Turbo Fundamentals

How a Turbo Works A turbocharger uses an engines exhaust gas to drive a turbine wheel at speeds up to 280,000 rpm. The turbine wheel is connected by a shaft to a compressor wheel and the two wheels turn together to suck in and compress large amounts of ambient air. This air is very dense and very hot, so it is passed through a charge-air cooler, where it cools and gains even higher density before entering the engine. The presence of this compressed air makes the fuel burn more efficiently, thereby delivering greater power while consuming less energy. Increasingly, turbos are coupled with high pressure fuel injection systems, a combination that makes for even more thorough, efficient and cleaner combustion.

The Benefits of Turbocharging Turbos make engines: More Efficient turbocharged gasoline engines deliver up to 20 percent better fuel economy over a nonturbocharged equivalent. A turbodiesel engine of the same power rating delivers up to 40 percent better fuel efficiency compared to a non-boosted gas engine. Better Performing turbocharged engines create more power and torque, making vehicles more responsive and safer to drive. Turbos also prevent the loss of power at high altitude, providing significant operational benefits to turbocharged trucks and off-road machinery. Cleaner and Greener turbocharged engines optimize engine air supply for cleaner combustion, enabling engines to be downsized without compromising performance, while cutting CO 2 levels and contributing to a reduction in NOx

Rotary Electric Actuator (REA)

Electric actuation, compared to pneumatic actuation, provides a faster and more responsive control for diesel VNT turbos and gasoline wastegate turbos in both passenger and commercial vehicles segments. Engine range Electric actuation is a growing feature of turbo control in gasoline powertrains from 0.8L to 3.5L and in diesel engines powering both passenger cars (from 1.4L) and commercial vehicles (up to 15.0L). Key Features REA is an electro mechanical device mounted on the compressor housing and connected to the VNT (for diesel applications) or the wastegate (for gasoline applications). In diesel applications, the electronic control of diesel fuel injection in recent years precipitated the need for the electronic control of airflow. Working in conjunction with Honeywell VNT turbos, the REA provides this control in both steady state and transient mode by knowing and controlling the vane position. It communicates with the Engine Management Unit (EMU) in either analogue, PWM or CAN form, receiving and carrying out instructions instantaneously. In gasoline applications, REA works through the control of the wastegate. Key Benefits Electric actuation offers faster response than its pneumatic counterpart using as little as one third of the time (150 millisecond vs.500 millisecond), and the overall turbo control is more precise due to on-board position sensing. The faster response and more precise control help improve engine performance, fuel efficiency and emissions control. Since REA does not rely on the engine as a pressure source, and with fewer vehicles in the future requiring vacuum systems, it liberates the turbo from its dependence on such systems and results in simpler engine architecture. Finally, REA can be designed to provide enhanced diagnostic capabilities, leading to better system reliability. Evolution and Future Trends In the late 1990s, BMW became the first passenger car manufacturer to adopt Honeywell Rotary Electric Actuation integrated into the VNT turbo, and in 2002, Hino became the first company to deploy this technology for heavy-duty applications. Since then, the output power of electric actuators has increased around three-fold and the response time has been reduced significantly. These lead to smaller-sized actuators with better cost advantage. Electric actuators for commercial vehicle turbos tend to be intelligent types with brushless motors (for durability and reliability), while their PV counterparts tend to feature brushed motors and can be either the intelligent or the simple type. Future Trends For diesel passenger cars, the engine downsizing trend will continue to drive the development of smaller, simpler

and more economical actuators for VNT turbos. For wastegate gasoline turbos, emissions regulations are driving the replacement of pneumatic actuators by rotary electric actuators, which offer better perceived value, more flexibility and similar overall system cost. For commercial vehicles, on-board diagnostics and brushless motors are here to stay, and there is a trend toward actuators (air cooled today) that are water cooled.

Ball Bearing

Its a technology that was originated in aerospace, spread into motorsports and is now moving mainstream commercially launched in both passenger car and commercial vehicle segments. Honeywell is a pioneer in ball bearing technology and has solidified its leadership in the area through successful commercial launches in high-profile vehicles. Engine range For passenger cars, the current focus is in the 1.6L-3.0L displacement range, while for light pick-up trucks and commercial vehicles, the technology is a core feature in engines of 6.0L and above (on-and-off highway). Key Features Typically, a Honeywell ball bearing system features ceramic balls as part of a high resistance steel cartridge design. Compared to the sliding mechanism of conventional journal bearing, the rolling mechanism of ball bearing results in enhanced mechanical efficiency and therefore better turbo efficiency. Honeywells ball bearing expertise not only lies in the product design, but also extends to the area of manufacturing. The assembly and balancing of ball bearing mechanism has to be extremely precise, with very tight measurement and tolerance level. Key Benefits For passenger vehicles, the ball bearing technology helps improve transient response. The magnitude of time-to-boost improvement attributable to ball bearing can be between 2070 percent. Second, ball bearing mechanism is shown to help deliver 2 percent fuel efficiency improvement compared to conventional journal bearing. Lastly, ball bearing turbos work wonders in cold start condition. This is because ball bearing is impediment to turbo responsiveness in ball bearing turbos. Honeywell remains the only commercial vehicle turbo manufacturer to exploit the unique advantages that ball bearing systems offer. The commercial advantages of ball bearings come from their inherent ability to withstand high load and their ultra-low friction losses. For all these reasons, interest in ball bearing systems for commercial vehicle turbos is growing, particularly in medium duty applications where operators are looking for driveability, fuel efficiency and a life cycle of up to 1 million kilometres.
High Temperature Ball Bearing VNT Turbo

