Compressor Pre-Spin Control for Turbocharger Wear Reduction
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Solution Overview
Problem
The existing methods for controlling the pre-spin operation of a compressor in an internal combustion engine with a turbocharger face challenges in managing the energy transfer between the crankshaft and the compressor, leading to clutch wear and potential turbocharger choking, limiting driving conditions and power output.
Innovation Solution
A method that calculates and sets a bypass throttle angle based on engine speed, load, and turbocharger conditions to reduce the speed difference between the crankshaft and compressor, ensuring the compressor is pre-spun before engagement, thereby reducing energy transfer and maintaining optimal turbocharger performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the compressor clutch is engaged when there is a large speed difference between the crankshaft and compressor, then the compressor can be activated quickly, but high energy transfer causes high wear of the compressor clutch
Solution Approach 1:
The system performs preliminary action by spinning up the compressor before clutch engagement using a pre-spin motor. This reduces the speed difference between the crankshaft and compressor at the moment of engagement, thereby reducing energy transfer and clutch wear while maintaining quick activation capability
Solution Approach 2:
The system changes the operational parameters of the compressor by controlling its speed through the pre-spin motor before engagement. By adjusting the compressor speed to match the crankshaft speed more closely, the system optimizes the engagement conditions to reduce mechanical stress and wear
2Reliability
If the compressor clutch engagement is restricted to limited speed difference ranges, then clutch wear is reduced, but the driving conditions where compressor use is allowed are severely restricted
Solution Approach 1:
The pre-spin motor performs preliminary compression of air and spinning of the compressor before clutch engagement, allowing the system to meet clutch engagement requirements across a broader range of driving conditions while protecting the clutch from excessive wear
Solution Approach 2:
The pre-spin motor acts as an intermediary device between the crankshaft and the compressor during the engagement phase. It mediates the speed mismatch by providing independent compression and spinning capability, enabling clutch engagement under more flexible driving conditions
3Productivity
If the compressor increases air mass flow to the turbocharger, then more power can be produced, but the compressor may stall the turbocharger
Solution Approach 1:
The pre-spin motor performs preliminary compression of air before the main compressor engages. This staged compression approach allows the turbocharger to receive air flow gradually, preventing sudden air mass flow increases that could cause turbocharger stalling while still achieving high power output
Data Source
AI summary
A method is provided for controlling a pre-spin operation of a compressor of an internal combustion engine provided with a turbocharger. The presence of a turbocharger imposes additional requirements on the method. The wear of a compressor clutch is proportional to the transferred energy when the clutch is engaged. In order to reduce the wear of the compressor clutch, or increase the maximum engine speed where it is allowed to engage the compressor, a compressor pre-spin operation is used to reduce the transferred energy when the clutch is engaged. The pre-spin is achieved by controlling the air mass flow over the compressor by controlling a bypass throttle angle of a bypass throttle. The bypass throttle is provided in a parallel conduit to the compressor, bypassing the compressor. Since the air mass flow over the compressor affects the air mass flow to the turbocharger, the method takes the turbocharger into consideration.