Ball Bearing Turbocharger – Technology development · Shaft displacement y Shaft displacement z....
Transcript of Ball Bearing Turbocharger – Technology development · Shaft displacement y Shaft displacement z....
![Page 1: Ball Bearing Turbocharger – Technology development · Shaft displacement y Shaft displacement z. 19 Schaeffler Symposium 2014 Christopher Mitchell BEARINX – Linear Rotor Dynamics](https://reader030.fdocuments.net/reader030/viewer/2022041214/5e034d84adee4c3fdc68aea6/html5/thumbnails/1.jpg)
Ball Bearing Turbocharger –
Technology development
Christopher Mitchell
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Schaeffler Symposium 2014 Christopher Mitchell 1
Introduction
Megatrend
Legislation
95 g/km in 2020
Commercial
Oil price, Cost minimisation
Consumer
Performance and Efficiency
Average CO2 Emissions Drivers
CO2 Reduction /
Efficiency Improvement
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Schaeffler Symposium 2014 Christopher Mitchell 2
Development Target
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Schaeffler Symposium 2014 Christopher Mitchell 3
Sub-Trends & Main Technologies
Megatrend
CO2 Reduction /
Efficiency Improvement
Legislation
95 g/km in 2020
Commercial
Oil price, Cost minimisation
Consumer
Performance and Efficiency
Drivers Average CO2 Emissions
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Schaeffler Symposium 2014 Christopher Mitchell 4
Sub-Trends & Main Technologies
Main Technology
Down-Sizing Down-Speeding Driving Resistance Comprehensive
Measurements
Subtrends
■ Thermal Management
■ Electrification Ancillary
Components
■ Lightweight
Construction
■ Low Friction
Lubrication / Materials
■ Low rpm provision of
power
■ Optimised
Transmission e.g.
■ Continuously
Variable
Transmission
■ Dual Clutch
Transmission
■ Forced Induction/
Boosting
■ Stratified DI / HCCI
■ Variable Valve Train
Megatrend
CO2 Reduction /
Efficiency Improvement
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Schaeffler Symposium 2014 Christopher Mitchell 5
Forced Induction Concepts
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Schaeffler Symposium 2014 Christopher Mitchell 6
Forced Induction
Gottlieb Wilhelm Daimler (1824 – 1900) Patent DRP 34926 1885
Grandfather Clock Design
[Utilising Gear Driven Precompression]
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Schaeffler Symposium 2014 Christopher Mitchell 7
Turbocharger - Origin
Alfred Büchi (1879-1959) Patent CH 35 259A 1905
Exhaust Driven Precompression
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Schaeffler Symposium 2014 Christopher Mitchell 8
Ball Bearing Guided Turbo Charger
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Schaeffler Symposium 2014 Christopher Mitchell 9
Schaeffler Ball Bearing Cartridge
Anti-Rotation Slot
Squeeze Film Land
Oil Jet
Ceramic Balls
Metallic Cage
Turbine Inner Ring
Outer Ring Compressor Inner Ring
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Schaeffler Symposium 2014 Christopher Mitchell 10
Stationary Ball Bearing Benefits F
riction p
ow
er
loss [
W]
Speed [Hz]
Operational Power Loss of Bearing System
400 600 800 1000 1200 1400 1600 Sourc
e: H
oneyw
ell
Tu
rbo T
echnolo
gie
s
Plain bearing
Ball bearing
~50% reduction
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Schaeffler Symposium 2014 Christopher Mitchell 11
Transient Ball Bearing Benefits
Sourc
e: H
oneyw
ell
Tu
rbo T
echnolo
gie
s
Plain bearing Ball bearing Plain bearing Ball bearing
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Schaeffler Symposium 2014 Christopher Mitchell 12
Friction Mechanisms
Film Bearing Rolling Bearing
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Schaeffler Symposium 2014 Christopher Mitchell 13
Flow Regimes
Optimally Flooded Completely Flooded
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Schaeffler Symposium 2014 Christopher Mitchell 14
Optimial Lubricant Flow
Completely Flooded
Optimally Flooded Power Loss [W]
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Schaeffler Symposium 2014 Christopher Mitchell 15
Turbo Charger Cartridge Power Loss
0
10
20
30
40
50
60
min.
