Five factors: why turbocharger becomes more and more important
Five Factors: Why turbocharger becomes more and more important.
The power of an automobile engine depends on the number and size of piston cylinders? This has become history. Today, the overall performance of the car is determined by the electronic engine control system, turbocharger or compressor. Especially the turbocharger plays a vital role in it. Since the Swiss inventor made the turbocharger in 1925, the performance of the engine has been greatly improved. What are the characteristics of this component, why is it becoming more and more important, and what are the advantages of using electrochemical machining—— Five interesting factors about turbochargers:
1.The basic principle remains unchanged.
The invention has a history of about 100 years, but its basic principle remains unchanged. The exhaust gas flow drives the turbine wheel, which is connected to another wheel by a shaft. This impeller compresses the intake fresh air and presses it into the combustion chamber. At this time, a simple calculation can be made: the more air enters the combustion chamber in this way, the more oxygen molecules combine with hydrocarbon molecules of fuel during combustion - which just provides more energy.
2. Almost 300000 revolutions.
Finally, the turbocharger can generate the highest possible air pressure to achieve the best results. In practice, the turbocharger can achieve extremely high power parameters: in modern engines, the maximum speed of the compressor rotor can even reach 290000 revolutions per minute. In addition, components can produce extremely high temperatures. Therefore, there is also an interface or system for water-cooling the charge air on the turbocharger. In general, four different substances are collected in the tiny space of this component: high-temperature exhaust gas, cold charge air, cooling water and oil (the oil temperature shall not be too high).
3. "Electrochemical advantages".
Under this premise, the production of turbocharger becomes one of the most challenging tasks in the automobile manufacturing industry. This is not only for complex housings, but also for turbine shafts. They are made of high-performance materials and can withstand temperatures of up to 1000 degrees Celsius without any problems. Such as heat-resistant cast steel or Inconel alloy materials. Machining of these parts usually includes a whole process chain from pre milling to deburring. In this case, the electrochemical process can bring great advantages. For example, when using this process, only one repeated step is required to complete the dynamic balance of the turbocharger shaft. Moreover, it will not cause thermal damage to the material. Even the hardest material will bring little tool wear - these are great advantages compared with traditional cutting technology. After all, materials such as Inconel will shorten the tool life.
4. Growing importance.
The production of turbocharger is becoming more and more rigorous, which is related to the general trend of automobile energy conservation and emission reduction: the displacement of many internal combustion engines is decreasing, but the compression of turbocharger can keep the performance consistent or even improve. Interestingly, due to the increased weight of turbochargers and charge coolers, the weight of emission reduction engines even exceeds that of similar engines without emission reduction design. Therefore, R&D personnel began to reduce the shell wall thickness to reduce the weight, which in turn further increased their processing requirements.
5. Future challenges.
Turbocharging is still the key technology for developing energy-saving and efficient engines. However, various technological trends also bring new challenges. For example, the so-called exhaust gas recirculation system is increasingly used, which cools a part of the exhaust gas, mixes it with the charge air and sends it back to the engine. This exhaust gas recirculation (EGR) system is one of the most important measures to reduce diesel engine emissions. Therefore, the turbocharger must press more air into the combustion chamber to provide it with enough oxygen. Many manufacturers use two-stage turbocharging systems with two different turbochargers here.