much less reliant on oil. Therefore, the high oil viscosity associated with cold start condition is much less an

Evolution and Future Trends From race cars to heavy-duty commercial vehicles to ligh-duty trucks, Honeywell has been at the forefront of extending the benefits of ball bearing turbos to more vehicle segments. In 2010, Honeywell ball bearing technology was adopted by Daimler for its 3.0L V6 diesel engine, which was equipped on Mercedes-Benz E, C, S and R class series. This follows the companies earlier success in applying this premium bearing technology to VNT DualBoost turbo (Ford F250/350) and to VNT DutyDrive (for Hino medium-duty trucks). Ball bearing turbos are becoming more commonplace, especially in passenger vehicle segment, because of their fuel efficiency and performance benefits and the contribution they make to meeting environmental standards. New design refinement will also make the technology more affordable as Honeywell accumulates more experience in manufacturing this high-precision technology in high volumes.

Racing Turbochargers

Honeywell Turbo Technologies boasts a strong experience 55 years of boosting race teams across the winning line, in virtually every single formulae and series. Whether its World Rally or World Touring Car championships, the Pikes Peak hill-climb or the Le Mans endurance series, the Honeywell Motorsports Team is there for every landmark moment, supporting teams, engineers and drivers every wheel turn of the way. Lighter and Lower In many respects, a racing turbo is closer to aerospace than conventional automotive engineering. While exact design will depend on race rules and vehicle design, the turbo is much lighter than its commercial counterpart, creates much higher pressure ratios, utilizes ball bearing systems and operates to the finest of tolerances in incredibly harsh, high temperature environments. The use of high-grade materials including titanium and magnesium and thin-wall geometry has significantly reduced turbo mass while improving core strength. As a result, by optimizing packaging and minimizing mass, Honeywell racing turbos provide race teams more leeway in overall weight distribution, leading to lower center of gravity and thus improving vehicle dynamics or handling. Crossover Technologies Today, motorsports is increasingly becoming a high-visibility platform for carmakers to test and showcase technologies destined for mainstream passenger cars. Take for example, the Audi R18 TDI which, with Honeywells aerodynamically re -engineered VNT turbo onboard, won the 24 Hours of Le Mans in 2011 to demonstrate, once again, the performance, fuel efficiency and emissions quality of its advanced TDI engine technology. And now arguably the most famous formulae of them all F1 is aligning itself more closely to the real world with plans for a new turbo era, not just to optimize power and relative fuel efficiency but also, with Honeywell, to spearhead the move to turbo energy recovery systems. And that would be a great result for everyone.

Meeting Race-Specific Challenges: Rally Cross Although founded on World Rally architecture, the turbos boosting rally cross competition need to deliver high levels of power up to 550hp but with the characteristics of a small turbo that spools up fast and creates rapid time-to-torque. These cars exhibit great acceleration and excellent performance around tight corners, thanks in part to Honeywell turbos high-flow compressor technology and highly-efficient turbine aerodynamics. Pikes Peak

Its all about performance at altitude with Pikes Peak, as unlimited sportscars race each other up to the 14,000ft finish line from a start position that is 4,600ft lower. In 2011, Honeywell helped boost the winning car to a record time, creating the high turbo pressure ratios needed through new compressor aerodynamics to minimize the power de-rating effect of altitude and maintain competitive advantage right to the top of the mountain. Formula 1 With turbochargers set to re-enter Formula 1 in 2014, teams are working with Honeywell to optimize not just the power benefits of engine boosting but to exploit the potential to recover wasted energy by marrying the turbo to electric motors and generators. This concept, tying in closely with industry-wide interest in energy efficiency, is also under close consideration by the governing body of the Le Mans Series. Honeywells innovation in racing has led to the development of turbochargers that optimize power, performance and reliability. This focus on succeeding through technology also drives its partnerships with auto manufacturers, delivering turbo solutions that save fuel and reduce emissions without compromising engine performance.