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1、ProclMechEPartD:DOI: 10.1177/09544070221104350S SageReviewArticIeStudyonturbocompoundsystemforaheavy-dutydieselenginebycombiningmatchinganalysiswithexperimentsYinYong1,2,WuZhijun1zZhaoRongchao3GzZhugeWeilin4andHuZongjie1AbstractJAutomobiteEngineering2023,Vol.237(8)1775-1789IMechE2022Articlereuseguid
2、elines:Inthiswork,toimprovethefueleconomyoflong-haulcommercialvehicles,theeffectsofturbocompoundsystemmatchingonengineperformancewerenumericallyandexperimentallystudied.Firstly,aIDGT-POWERsimulationmodelofan11Lheavy-dutydieselenginewasestablishedandverifiedbytheexperimentaldata.Secondly,theperforman
3、cesoftheturbocompoundenginematchingwithdifferentsizesoffixedgeometryturbine(FGT)andpowerturbineswereanalyzed.Itwasfoundthattheexhaustenergydistributionbetweentheturbochargerturbineandpowerturbinehadasignificantimpactonengineperformance,andthesizeoftheturbochargerturbinehadamorenoticeableimpactthanth
4、epowerturbine.BasedontheFGTturbocompoundsystemsimulationresult,anappropriatevariablegeometryturbocharger(VGT)andthreewastegateturbochargers(WGT)wereselectedforfurthersimulationandexperimentalresearch.Inaddition,theimpactsofthetransmissionratiobetweenthepowerturbineshaftandtheenginecrankshaft,andthef
5、uelinjectiontimingontheengineperformancewereexperimentallystudied.Theenginetestresultshowedthatthefueleconomywasimprovedby1.6%underEuropeanSteadyState(ESC)cyclewhilekeepingtheweightedNOxemissionthesameastheoriginalengine.Finally,theturbocompoundenginewithWGTwasinstalledonaheavy-dutylong-haulcommerci
6、alvehicleforroadtests.Thefueleconomyofthevehiclewasimprovedby2.54%underthe80km/hconstantspeedroadtest.KeywordsTurbocompoundsystem,heavy-dutydieselengine,variablegeometryturbine,wastegateturbine,powerturbineDatereceived:27October2021;accepted:2May2022IntroductionDieselengineshavebeentheprimarypowerso
7、urcesforcommercialvehiclesandengineeringmachineryforalongtimebecauseoftheirexcellentadaptability,highefficiency,andreliability.Itisimportanttofurtherimprovethedieselenginesthermalefficiency.Thein-cylindercombustionprocessofdieselengineshasbeendramaticallyimprovedbytechnologiessuchashigh-pressurecomm
8、on-rail,high-efficiencyturbocharging,andexhaustgasrecirculation(EGR).Dieselenginesbrakethermalefficiency(BTE)hasreachedmorethan45%.However,ithasbecomeincreasinglydifficulttoimproveBTEonlybyoptimizingtheincylindercombustionprocess.Wasteheatrecoveryisgenerallyacceptedtoimprovetheenginesoverallefficien
9、cy.Themaintechnologiesofwasteheatrecoverj,includeOrganicRankineCycle(ORC),1ThermoelectricGeneration(TEG),2andturbocompounding.3ComparedwithORCandTEGtechnology,turbocompoundinghastheadvantagesofrelativelysimplestructureandgoodenergy-savingperformance.Inaddition,theenginebackpressurecanbeincreasedsign
10、ificantlyduetoapowerturbinedownstreamoftheturbochargerturbine.Asaresult,ahigherEGRratecanbeadoptedtoreduceNitrogenOxides(NOx)emission.Furthermore,theengineexhaustenergyisabundantforlong-haulcommercialvehiclesbecausetheir1TongjiUniversity,Shanghai,China2DongfengCommercialVehicleCo.Ltd.,Wuhan,China3So
11、uthChinaUniversityofTechnology,Guangzhou,China4TsinghuaUniversity,Beijing,ChinaCorrespondingauthor:ZhaoRongchao,SouthChinaUniversityofTechnology,381WushanRoad,TianheDistrict,Guangzhou510640,China.Email:merczhaoenginesmainlyoperateathighspeedsandhighloadscomparedwithpassengercarengines.Therefore,itis
12、conducivetoreducingfuelconsumptionbyapplyingturbocompoundtechnologyinlong-haulcommercialvehicles.Inaturbocompoundengine,apowerturbineisusedtorecovertheexhaustenergyandturnitintomechanicalworkorelectricity.Therearethreemainconfigurationsforthepowerturbineandturbocharger,includingseries,parallelandint
13、egratedlayouts.Weietal.4comparedtheperformanceofa1.8LturbochargedgasolineenginewiththreeIurbocompoundlayoutsunderdrivingcycles.Itwasshownthattheparallelturbocompoundlayouthadthebestfuelsavingperformance.However,theexhaustmassflowratiobetweenthepowerturbineandturbochargerturbineneedstobeadjustedusing
14、twovalvesaccordingtotheengineoperatingcondition.Sincetheoperationconditionfrequentlychangesontheroad,theparallelconfigurationisunsuitableforvehicleapplication.Inintegratedlayouts,5amotor/generatorisintegratedwiththeturbocharger.Itactsa$amotortoacceleratetheturbochargeratlowenginespeedconditionsforbe
15、ttertransientresponseandasageneratortorecoverthewasteheatforlowerfuelconsumptionathigh-speedconditions.Thematchingandcontrolmethodfortheintegratedturbocompoundsystemiscrucialtogethighoverallefficiency.Yangetal.6proposedamatchingguidelinefortheintegratedturbocompoundsystemandappliedittoatwo-strokelow
16、speedmarineengine.Resultsshowedthatthefuelconsumptioncouldbereducedby2%-3%althreeloadprofiles.Joshietal.78proposedanovelsystemconsistingofsupercharging,turbocompounding,andelectrification.Thepowerflowcouldbeoptimallymanagedinthislayoutbyemployingaplanetarygearsetaccordingtotheroadconditions.Resultsshowedthatthefueleconomywasimprovedby11.1%.Themainchallengeforan
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