Turbocharger and Supercharger (Anil Sharma)

Internet and Books

1. ADVANCED TOPIC
OF
TURBO CHARGER AND SUPER CHARGER
Submitted by
ANIL SHARMA
(ME 13402)
Bachelor of technology
In
MECHENICAL ENGINEERING
At


SHRI JAGDISH PRASAD JHABARMAL TIBREWALA
UNIVERSITY JHUNJHUNU
2015-2016

2. Table of Contents
INTRODUCTION .............................................................................................................. 1
Turbo-Charger................................................................................................................ 2
WORKING OF TURBOCHARGER ....................................................................................... 5
HOW TURBOCHARGER WORKS ....................................................................................... 5
INSTALLATION OF TURBOCHARGER ................................................................................. 6
WORKING PRINCIPLE ...................................................................................................... 6
BENEFITS OF TURBOCHARGING....................................................................................... 7
CONCLUSION ................................................................................................................. 8
Supercharger ............................................................................................................... 10
Type of supercharge ..................................................................................................... 10
The Difference between a Turbocharger and a Supercharger .......................................... 12
Comparing Performance between a Turbocharger and a Supercharger................. 13
Twin-turbo ................................................................................................................... 14
TYPE OF TWIN TURBO CHARGER ................................................................................... 14
Parallel Twin Turbochargers............................................................................................. 14
Sequential Twin Turbochargers ........................................................................................ 14

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INTRODUCTION
The output of the engine exhaust gas is given to the input of the turbine blades,
so that the pressurized air produced. This power, the alternate power must be
much more convenient in availability and usage. The next important reason for
the search of effective, unadulterated power are to save the surrounding
environments including men, machine and material of both the existing and
the next fourth generation from pollution, the cause for many harmful
happenings and to reach the saturation point. The most talented power against
the natural resource is supposed to be the electric and solar energies that best
suit the automobiles. The unadulterated zero emission electrical and solar
power, is the only easily attainable alternate source. Hence we decided to
incorporate the solar power in the field of automobile, the concept of many
Multi-nationals Companies (MNC) and to get relieved from the incorrigible air
pollution. What the turbo-charger was does is that it simply increases the
volumetric efficiency of the engine. The performance of an internal
combustion engine can be increased by adding turbocharging. A turbocharger
compresses the air so that more oxygen flows into the combustion chamber. In
this way, more fuel is burned and the power output of the engine increases
accordingly. The turbocharger is driven by exhaust gas, which makes
turbocharged diesel engines very efficient. MTU develops this key technology
for high-performance engines in-house. Turbocharger development and
production at MTU Turbocharging is an integral component of the engine
design concept. It shapes the characteristics of the engine more than almost
any other system, as it affects its economy, dynamics and emission
characteristics. This is why turbocharging is one of MTU’s key technologies.
MTU has a tradition of maintaining the expertise for developing and producing
its turbochargers in-house. The range of MTU turbochargers extends across
engine power ratings from 400 to 10,000 kW. Turbochargers are purchased for
engine designs in which synergy effects with the commercial vehicles sector
can be used.

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In turbocharging, the turbocharger is being driven by a gas turbine using the
energy in exhaust gases. The major parts of turbocharger are turbine wheel,
turbine housing, turbo shaft, comp. wheel, comp. housing & bearing housing.
A 4-stroke S.I. Engine is an engine that uses gasoline as fuel. S.I.engine is a
spark ignited engine that is the combustion is carried out by spark ignition, it is
achieved by installation of spark plug on cylinder head.
In this project we are using Honda Stunner CBF 125cc for the installation of
turbocharger. The CBF125 is a motorcycle manufactured by Honda's Indian
subsidiary HMSI. The motorcycle is known as Stunner in the Indian market. In
India, it has two variants, the carburetor version simply called Stunner.
Turbo-Charger
Turbo-charging, simply, is a method of increasing the output of the engine
without increasing its size. The basic principle was simple and was already
being used in big diesel engines. European car makers installed small turbines

