Measuring the temperature distribution in a complex and important engine part, such as a turbocharger, is essential for improving engine performance and efficiency. Heat transfer from the turbine to the compressor can strongly influence the turbocharger performance. One of the main measurement methods involves the installation of multiple K-type sensors. However, the location as well as the maximum and minimum temperatures of the turbocharger and the subsequent critical points may not be obtained by using sensors. In the current study, thermocouples, as well as an infra-red camera, are used to study the temperature distribution of the turbocharger housing in a spark ignition engine. A new method is introduced to determine the thermal radiation coefficient of the turbocharger housing by using a laboratory furnace and an infra-red camera. Together with experiments, the finite element method is used to find the temperature distribution in the turbocharger for all thicknesses. Comparing the temperature distribution obtained from simulation with experimental data, an acceptable level of agreement is observed. The location and temperature of the hottest area in experimental and numerical investigations are close to the waste gate. Temperatures using the finite element method for bearings exhibit maximum and minimum errors of 4.9% and 2.3%, respectively, indicating reasonable accuracy for the simulation.
An experimental thermal survey of a turbocharger was performed in an engine test cell using IR thermography. The emissivity coefficients of housings were specified using a furnace and camera. It was shown that the emissivity of the turbine, compressor, and bearing housings are 0.92, 0.65, and 0.74, respectively. In addition, thermocouples were mounted on the housing to validate the temperature of the thermal camera while running in an engine test cell. To compare the data of the thermocouple with data from the thermal camera, an image was taken from the sensor’s location on the housing. The experimental results show that the temperature prediction of the thermal camera has less than 1 percent error. Steady-state tests at various working points and unsteady tests including warm-up and cool-down were performed. The measurements indicate that the turbine casing’s maximum temperature is 839 °C. Furthermore, a thermal image of the bearing housing shows that the area’s average temperature, which is close to the turbine housing, is 7 °C lower than the area close to the compressor housing. The temperature of the bearing housing near the turbine side should be higher; however, the effect of the water passing through the bearing housing decreases the temperature.
Understanding heat delivery in a multifaceted and vital engine component, such as the turbocharger, is important for improving engine performance and efficiency, but it is challenging to determine. In this paper, the temperature distribution in a turbocharger body was measured experimentally using a thermal camera, and a one-dimensional simulation of a turbocharger was developed for the temperature distribution. As part of the work, an innovative method is used to determine the thermal radiation constant of the turbocharger housing. In this method, the complete turbocharger system was first installed in a laboratory furnace and, at each stage, the temperature of the furnace was carefully adjusted. After temperature stabilization, a thermal image was taken with a thermal camera, and the radiation coefficient was obtained. Finally, a measurement of the temperature distribution was performed on the engine's test cell for the turbochargers of two three-cylinder gasoline engines (i.e. engines 1200 cc and 999 cc). The experiments include steady-state and transient tests. The transient tests include hot and cold tests at various operating conditions. The results showed that the maximum temperature of the turbine housing varies linearly with inlet gas temperature. Also, the axial distribution of the temperature in the compressor volute shows that temperature increases from the inlet side to the bearing housing side. Based on the numerical results, the maximum turbine housing temperature for engine 1200 cc is 679 °C and for engine 999 cc is 523 °C.
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