measurement
max.
measurement
analysis
Po
wer
loss [
W]
viscous friction
circumferrential gap
load dependent
friction
catalogue
supplement for fully
floodedcatalogue speed and
viscocity
experiment (max)
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Schaeffler Symposium 2014 Christopher Mitchell 16
1-D Fluid Dynamics
Investigation on Lubricant Availability throughout Operating Conditions
Optimization of Lubricant Supply Paths
Oil Jets into Bearing
Squeeze Films
Oil Drain
1-D Simulation Model Investigated Geometry
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Schaeffler Symposium 2014 Christopher Mitchell 17
Dynamic Bearing Behaviour
Contact Forces Differential Speed
Contact Pressure Contact Angle
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Schaeffler Symposium 2014 Christopher Mitchell 18
CABA3D – Bearing Interior Dynamic Simulation
Ball and Cage Dynamic Behavior
Contact Forces (vs. Race and vs. Cage)
Spin/Roll; Ball Excursion, …
Shaft displacement y
Shaft d
ispla
cem
ent
z
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Schaeffler Symposium 2014 Christopher Mitchell 19
BEARINX – Linear Rotor Dynamics
Eigenmodes
Eigenfrequencies
Campbell Diagrams Shaft speed
Eig
en
fre
quen
cie
s
x
y
z x
y
z
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Schaeffler Symposium 2014 Christopher Mitchell 20
FEA and Multi-Body-Structure
Modal Reduction for the Simulation Platform
Pre-Tension Force
Axial Contact
Installation Effects
Contact & Centrifugal Forces
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Schaeffler Symposium 2014 Christopher Mitchell 21
Schaeffler Simulation Platform – System Dynamics
Fully Integrated Development Process
■Direct Integration of Nonlinear BEARINX Subsystem into Full System Dynamic Model
■ Component Know-How vs. System Know-How
BEARINX®
Waterfall Diagram Simulation Platform
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Schaeffler Symposium 2014 Christopher Mitchell 22
Combined FEM-CFD Analysis
CFD Model
FEM Model
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Schaeffler Symposium 2014 Christopher Mitchell 23
Temperature of Bearing Parts
Tem
pera
ture
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Schaeffler Symposium 2014 Christopher Mitchell 24
Real World Data
■ Applicable to existing hardware
■ Compatible with low viscosity
engine oil
■ Cold start improvement + 80%
■ Drive away torque improved
■ Transient response - 41%
to boost
@ 1500rpm
■ Engine rated power increase + 5%
■ Engine torque increase + 10% @ ISO soot
■ "Kick-down" performance + 2%
Data source: Honeywell
Fuel Economy Performance
Performance Convenience
■ Friction power loss - 50% in the bearing system
■ Fuel consumption - 2.5% (dir. cor. to CO2
emission)
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Schaeffler Symposium 2014 Christopher Mitchell 25
Summary
Main Technology
Down-Sizing Down-Speeding Driving Resistance Comprehensive
Measurements
Subtrends
■ Thermal Management
■ Electrification Ancillary
Components
■ Lightweight
Construction
■ Low Friction
Lubrication / Materials
■ Low rpm provision of
power
■ Optimised
Transmission e.g.
■ Continuously
Variable
Transmission
■ Dual Clutch
Transmission
■ Forced Induction/
Boosting
■ Stratified DI / HCCI
■ Variable Valve Train
Megatrend
CO2 Reduction /
Efficiency Improvement
~ + 5% Power increase
~ + 20% Torque increase
~ - 2.5% CO2 Emission
Superior cold start behaviour
Superior transient response
Turbocharger Ball Bearing
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We can't solve problems by using the same kind of thinking
we used when we created them.
” ‟
Albert Einstein
1879-1955
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[Turbo charging is,] briefly spoken,
open the throttle today, are ready to go tomorrow.
” ‟
Walter Röhrl
Rallye Champion
1980 and 1982