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turned by the exhaust gases of the same engine. This turbine compressed the
air that went on to the combustion chamber, thus ensuring a bigger explosion
and an incremental boost in power. The fuel-injection system, on its part, made
sure that only a definite quantity of fuel went into the combustion chamber.
BMW was the first to use turbo-charging in a production passenger car when
they launched the 2002 in 1973. The car was brilliantly packaged too and
paved the way for a simply magnificent ‘Turbo Era’ in the automotive world.
Swedish giant Saab took its cue from this and its ensuing 900 series was one of
the most characteristic turbo cars of its time. Intercoolers the latest turbo’s they
are used by most of today’s turbo-diesel engines to make the compressed air
denser. It works like this – on starting, exhaust gases spin the turbine and thus
activate a compressor that pressurizes the air. This pressurized air from the
turbo-charger is then sent through a duct to an air-cooled intercooler, which
lowers the temperature of the intake charge and thus increases its density. The
air-cooled intercoolers receive air through separate intakes and that explains
the small scoops and louvers usually found on the hoods of turbo-charged cars.
Modern turbo-diesel engines also make use of a temperature-sensitive, motor-
driven fan which boosts airflow at low engine speeds or when the intake air
temperature is high. Computers soon started playing an even bigger role in
cars. Engine management systems linked to fuel-injection systems meant
getting more out of the engine was even easier. For example, one can buy
chips that can boost power by 100 bhp for some Japanese cars, such as the
Nissan Skyline. Moreover, on-road speeds were being restricted all over the
world. Though most of the sports cars today are capable of doing more, they
are restricted electronically not to exceed 250 kmph even in autobahn-blessed
Germany. Turbo-charging lost its edge towards the end of the 1980s and today
this technology is used only in select performance cars. Porsche, for example,
is all set to build a turbo-charged version of its all-new 911 (water-cooled)
with added performance. Turbo engines were banned in Formula One too with
the idea of restricting the performance of the cars (and thereby making them
safer too). There are many who consider this a backward step in the world of
Formula One, which is considered to represent the ‘tomorrow’ of automotive
technology. But if one analyses the performance of normally aspirated cars in
F1 today (3,500 cc non-turbo), they perform as well, if not better, than the

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turbo cars of the early 1980s. So, there are no full stops in technology. While
road cars and even sports and racing cars are going in for more efficient
engines, better metallurgy and wilder-than-ever electronics to get their engines
to perform at an optimum level without sacrificing the performance edge,
turbochargers still continue to serve the same purpose they were invented for
albeit more so with diesel engines. Modern turbocharger is based on the
principle that if air entering in an engine is pressurized more oxygen and then
adding more fuel in the engine result in high torque and more power. A
turbocharged engine produces more power overall than the same engine
without the charging. This can significantly improve the power to weight ratio
for the engine. Now a day’s turbochargers are used in heavy vehicle, racing
cars and racing bikes. The Supercharger – or, as the Germans call it,
Kompressor! It’s a common tendency, especially amongst enthusiasts, to look
for ways in which to quench the thirst to produce ever more power from the
engine of their cars. Well, maybe not so much in our country—but certainly in
more affluent countries, where enthusiasts have the financial capability, and
desire, to soup up their cars in the search for better performance. One of the
most common solutions is to turbocharge a car—a technology we’ve looked at
in detail in the past—while the other popular route is to install a supercharger.
Now, these were actually invented even before the internal combustion engine
was developed for mainstream use in industrial and automotive applications.
So, as a technology, it’s been around for a while—and has seen constant
development over the years. Some of the earliest performance cars of the
world used superchargers to boost their performance—these included
legendary classics such as the Mercedes 540K, Bugatti Type 35C, and, of
course, the famous ‘Blower’ Bentley’s, which conquered Le Mans and were
the fastest cars of their day. So, it could be said that in the history of force
induction, this is the earliest, and one of the most successful progenitors. In the
1970s of past century, with the turbocharger’s entry into motor sports,
especially into Formula I racing, the turbocharged passenger car engine
became very popular. The word “turbo” became quite fashionable. At that
time, almost every automobile manufacturer offered at least one top model
equipped with a turbocharged petrol engine. However, this phenomenon

