Analysis of Thrust Bearing Impact on Friction Losses in Automotive Turbochargers

Author:

Hoepke Bjoern1,Uhlmann Tolga2,Pischinger Stefan1,Lueddecke Bernhardt3,Filsinger Dietmar3

Affiliation:

1. Institute for Combustion Engines, RWTH Aachen University, Forckenbeckstraße 4, Aachen 52074, Germany e-mail:

2. FEV GmbH, Neuenhofstrasse 181, Aachen 52078, Germany e-mail:

3. IHI Charging Systems International GmbH, Haberstrasse 3+24, Heidelberg 69126, Germany e-mail:

Abstract

The importance of automotive turbocharger performance is continuously increasing. However, further gains in efficiency are becoming progressively difficult to achieve. The bearing friction losses impact the overall efficiency of the turbocharger and accordingly the understanding of bearing systems and their characteristics is essential for future improvements. In this work, a detailed analysis on the mechanical losses occurring in the bearing system of automotive turbochargers is presented. Friction losses have been measured experimentally on a special test bench up to rotational speeds of nTC = 130,000 1/min. Special interest was given to the thrust bearing characteristics and its contribution to the total friction losses. For this, the experiments were split into three parts: first, friction power was determined as a function of turbocharger speed at zero externally applied thrust load. Second, external thrust load up to 40 N was applied onto the turbocharger bearing at fixed rotational speeds of nTC = 40,000, 80,000, and 120,000 1/min. Increasing thrust load was observed to result in increasing friction losses amounting to a maximum of 32%. At last, a specially prepared turbocharger center section with deactivated thrust bearing was investigated. A comparison of these results with the measurement of the conventional bearing system under thrust-free conditions allowed separating journal and thrust bearing losses. The contribution of the thrust bearing to the overall bearing losses appeared to be as high as 38%. Furthermore, a modeling approach for estimating the friction power of both fully floating journal bearing as well as thrust bearing is illustrated. This theoretical model is shown to predict friction losses reasonably well compared to the experimental results.

Publisher

ASME International

Subject

Mechanical Engineering,Energy Engineering and Power Technology,Aerospace Engineering,Fuel Technology,Nuclear Energy and Engineering

Reference19 articles.

1. Lüddecke, B., Filsinger, D., Erhard, J., and Bargende, M., 2012, “Heat Transfer Correction and Torque Measurement for Wide Range Performance Measurement of Exhaust Gas Turbocharger Turbines,” 17th Supercharging Conference, Dresden, Sept. 13–14, pp. 465–497.

2. Baines, N., 2009, “Turbocharger System Modeling Developments,” 2nd Conference on Advanced Charging and Downsizing Concepts, Wiesbaden, Mar. 31–Apr. 1.

3. Scharf, J., 2010, “Extended Turbocharger Mapping and Engine Simulation,” Ph.D. thesis, RWTH Aachen, Aachen.

4. Lückert, P., Kreitmann, F., Merdes, N., Weller, R., Rehberger, A., Bruchner, K., Schwedler, K., Ottenbacher, H., and Keller, T., 2009, “The New 1.8-Litre 4-Cylinder Petrol Engine With Direct Injection and Turbo Charging for All Passenger Cars With Standard Drive Trains From Mercedes-Benz,” 30th Vienna Engine Sympsosium, Vienna, May 7–8, pp. 11–30.

5. Hagelstein, D., Hentschel, L., Strobel, S., Szengel, R., Theobald, J. R., and Middendorf, H., 2009, “Die Aufladeentwicklung für den Neuen 1.2l TSI Motor von Volkswagen,” 14th Supercharging Conference, Dresden, Sept. 24–25, pp. 407–450.

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