As turbocharging gains traction as an essential gasoline powertrain technology, Honeywell’s high temperature wastegate solutions are delivering class-leading fuel efficiency and performance benefits through the application of advanced aerodynamics, materials and bearing systems.
Honeywell’s latest generation gasoline wastegate turbos are available in a broad range mono-scroll and twin-scroll configurations to boost engines from 0.9L displacement to premium V8 engines delivering 400kW peak power.
Modern gasoline engines adopt wastegate architecture – where engine boost levels are controlled by actuator and by-pass valve coordination. Compared with their diesel counterparts, gasoline turbos function in a much higher temperature environment, up to 1050oC. They tend to be water-cooled and manufactured in advanced materials – in the case of Honeywell using special alloys and composites developed originally for its aerospace business.
Aerodynamic optimization is critical in enhancing turbo performance for gasoline engines. On the turbine side, Honeywell has developed new generation wheels with radial, mixed, low and high flow capability, along with compact volutes, to meet specific engine flow characteristics. On the compressor side, new wheels and volutes help satisfy the distinct requirements of low and high power engines.
Other Honeywell innovations include a 4-pad Z bearing that is 30 percent smaller and reduces friction losses by 20 percent, a redesigned recirculation valve to minimize surge, and an electric actuator option that enhances transient response.
The result of these technological advances is a turbo that is 25 percent smaller and 30 percent lighter than the previous generation but with flow characteristics that help achieve class-leading performance. Honeywell turbos cover the full range of engine sizes to meet the specific requirements of auto manufacturers in terms of power, torque, transient response, system cost and CO2 and emissions compliance. On average, turbogas engines are 20 percent more fuel efficient than their naturally-aspirated counterparts of equivalent power rating.
Evolution and Future Trends
Honeywell gasoline turbos help boost a wide range of engine sizes – from the mono-scroll 1.4L Opel Astra, to the twin-scroll 1.6L BMW, the V6 Ford EcoBoost and the V8 twin-turbo BMW X-Series.
As emissions and fuel efficiency standards tighten, demand for turbo technologies will continue to grow and Honeywell, with its global engineering and manufacturing footprint, is well placed to satisfy demand.
Honeywell’s strong innovation pipeline takes account of new by-pass systems and aerodynamic concepts – including axial turbine flow – to help optimize engine control, fuel efficiency and performance. With the introduction of new materials, simple electrical actuation and ball bearing systems (particularly in larger turbos), gasoline wastegate architecture will grow as a key enabling technology, with the likelihood of increasing levels of engine system integration.