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disappeared after a few years because although the turbocharged petrol engine
was more powerful, it was not economical.
WORKING OF TURBOCHARGER
Since the power a piston engine can produce is directly dependent upon the
mass of air it can ingest, the purpose of forced induction (turbo-supercharging
and supercharging) is to increase the inlet manifold pressure and density so as
to make the cylinders ingest a greater mass of air during each intake stroke. A
supercharger is an air compressor driven directly by the engine crankshaft, and
as such, consumes some of the power produced by the combustion of fuel,
thereby increasing BSFC and engine wear for a given amount of produced
power. A turbocharger consists of a single-stage radial-flow (―centrifugal‖)
compressor (air pump), which is driven by a single-stage radial-flow turbine,
instead of being driven directly by the crankshaft. The turbine extracts wasted
kinetic and thermal energy from the high-temperature exhaust gas flow and
produces the power to drive the compressor, at the cost of a slight increase in
pumping losses.
HOW TURBOCHARGER WORKS

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INSTALLATION OF TURBOCHARGER
Steps for installation
1. Connect the turbo inlet with engine exhaust port with the help of studd nut &
welding.
2. The turbine shaft is connected to a compressor, which draws in combustion
air, compresses it, and then supplies it to the engine.
3. Now connect air filter with turbo compressor section.
4. Connect turbo air inlet with hos pipe with bike air cleaner.
5. Now connect carburettor with air cleaner & with engine.
6. Connect silencer with waste gate from where the waste gas will flow.

WORKING PRINCIPLE
A turbocharger consists of a turbine and a compressor on a shared shaft. The
turbine converts heat to rotational force, which is in turn used to drive the
compressor. The compressor draws in ambient air and pumps it in to the intake
manifold at increased pressure, resulting in a greater mass of air entering the
cylinders on each intake stroke. The output of the engine exhaust gas is given
to the input of the turbine blades, so that the pressurized air produced. This

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power, the alternate power must be much more convenient in availability and
usage. The next important reason for the search of effective, unadulterated
power are to save the surrounding environments including men, machine and
material of both the existing and the next fourth generation from pollution, the
cause for many harmful happenings and to reach the saturation point. We have
designed and fabricated a prototype of the Turbocharger was implemented in
Two- wheeler, In which the efficiency of the Engine can be increased. Thus
we have developed a method to increase the efficiency of the engine and at the
same time to control the Emissions from the engine. The experimental setup of
block diagram shows the arrangement of turbocharger in two- wheeler. This
type of engine will be more efficient than existing engine
BENEFITS OF TURBOCH ARGING
Increased engine power output (in the region of 50%increase).
Improved fuel consumption on (improved pressure balance across the engine.
Altitude compensation.
A very high percentage of two wheel gasoline vehicles (48%) were found not
complying with the prescribed National Emission Standards. The increase in
Carbon monoxide and Hydro carbon emissions by two wheel gasoline engine
sat accelerated engine speed was quite significant.
About90%ofscootersand85%ofmotorbikes were found emitting CO within the
prescribed national standard of 4.5%. About 33% of scooters and 83% of
motor bikes were found emitting Hydrocarbon within 2000ppm.
Duringhalfthrottlingabout90%ofscooters and 93%ofmotorbikes were found
emitting HC within the prescribed national standard of 2000PPM.
•During full throttling about 52% of scooter sand 47% of motorbikes were
found emitting HC not within the prescribed national standard of 2000PPM.
It was observed that the Carbon monoxide emissions from two wheel vehicles
increased from two to three times at the full acceleration engine conditions.

