Honeywell Transportation Systems

Technical Papers

September 2016

MAN D26 Two Stage development, heavy duty commercial engines optimized with respect on low fuel consumption and emissions Author: P. Glonegger a ,C. Weiskircha, M. Eratha, P. Pribylb, R. Cadlec
(a: MAN Truck & Bus AG, b: Honeywell, spol. s r.o., c: Honeywell International Inc)

Summary: The development of heavy duty engines is driven by customer as well as legal demands. To find the best compromise between low gaseous and particulate emissions with lowest fuel consumption and high reliability MAN Truck & Bus in cooperation with Honeywell developed a Two Stage turbo charging system for the D26 launched in 2009. This paper describes the evolution of the D26 engine up to the present challenging emission legislation. The benefits of a Two Stage system compared to a Single Stage are discussed. Finally a detailed description of the turbo charger development such as matching challenges, aero selection and test bench work as well as special features of the latest evolution are part of the paper.

Publisher: 21st Supercharging Conference, Dresden

June 2016

An Improved Approach to HCF Development for Vaneless Turbine Stages Author: William Smith, Christopher Wilkins, Durga Gouravaraju, Wagner Magalhaes, Zdenek Neterda

Summary: This paper highlights the steps that have been taken to improve the design, analysis, measurement and verification of HCF in vane less turbine stages, the intent being to improve both the HCF robustness and maintain performance. In making these improvements the impact on the aerodynamic performance of the turbine stages was also strongly considered to ensure that improvements made for HCF were not made at the expense of performance. The investigation of these new design options required developments in analytical capabilities, specifically 3D unsteady CFD, in order to make the necessary iterations with adequate fidelity in a practical timeframe. To verify the analysis techniques comprehensive experimental measurement of blade strain levels across multiple designs was also conducted and the results compared with analysis. Finally endurance testing was conducted to confirm that the measured improvements in HCF resulted in longer (and sufficient) service life of the turbine stage. Estimation of the required service life was accomplished using the process presented by Kulkarni et al (IMechE 2010).

Publisher: Institution of Mechanical Engineers, London, UK

June 2016

Ultra-High Efficiency Serial TwoStage Turbocharging System for Maximum Engine Efficiency Author: Rob Cadle, Dietmar Giebert, Ashraf Mohamed, Ronren Gu, Matthew Oakes

Summary: Honeywell Transportation Systems has collaborated on an ultra-high efficiency two stage serial turbocharger system under the European Union FP7 GA-2012 CORE project. The compressors of both the low pressure and high pressure turbochargers were design optimized for the highly specific operating conditions of two stage boosting. The high pressure turbine is characterized by a sector divided fixed vane nozzle, while the low pressure turbine stage features an axial turbine wheel. The two turbines were designed specifically to achieve highest possible efficiency while minimizing ducting losses between the two stages. The end result is a novel high performance boosting system that fits in a unique package. This paper describes the approach used to set design targets for each stage of the two stage turbocharger system. The design approach used to meet these targets will be presented, and test results from gas stand will be shown measured against performance targets and performance predictions.

Publisher: Institution of Mechanical Engineers, London, UK

May 2014

Improvement of a turbocharger by-pass valve and impact on performance, controllability, noise and durability. Author: L. Toussaint, M. Marques, N. Morand, P. Davies, C. Groves, F. Tomanec, M. Zatko, D. Vlachy, R. Mrazek

Summary: While engine boundary conditions have become harsher, fine, accurate and sustainable control of boost is challenging the way mechatronics components are engineered. This paper describes key elements of the kinematic tools developed by Honeywell Turbocharger Technologies in order to optimize turbocharger control solutions. It includes details on CAE applications such as fluid dynamics, flexible multi-body dynamics and thermo-mechanical simulations and how they can be linked together to analyse a complete system.

Publisher: Institution of Mechanical Engineers, London, UK

May 2014

The Modified Phan-Thien and Tanner model applied to turbochargers thrust bearing Author: B. Rémya,b, T. Lamquina, B. Bou-Saïdb (a: Honeywell Turbo Technologies; b: Université de Lyon, France)

Summary: In this paper, an unsteady thermohydrodynamic formulation of a turbocharger’s thrust bearing contact is presented. The Modified Phan-Thien and Tanner model takes into account complex rheological characteristics of the lubricant, transient aspects and inertia effects due to the very high rotational speed. An extensive rheological testing campaign was performed to get data as input for the numerical model. The results obtained from this model are compared to experimental data provided by a thrust bearing rig. It shows acceptable correlation between prediction and test data of axial thrust load versus thrust bearing oil film thickness for two typical turbocharger frame sizes.

Publisher: Institution of Mechanical Engineers, London, UK

June 2012

GTD10: The Smallest Honeywell VNT™ Turbo Designed for C02 Reduction Author: P.Barthelet, J.Mailfert, E.Bouvier, C.Riviere, N.Morand

Summary: GTD range, the latest Honeywell VNT generation designed for EU6 applications, now includes the smallest VNT turbo from Honeywell. This new product has been designed to reduce fuel consumption and provide better transient response, enabling further downsizing. The GTD10 can be matched as a single VNT turbo for engine power rating between 45 to 65kW or as High Pressure Turbo for Two-Stage engine power rating between 110 to 120kW.

Publisher: Diesel International Conference – SIA Rouen

May 2012

Development of a Common Dual Axle VNT™ for Single and Two-Stage Off-Highway Applications Author: J. Wilson, M. Avila, P. Davies, N. Theiss, B. Zollinger

Summary: Honeywell launched the latest generation DutyDrive VNT for off-highway on John Deere's 9.0L Tier4 engine. Developments made to the VNT stage resulted in improved efficiency and allowed over 20 unique power ratings, including both two-stage and single stage air systems, with the same turbo design. The turbo also features an integrated electro-hydraulic actuation system developed to operate in high-temperature, high-vibration environments in a compact package size.

Publisher: Institution of Mechanical Engineers, London, UK

May 2012

Shaft Coking Resolution using Multiple Variable Bearing System Design Optimization for CV Turbochargers Author: A. Bhattacharya, M. Hake, J-M. Geoffroy, V. Barbarie

Summary: Honeywell has been able to find a solution to the shaft coking problem in CV using innovative prediction capabilities including advanced rotor-dynamic analysis coupled with shaft thermal prediction. This led to significant saving in development and testing time and provided a robust bearing system in the first attempt.

Publisher: Institution of Mechanical Engineers, London, UK

May 2012

Transient Response of Turbocharger Turbines Author: H. Chen, T. Cai, P. Li

Summary: The transient response of turbocharged engines is becoming critical to passenger vehicles because of the recent trend in engine downsizing and the expansion of gasoline turbocharging. Honeywell has examined the transient behavior of turbo turbines through Newton’s equation of motion and has identified a single non-dimensional variable controlling the transient. The effects of various parameters on turbine acceleration are discussed and viable options to improve engine acceleration are demonstrated.

Publisher: Institution of Mechanical Engineers, London, UK

September 2011

New Turbocharger Concept for Boosted Gasoline Engines Author: J. Lottermanna, Dr N.Schornb, D. Jeckela, F. Brinkmannb, K-H Bauera (a: Honeywell Turbo Technologies b: Ford Research Center)

Summary: Honeywell has designed an innovative turbo system for gasoline engines featuring a new aerodynamic configuration. The new system, which does not use expensive materials such as TiAl, has demonstrated a ≥ 25 percent improvement in torque transient performance at low engin e speeds. This technology enables increased levels of engine downsizing and down-speeding and thus allows further reductions in fuel consumption and CO2 emissions.

Publisher: Technische Universität Dresden, Germany