Effect of Turbocharging on Exhaust Brake Performance in an Automobile

Chengye Liu1 and Jianming Shen2

1

School of Mechanical & Automotive Engineering, Jiangsu Teachers University of Technology 213001, Changzhou, China lccyyyy@163.com 2 Changzhou Institute of Light Industry Technology, 213164, Changzhou, China sjmczjs68@163.com

Abstract. More and more diesel engines had been used as power source in an automobile when power was increasing and exhaust regulations for an automobile became more and more strict. Because compression ratio of diesel engines was higher than that of gasoline vehicles its performance of exhaust brake was prior to that of gasoline vehicles. Turbocharger was commonly used to improve power and reduce fuel consumption ratio. Study on effect of turbocharger on exhaust brake for diesel engines had practical significance. In this paper the effect of turbocharger on exhaust brake had been studied by theory method. Keywords: Automobile, Turbocharging, Exhaust brake, Diesel engine.

Introduction

With the development of highways, logistics and the pace of life weight and velocity of vehicles become more and larger, which make driving safety of vehicles lowered. Braking load of vehicles increases quickly so that primary brake system is easy to be overloaded and damage for overheating, then traffic accident will take place. In addition, for vehicles in the mountains, hills and city, the driver have to use the main braking system frequently for security reasons, which leads to the average speed lowed, and it would affect the operating cost. In Europe, UN-ECE R13 regulatory requirements that auxiliary braking system must be installed as compliant brake set for heavy vehicles [1]. Currently, more types of auxiliary brake, such as an eddy current retarder, hydraulic retarder, engine braking, etc., and they have their own characteristics, and have better braking effect only in a certain speed range [2]. The more popular method is that more than one retarders are installed to compensate for each other in their lack of braking, so brake load of primary braking system can be reduced to improve traffic safety [3]. The initial exhaust brake appeared in Alps mountain area during World War I, and it was used for a long history [4], then there was significant development in research aspect. Working principle of the exhaust brake is that a butterfly valve or similar body is built in the engine exhaust manifold, and when the valve closes wind tunnel the brake force of the vehicle starts to increase, so the engine's exhaust resistance
D. Jin and S. Lin (Eds.): Advances in CSIE, Vol. 2, AISC 169, pp. 153158. springerlink.com Springer-Verlag Berlin Heidelberg 2012

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increases accordingly, and it makes the engine that takes as the source of automotive power becomes a set that consumes vehicle kinetic energy, in fact, the engine is transferred into the air compressor. The exhaust brake can prevent vehicle accidents due to rapid deceleration and skidding. Exhaust brake has simple structure, reliable performance and easy operation, and its braking power can reach about 60% rated power of the engine [5]. Many diesel vehicles are equipped with this device, such as the Steyr series, Dongfeng EQ Series, Isuzu EHD. Series of diesel vehicles are equipped with a structure similar to the exhaust brake. Especially in Japan, diesel exhaust brake usage of the car has more than 70% [6]. As the diesel engine compression is relatively larger than gasoline engine, when an engine works as the air compressor its retarder resistance is better than gasoline (because of its higher absorption of energy), so this set is mainly used for diesel engine. Turbocharged diesel engine unit is commonly used to improve the power per quality of the engine and to reduce fuel consumption rate, so effect of the exhaust gas turbocharger on braking performance has certain significance. 1.1 The Structure of the Exhaust Brake

Exhaust brake is generally divided into two kinds of pneumatic and vacuum form, and pneumatic controlled exhaust brake is used more. Figure 1 is electronic-controlled valve exhaust brake structure diagram. It consists of actuator, control organization and break-oil organization. The actuator includes brake cylinder and the butterfly valve, and control organization includes the brake switch, pedal and clutch switch, work lights, electromagnetic valve and air tubes, and break-oil organization includes the oil tank and other institutions and so on.

Fig. 1. Electronic-controlled valve exhaust brake structure 1. Battery 2. Brake Switch 3. Work Lights 4. Clutch Switch 5. Accelerator Pedal Switch 6. Brake Valve 7. Brake Cylinder 8. Electromagnetic Valve 9. Gas Tank

1.2

Working Principle of the Exhaust Brake

When a four-stroke diesel engine works, as shown in Figure 2 heat energy that fuel releases is transferred into mechanical energy and transmitted by the camshaft out. Exhaust brake is the set that a special butterfly valve is installed in the engine exhaust

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manifold as shown in Figure 3. In the normal working conditions the butterfly valve is opened, and this condition is similar to the status that exhaust brake is not installed, and flow area that exhaust manifold is cut is slightly reduced. When the exhaust brake retarder need work, firstly the fuel supply system is cut off, and this will make the engine flameout, secondly pressure cylinder and rocker promote the butterfly valve closed, and at this time exhaust gas emission is limited, and back pressure in the engine exhaust manifold start to increase, in the exhaust stroke gas in the cylinder and manifold is compressed again, and it will make the diesel engine become a air compressor that absorbs kinetic power of the vehicle, and movement of the engine piston is hampered by the compression of the gas, so this resistance is like a big spring stiffness (air springs), acting directly on the engine piston, and the equivalent retarder device provides a vehicle through the transmission gear wheel and makes the vehicle speed reduction without the use of or less the case with the primary braking system, and the speed of the vehicle is easy under control, meanwhile this affect can reduce the primary braking system maintenance chance. As there is cushion effect between the piston and cylinder it is benefit for extending the life of the engine after exhaust brake is used. And it can be overcome bigger inertial force when the vehicle is drove at the over speed, and in addition because the engine is used as brake set kinetic energy of vehicle is transfer into pressure energy and heat energy, at this time brake the engine temperature can keep constant, so engine thermal fatigue can be reduced in the mountain area [7,8].