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It was observed that the Hydrocarbon emissions from two wheel vehicles
increased from two to four times at the full acceleration engine conditions.
By the use of turbo charging in two wheelers the power can be enhanced. A
properly tuned turbo engine can produce 20% + more power compared to
stock but expect an increase in fuel consumption.
More power compared to the same size naturally aspirated engine.
Better thermal efficiency over naturally aspirated engine and super charged
engine because the engine exhaust is being used to do the useful work which
otherwise would have been wasted.
Automotive oil condition monitoring is far from a mature technology. As this
technology progresses and becomes more popular in the auto motive industry,
there will be many generations of sensors developed to improve accuracy and
range of capability.
While some vehicles come standard with oil change technologies today, the
majority do not. The companies developing these sensor technologies must be
able to convince the automotive industry and the public of their general
reliability and value. If this is successful, we may see condition-based oil
changes become the latest trend in vehicle technology over the next few years.


CONCLUSION
We have designed and fabricated a prototype of the Turbocharger was
implemented in Two- wheeler, In which the efficiency of the Engine can be
increased .Thus we have developed a method to increase the efficiency of the
engine and at the same time to control the Emissions from the engine. The
experimental setup of block diagram shows the arrangement of turbocharger in
two- wheeler. This type of engine will be more efficient than existing engines.
This work is an attempt to reduce our dependency on foreign oil and reduce

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the tailpipe emission from automobiles and this was an attempt to design and
implement this new technology that will drive us into the future. Use of
production turbo charger will reduce smog- forming pollutants over the current
national average. The first hybrid on the market will cut emissions of global-
warming pollutants by a third to a half and later modes may cut emissions by
even more.

ADVANTAGES
More power compared to the same size naturally aspirated engine.
Better thermal efficiency over naturally aspirated engine and super charged
engine, because the engine exhaust is being used to do the useful work which
otherwise would have been wasted.
Better Fuel Economy by the way of more power and torque from the same
sized engine. A century of development and refinement—for the last century
the SI engine has been developed and used widely in automobiles.
Continual development of this technology has produced an engine that easily
meets emissions and fuel economy standards. With current computer controls
and reformulated gasoline, today’s engines are much more efficient and less
polluting than those built 20 years ago.
Low cost–The SI engine is the lowest cost engine because of the huge volume
currently produced.
High Thermal efficiency.
Better volumetric efficiency.
High speed obtained.
Better average obtained.
Eco-friendly

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DISADVANTAGES
Bike cost will increase. Engine weight will increase. If there will be improper
maintenance then there will be problem in turbo such as turbo lag.
Supercharger
A supercharger is an air compressor that increases the pressure or density of
air supplied to an internal combustion engine. This gives each intake cycle of
the engine more oxygen, letting it burn more fuel and do more work, thus
increasing power.
Power for the supercharger can be provided mechanically by means of a belt,
gear, shaft, or chain connected to the engine's crankshaft. When power is
provided by a turbine powered by exhaust gas, a supercharger is known as a
turbosupercharger. – typically referred to simply as a turbocharger or just
turbo. Common usage restricts the term supercharger to mechanically driven
units.
Type of supercharge
1. Root
2. Screw
3. Centrifugal
Root: - The roots type supercharger is by far the
oldest, dating back to before the 20th century.
However, it has been continuously updated since it
was first invented and used, and has managed to
hold its own in modern times in several areas.
Originally, roots type superchargers push extra
oxygen into engines by using meshed-lobe rotors
with two lobes. These rotors rotate in opposite
directions, trapping air in pockets and forcing it
from the inlet to the compressor chamber, where it is

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compressed and moved into the engine. Modern designs use the same basic
principal, but usually use rotors with three or even four lobes, as well as other
upgrades that can improve efficiency in dramatic ways.
Screw: - The screw type supercharger works in a similar way to the roots type
supercharger. Screw type superchargers work by using two counter rotating
screws, rather than rotors. While this seems similar enough to a roots type
supercharger, it actually offers very different advantages and disadvantages.
Screw type superchargers are very good at moving air — they lose very little
of it due to their design. Additionally, they can compress air as they move it
using their screws. However, these advantages are not without cost. Screw
type superchargers are significantly less powerful before reaching high RPM
— and if used on an engine that never reaches high RPM, they will not ever
achieve their potential.

