Theoretical and experimental investigation of a novel hydraulically assisted turbocharger system for future automotive applications

Abstract

The work was concerned with the design, analysis and basic demonstration of a novel hydraulically assisted fixed geometry turbocharger system intended to help overcome some of the transient issues associated with current automotive boosting technologies. The novel system was based upon use of relatively lightweight parts, where kinetic energy is recovered during vehicle braking, stored in a simple hydraulic accumulator and then used later on to rapidly accelerate the engine's turbocharger. The turbocharger is fitted with a replacement centre housing enclosing a small impulse turbine, rigidly mounted to the turbocharger shaft and powered by a jet of oil. The aim is one of helping the engine to accelerate the vehicle while operating in a region of much higher brake efficiency due to the reduction in exhaust backpressure when compared with competing variable geometry and/or compound boosting technologies. The specific tasks involved concept design and computational analysis, including specification of the turbine type and geometry together with the associated hydraulic parts. A production turbocharger was reverse engineered to confirm the feasibility of packaging the hydraulic turbine system into the centre housing of a typical fixed geometry design. Finally an experimental rig was designed and manufactured to allow basic demonstration of the system, with speeds of up to ~90000 rpm @ 200 bar pressure from the pump via the accumulator achieved in ~0.8 seconds and clear potential for further optimisation. This hydraulic boosting system is capable of attaining 70% efficiency (a product of 0.85 from the oil pump, 0.95 from the hydraulic accumulator and 0.88 of Pelton wheel). The system has higher power density at low cost compared to the main competitor ‘E Boosting - with efficiency in the region of 90%’. The cost of E boosting and need for 48 volt battery makes it less favourable compared to the hydraulic turbine system. The concept has been shown to offer significant potential to assist a turbocharger to spool up via a Novel Hydraulic Kinetic Energy Recovery System approach.