Intake stroke

Compression stroke

Combustion stroke

Exhaust stroke

Fig. 2. Working process of four-stroke diesel engine

1.3

Turbocharging

Turbocharger driven by exhaust gas can add inlet air pressure to increase the amount of fresh air for diesel engine. So quality per power of diesel engine can be reduced, meanwhile the dimensions also is reduced, and raw materials and fuel consumption of the diesel engine is decreased. Above advantage can satisfy lightweight of a vehicle. Work principle of turbocharging is as followed. Exhaust manifold is connected to the turbine housing of the turbocharger, and diesel exhaust has a certain pressure and high-temperature, and exhaust gas pass through the turbine housing into the nozzle

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ring, because the channel area of the nozzle ring changes from large to small, thus pressure and temperature of exhaust gas has a very large drop, while the rotation speed of the turbocharger is rapidly increasing, and high-speed exhaust gas flows and has a certain impact on the direction of the turbine, such as the turbine rotation speed, exhaust gas temperature. Pressure and temperature is higher, the higher the rotation speed of the turbine. Finally, exhaust gas go into the atmosphere through the turbine. And the shaft of turbine is connected with the shaft of a compressor, so their shafts are the same speed of rotation, and fresh air through the filter is inhaled into the compressor shell. High-speed rotation of the impeller presses fresh air through edge of the compressor impeller to increase the pressure and velocity, and fresh air flows into the diffuser to slow speed and increase pressure further. The pressurized air flows through the engine intake manifold into the combustion cylinder and more fuel can be injected to ensure a greater issue of diesel power.

Fig. 3. The structure of exhaust brake

Effect of Turbocharging on Exhaust Brake

Without using turbocharger of exhaust gas the working process of engine is 1 2 3 4 5, in a complete cycle negative power of the diesel is made up of two parts: A and B as Fig.4 shows. A part indicates consumption of power of the compression and expansion stroke for diesel engine, in this part the negative work is a relatively small; however in the B part exhaust stroke in the normal working hours (intake valve is closed at this time) is changed into the compression stroke (equivalent to the air compressor), so negative power caused by the compression and expansion stroke has an much larger area than the negative power in the normal working. Negative power can increase the engine power loss to improve the exhaust brake retarder effect. When

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the intake valve is opened the air inside the cylinder with high pressure and temperature will cause air to the intake pipe, so air will flow back in the intake at this time. After installation of turbocharger diesel engine at this time does not work, and butterfly valve is closed, and in exhaust manifold there is no exhaust emissions so the turbine blades can not work, but because turbine blades has the blocking effect, and this effect can make lower inlet pressure of the diesel engine than it with no turbocharger, so air put is relatively small. At the end of the compression stroke or the piston reaches TDC the peak pressure will decrease a little, so the PV curve will have a slightly decreased (this condition is not shown in order to show clear). Above condition shows the installation of turbocharger of exhaust gas diesel engine will have some negative impact on exhaust brake. Diesel engine with turbocharger will consume more air and fuel and produce more gas, and in the same circumstances exhaust gas has higher air pressure and temperature, so at the beginning of the implementation of exhaust braking system a greater dynamic torque will generate, after the intake valve opens brake torque will decline, and at this time brake torque is lower than that no turbo exhaust brake system at same rotation speed.

Fig. 4. P-V diagram of the diesel with supercharged and no turbocharged

We can see from the characteristics of the exhaust brake that exhaust brake energy is closely related to engine speed. At lower rotation speed the braking energy is smaller, and the higher speeds, greater braking energy, and this performance is in line with vehicle braking requirements, so in order to maximize the effect of exhaust brake some certain measures such as exhaust valve is mounted near the exit of the turbocharger shell to minimum compression volume in order to improve braking performance; meanwhile brake body of the exhaust valve can be added, and its effect is that the exhaust valve can be opened instantly when piston reaches at the end of the TDC at compression stroke , so that air pressure inside the cylinder declines quickly, and in next stroke compression air do not form a thrust piston, then energy absorption

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in compression stroke plays a role in the effective retarder, thereby the sum of both brake function can enhance the braking effect.

Conclusion

Followed conclusion can be obtained through PV diagram of diesel engine with exhaust gas turbo: There are greater braking force for exhaust gas turbocharged diesel than that no turbocharged diesel at the beginning, then brake torque start to reduce and has approximately equal to torque with on turbocharged diesel, and it is said that effect of turbocharger on exhaust brake is very little. Some certain measures can be taken to improve the braking performance such as the exhaust brake (butterfly valve) is mounted near the exit of the turbocharger shell to minimum compression volume, or the exhaust valve can be opened instantly when piston reaches at the end of the TDC at compression stroke.

References
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