SuperTurbo for Engine Downsizing and Formula 1 Engine Expo Conference October 2011

SuperTurbo for Engine Downsizing and Formula 1 Engine Expo Conference October 2011

SuperTurbo Movie

BMEP (bar) Turbo-Machinery Power (kw) Transient Supercharging 18 SuperTurbo 6 SuperTurbo 16 14 12 Baseline 5 4 Compressor power leads turbine power due to supercharging 10 8 6 3 2 Compressor power lags the turbine power 4 2 0 BMEP w/o ST BMEP w/ ST 0 1 2 3 4 5 6 7 8 Time (sec) 1 0 Baseline 0 1 2 3 4 5 6 7 8 Time (sec) CompPwr TurbPwr 250,000 rpm/second

What can be Done Differently Eliminates surge condition at low speed high load Provides control over turbine inlet temperature at high speed high load 4

Compressor Map Three points moved out of surge by opening bypass valve

Torque (Nm) DOUBLE the TORQUE or HALF the ENGINE 500 450 400 350 2 Liter SuperTurbocharged 4 cylinder 4.2 Liter V8 300 250 200 150 SuperTurbo Modeled by Southwest Research Institute 100 50 0 2.0L SuperTurbo w/airbypass 4.2L Interpolated NA 0 1000 2000 3000 4000 5000 6000 7000 RPM Based on 26 Bar BMEP in the 2 L Engine 6

BSFC (g/kw-h) Efficiency at Full Power 330 310 SuperTurbo Modeled by Southwest Research Institute 290 270 250 230 210 190 2.0L SuperTurbo w/airbypass 170 4.2L Interpolated NA 150 0 1000 2000 3000 4000 5000 6000 7000 RPM Estimated efficiency gain of 36% in EPA test 7

Bypass Benefits With a bypass more low rpm torque is possible with one big compressor When you bypass to the turbine for surge control the high efficiency of the supercharging is maintained Using the bypass valve to control turbine inlet temperature eliminates fuel cooling More air mass flow of 950 C air creates more power on the turbine

NSF Project Set-up Air Mixer Bypass Air Valve Catalyst Waste Gate Schumacher Turbine

Road Car SuperTurbo Benefits Turbo machinery has higher efficiency Low turbo lag (less than 1 second) Highest efficiency supercharging Smaller lower cost catalyst because of higher density before turbine Lower engine backpressure Better mileage from a ½ size engine Lambda 1 to full power Lower cold start emissions

Turbine Comparison Confidential Stock Turbine Schumacher

Schumacher Turbine Map

Velocity in Meters per Second

Big Diesel SuperTurbo Making 1.7kW at 1200 rpm 75kW load

2014 Formula 1 Modeling GT Power modeling software was used 1.6L, V6 cylinder engine modeled at 8000, 10,000, 12,000 13,500 and 15,000RPM Estimated cylinder dimensions and valve profiles based on max piston speed Gross IMEP was limited to 29 bar

Stock turbo is modeled to be free-spinning with a waste-gate SuperTurbo assumes an 80% efficient CVT transmission to enable turbocompounding SuperTurbo with Bypass includes a post compressor intake air bypass into the preturbine exhaust, upstream of a catalyst to enable excess fuel in exhaust from rich incylinder conditions to burn and produce more turbine work for turbo-compounding

Stock Turbo

SuperTurbo

SuperTurbo with Bypass

Maximum fuel flow limited to 120 kg/hr Lambda target was.92 for best in cylinder power, but was allowed to deviate for turbine temperature control and best fuel efficiency Same compressor map used for all cases In both SuperTurbo cases the turbine was customized in order to achieve the best turbo-compound power level Turbine inlet temp limited to 950C

HP kw Horsepower Gain 700 498.4 650 600 448.4 550 Stock Turbo 398.4 SuperTurbo SuperTurbo Bypass 500 348.4 450 14% more power at 15,000rpm 400 298.4 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

