

It was not a good practice to heat up the Exhaust gas to reach the volume flow (EGF/RCG) needed!

Diss: Emanuel Binder, TU Braunschweig 2015

New Technology: Catalyst position

• Impact of catalyst position upstream the PWS.Less backpressure, f.e. only 3.25bar instead 5.55barExtrem fast light off! Compared to TC Engine.

4-way Cat

4-way Cat

Turbochargerturbine

PWS

With MufflerWithout Muffler

• Environment?: PWS gives you much more possibilities for downsizing and downspeeding. Less CO2 and NOx, less particles.

• Fun?: Huge Torque is immediately available at very low engine speeds. Time to Torque around 1 sec

• Well to wheel?: Spark ignition engines (Petrol and Compr. Synthetic Methan!) can compete with a Diesel engine without having the well know problems concerning costly exhaust gas cleaning. See next page …

What is the motivation to use a Pressure Wave Supercharger?

What is the motivation to use a Pressure Wave Supercharger?

• In the following you see the original model as you can find it in the examples.

• To get the newest development of Comprex there have been some changes to be made.

• Some of them you can see in the following slides together with some major results

How is the PWS implemented in GT-SUITE?

PWS model as you can find it in your example database

PWS

muffler and resonators are not needed.

Adjustments concerning dimensions and rotor gaps and more.

Adjustments concerning dimensions and rotor gaps and more.

104.0100.0

100.0

Adjustments concerning heat an friction multi-fr and multi-ht.

The shown gas pocket is fix. New Version has its own gas inlet which can be governed.

How the rotor is modelled in GT-SUITE and how it looks like in reality

Inlet and outlet angles of the gas channels relative to the rotor

Inlet and outlet angles causes a new calc. of the channel area.

Areas can be governed to get the demanded load pressure.

Gas pocket areas governed by PID..

Cycle switch to run one or both..

Some results from GT-SUITE

In the following you see some results which have been found without optimizing the PWS.

This was the first try and I got already nice results.Max Power of 180 HP out of a 1.2 Liter engine.

Max Torque close to 250 Nm at low engine speed. (to be optimized)

All by using only one charging device. Plus a quick response that makes it very difficult to stall the engine.


1130kW


250 Nm at 1500 rpm

291 Nm at 1800 rpm


31 bar at 1800 rpm

Some results from measurements

Optimizing with GT-SUITE

In the following you see a screen shot how the best speed of the PWS can be found in every load point.

I love this tool very much and found f.e. 14480 rpm opt. PWS speed at max Power of the engine.

But there is still some work to do to fit the PWS to the engine.

Future Developments with Comprex PWS

The PWS can boost a small spark engine as a cheap alternative to small and even larger diesel engines.Also interesting for lean engines.

PWS with methane gas (130 octane) engine brings the power to be a real Competitor to Electric Cars

But there is a lot more to optimize! Up to you Experts to do this for your engine with GT-POWER!

My new PWS input and help is available under:

[email protected]

mailto:[email protected]

Many thanks for your attention!

[email protected]

mailto:[email protected]

the new comprex - gamma technologies...comprex pws how does it work: advantages: • very fast...

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