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Centrifugal: - Centrifugal superchargers are similar to many pumps or fans.
They pull air through an intake using an impeller, which collects air and forces
it out into a progressively smaller area, compressing it and leading to an
engine, where it is put to work.
Centrifugal superchargers use their special features to their advantage, but not
without drawbacks. In general, they are excellent at moving a large volume of
air. As a result of this, they are among the most efficient and effective
superchargers. Centrifugal superchargers have comparatively few moving
parts. As a result of this, they are quite reliable, requiring little maintenance.
They also generate much less heat than their more complicated equivalents.
Unfortunately, they put a limited amount of pressure on this air, unlike the
other kinds of superchargers. They also perform less effectively at lower RPM.



The Difference between a Turbocharger and a Supercharger
Both turbochargers and superchargers are designed to force air into the
combustion chambers of the engine, yet they use different mechanical
operations to accomplish the task. A supercharger uses a gear driven by
another engine component; commonly, the crankshaft is equipped with a gear
to drive a belt, which drives the supercharger’s gear. As the engine spins, the

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belt drives a turbine that acts as an air compressor to condense the ambient air
and force it into the engine’s air intake, where it is sucked into the cylinder by
the piston’s intake stroke. The air is compressed further during the piston’s
compression stroke. With a turbocharger, the centrifugal compressor turbine is
spun by exhaust gases escaping the engine after they have been forced out of
the cylinder by the combustion of the air/fuel mixture and the piston’s exhaust
stroke. Other than where they derive their propulsion from, the process of air
induction is essentially the same for both superchargers and turbochargers.

Comparing Performance between a Turbocharger and a
Supercharger
Generally, the conventional theory is that turbochargers operate in a more
efficient manner than superchargers, as they do not rob from the power an
engine produces by placing a drag on the mechanical parts that power the
supercharger. Therefore, turbochargers provide performance enhancements
without robbing from fuel economy. Superchargers make the engine work
harder, and therefore, they theoretically rob from fuel economy; this is not
something most performance drivers consider a big concern, however. The
supercharger is considered to provide better throttle response because the air is
constantly being pumped at a high volume. Turbochargers have a tendency to
lag, waiting for the exhaust gas pressure to build and raise the air intake RPM
of the turbine. With that being said, modern turbo design combined with
advanced engine electronics has leveled the playing field, and most
turbochargers on today’s performance vehicles do not suffer from turbo lag.

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Twin-turbo
Twin-turbo or biturbo refers to a turbocharged engine in which two
turbochargers compress the intake charge. More specifically called "parallel
twin-turbos". Other kinds of turbocharging include sequential turbocharging,
and staged turbocharging. The latter is used in diesel automobile racing
applications.
TYPE OF TWIN TURBO CHARGER
1. Parallel twin turbo charger
2. Sequential Twin Turbochargers
Parallel Twin Turbochargers
With a parallel design, the two turbochargers each share half of the engine’s
exhaust gases. Commonly used in a V6 engine, one turbo feeds off the left
bank of cylinders, and the other feeds off the right bank. Think of it as running
two three-cylinder engines that are synced together. This type of design model
would not be possible without advanced engine electronics that can balance
the airflow of the twin turbos to achieve the synced intake of combustion
gasses. The functional advantage of parallel twin turbos is that with the
sophisticated engine electronics in today’s cars, the turbo can add performance
while adding to the engine’s fuel economy.
Sequential Twin Turbochargers
With sequential twin turbos, the smaller of the two operates at low speeds and
the larger turbo kicks in at high speeds. Sequential twin turbos are often called
“two-stage turbo” because the smaller turbo will actually continue to run and
feed the larger turbo when it activates; hence, the sequential two-stage
moniker. This engineering design is not without fault; it takes a somewhat
complicated series of tubes or pipes to plumb a sequential twin turbo. The
design works well with diesel engines, which is where this type of
turbocharger is commonly used. Sequential twin turbos do a good job of

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reducing turbo lag, something that would be more noticeable in a diesel-
powered vehicle.