Equations

Brake Torque (Nm) BSFC (g/kwh) Torque and Fuel Consumption 380 280 370 360 270 350 260 340 Stock Turbo Torque 330 250 SuperTurbo SuperTurbo Bypass 320 310 240 Stock Turbo BSFC SuperTurbo SuperTurbo Bypass 300 230 290 280 220 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

MEP (Bar) Stock Turbo Mean Eff. Pressure 33 32 31 30 29 28 27 GIMEP Plus PMEP BMEP 26 25 24 23 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

MEP (Bar) SuperTurbo Mean Eff. Pressure 33 32 31 30 29 28 27 GIMEP GIMEP+ST MEP Plus PMEP BMEP 26 25 24 23 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

MEP (Bar) Bypass Mean Effective Pressure 33 32 31 30 29 28 27 GIMEP GIMEP+ST MEP Plus PMEP BMEP 26 25 24 23 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

Pressure (bar abs) Intake System Pressures 3.2 3 Throttle used to provide bypass pressure differential for adequate turbine cooling 2.8 Stock Turbo Comp Out 2.6 2.4 SuperTurbo SuperTurbo Bypass Stock Turbo Manifold SuperTurbo SuperTurbo Bypass 2.2 2 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

Pressure (bar abs) Turbine Inlet Pressures 2.9 2.7 2.5 2.3 2.1 Stock Turbo Turbine In SuperTurbo SuperTurbo Bypass 1.9 1.7 1.5 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

Racing Engine Benefits Catalytic converter becomes a burner when fed with oxygen from the compressor Smaller catalytic converter is possible because of higher density before turbine Higher engine backpressure is beneficial to a SuperTurbo at high IMEP levels Better in cylinder fuel utilization is possible when a fuel flow limitation exists Highest amount of turbocompounding when using the bypass configuration

Cyinder Pressure (bar) Pressure vs. Volume Diagram 12000 RPM 100 Stock Turbo 10 SuperTurbo SuperTurbo Bypass 1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Volume/Vmax

Power (kw) Turbine vs. Compressor Power 160 140 120 100 80 60 40 20 Stock Turbo Compressor Power SuperTurbo SuperTurbo Bypass Stock Turbo Turbine Power SuperTurbo SuperTurbo Bypass Stock Turbo Pumping Power SuperTurbo SuperTurbo Bypass 0-20 8000 9000 10000 11000 12000 13000 14000 15000-40 Engine RPM

Exh Manifold Out Temperature (C) Exhaust System Temperatures 1000 980 960 940 920 900 Stock Turbo SuperTurbo SuperTurbo Bypass Stock Turbo Turbine In SuperTurbo SuperTurbo Bypass 880 860 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

PMEP (bar) Pumping Mean Effective Pressure 0.7 0.2 8000 9000 10000 11000 12000 13000 14000 15000-0.3 Stock Turbo SuperTurbo SuperTurbo Bypass -0.8-1.3-1.8 Engine RPM

Air Flow Rate (kg/s) Air Mass Flow 0.6 0.5 0.4 0.3 0.2 Stock Turbo SuperTurbo SuperTurbo Bypass Compressor Flow SuperTurbo Bypass Flow SuperTurbo Bypass Engine Flow 0.1 0 8000 9000 10000 11000 12000 13000 14000 15000 Engine RPM

Horsepower Gain 100 Horsepower more with Bypass and the same fuel flow limitation at 15,000 rpm 5% to 10% more power over the whole curve just from waste heat energy with the same in cylinder power 5% lower fuel consumption with Bypass at 13,500 rpm for the same power gain as a conventional SuperTurbo

SuperTurbo vs. Competition We win on peak power: Turbocompounding We win on peak torque: Supercharging We win on efficiency: Lambda 1 May require a clutch to win at all points We win on emissions: Pre-turbine catalyst We win on turbo lag: Transmission We win on COST: ½ size catalyst

Powering the way to greater fuel efficiency! THANK YOU Ed VanDyne Cell: 970-215-4584 Ed@VanDyneSuperTurbo.com VanDyneSuperTurbo.com