Performance analysis of a feasible air-cycle refrigeration system for road transport

The performance of an air-cycle refrigeration unit for road transport, which had been previously reported, was analysed in detail and compared with the original design model and an equivalent Thermo King SL200 vapour-cycle refrigeration unit. Poor heat exchanger performance was found to be the major contributor to low coefficient of performance values. Using state-of-the-art, but achievable performance levels for turbomachinery and heat exchangers, the performance of an optimised air-cycle refrigeration unit for the same application was predicted. The power requirement of the optimised air-cycle unit was 7% greater than the equivalent vapour-cycle unit at full-load operation. However, at part-load operation the air-cycle unit was estimated to absorb 35% less power than the vapour-cycle unit. The analysis demonstrated that the air-cycle system could potentially match the overall fuel consumption of the vapour-cycle transport refrigeration unit, while delivering the benefit of a completely refrigerant free system.

Numerical and Experimental Study of the Performance Effects of Varying Vaneless Space and Vane Solidity in Radial Inflow Turbine Stators.

An extensive experimental program has been carried out on a 135?mm tip diameter radial turbine using a variety of stator designs, in order to facilitate direct performance comparisons of varying stator vane solidity and the effect of varying the vaneless space. A baseline vaned stator was designed using commercial blade design software, having 15 vanes and a vane trailing edge to rotor leading edge radius ratio (Rte/rle) of 1.13. Two additional series of stator vanes were designed and manufactured; one series having varying vane numbers of 12, 18, 24, and 30, and a further series with Rte/rle ratios of 1.05, 1.175, 1.20, and 1.25. As part of the design process a series of CFD simulations were carried out in order to guide design iterations towards achieving a matched flow capacity for each stator. In this way the variations in the measured stage efficiency could be attributed to the stator passages only, thus allowing direct comparisons to be made. Interstage measurements were taken to capture the static pressure distribution at the rotor inlet and these measurements were then used to validate subsequent numerical models. The overall losses for different stators have been quantified and the variations in the measured and computed efficiency were used to recommend optimum values of vane solidity and Rte/rle.

A Comparison of the Flow Structures and Losses Within Vaned and Vaneless Stators for Radial Turbines

This paper details the numerical analysis of different vaned and vaneless radial inflow turbine stators. Selected results are presented from a test program carried out to determine performance differences between the radial turbines with vaned stators and vaneless volutes under the same operating conditions. A commercial computational fluid dynamics code was used to develop numerical models of each of the turbine configurations, which were validated using the experimental results. From the numerical models, areas of loss generation in the different stators were identified and compared, and the stator losses were quantified. Predictions showed the vaneless turbine stators to incur lower losses than the corresponding vaned stator at matching operating conditions, in line with the trends in measured performance.. Flow conditions at rotor inlet were studied and validated with internal static pressure measurements so as to judge the levels of circumferential nonuniformity for each stator design. In each case, the vaneless volutes were found to deliver a higher level of uniformity in the rotor inlet pressure field. [DOI: 10.1115/1.2988493]

An Impact Of Various Shroud Bleed Slot Configurations And Cavity Vanes On Compressor Map Width And The Inducer Flow Field

This paper describes an investigation of map width enhancement and a detailed analysis of the inducer flow field due to various bleed slot configurations and vanes in the annular cavity of a turbocharger centrifugal compressor. The compressor under investigation is used in a turbocharger application for a heavy duty diesel engine of approximately 400 hp. This investigation has been undertaken using a computational fluid dynamics (CFD) model of the full compressor stage, which includes a manual multiblock-structured grid generation method. The influence of the bleed slot flow on the inducer flow field at a range of operating conditions has been analyzed, highlighting the improvement in surge and choked flow capability. The impact of the bleed slot geometry variations and the inclusion of cavity vanes on the inlet incidence angle have been studied in detail by considering the swirl component introduced at the leading edge by the recirculating flow through the slot. Further, the overall stage efficiency and the nonuniform flow field at the inducer inlet have been also analyzed. The analysis revealed that increasing the slot width has increased the map width by about 17%. However, it has a small impact on the efficiency, due to the frictional and mixing losses. Moreover, adding vanes in the cavity improved the pressure ratio and compressor performance noticeably. A detail analysis of the compressor with cavity vanes has also been presented.

Map Width Enhancement Technique for a Turbocharger Compressor

This paper presents an investigation of map width enhancement and the performance improvement of a turbocharger compressor using a series of static vanes in the annular cavity of a classical bleed slot system. The investigation has been carried out using both experimental and numerical analysis. The compressor stage used for this study is from a turbocharger unit used in heavy duty diesel engines of approximately 300 kW. Two types of vanes were designed and added to the annular cavity of the baseline classical bleed slot system. The purpose of the annular cavity vane technique is to remove some of the swirl that can be carried through the bleed slot system, which would influence the pressure
ratio. In addition to this, the series of cavity vanes provides a better guidance to the slot recirculating flow before it mixes with the impeller main inlet flow. Better guidance of the flow improves the mixing at the inducer inlet in the circumferential direction. As a consequence, the stability of the compressor is improved at lower flow rates and a wider map can be achieved. The impact of two cavity vane designs on the map width and performance of the compressor was highlighted through a detailed analysis of the impeller flow field. The numerical and experimental study revealed that an effective vane design can improve the map width and pressure ratio characteristic without an efficiency penalty compared to the classical bleed slot system without vanes. The comparison study between the cavity vane and noncavity vane configurations presented in this paper showed that the map width was improved by 14.3% due to a significant reduction in surge flow and the peak pressure ratio was improved by 2.25% with the addition of a series of cavity vanes in the annular cavity of the bleed slot system.

An Experimental Assessment of the Effects of Stator Vane Tip Clearance and Back Swept Blading on an Automotive Variable Geometry Turbocharger

Off-design performance is of key importance now in the design of automotive turbocharger turbines. Due to automotive drive cycles, a turbine that can extract more energy at high pressure ratios and lower rotational speeds is desirable. Typically a radial turbine provides peak efficiency at U/C values of 0.7, but at high pressure ratios and low rotational speeds, the U/C value will be low and the rotor will experience high values of positive incidence at the inlet. The positive incidence causes high blade loading resulting in additional tip leakage flow in the rotor as well as flow separation on the suction surface of the blade. An experimental assessment has been performed on a scaled automotive VGS (variable geometry system). Three different stator vane positions have been analyzed: minimum, 25%, and maximum flow position. The first tests were to establish whether positioning the endwall clearance on the hub or shroud side of the stator vanes produced a different impact on turbine efficiency. Following this, a back swept rotor was tested to establish the potential gains to be achieved during off-design operation. A single passage CFD model of the test rig was developed and used to provide information on the flow features affecting performance in both the stator vanes and turbine. It was seen that off-design performance was improved by implementing clearance on the hub side of the stator vanes rather than on the shroud side. Through CFD analysis and tests, it was seen that two leakage vortices form, one at the leading edge and one after the spindle of the stator vane. The vortices affect the flow angle at the inlet to the rotor, in the hub region. The flow angle is shifted to more negative values of incidence, which is beneficial at the off-design conditions but detrimental at the design point. The back swept rotor was tested with the hub side stator vane clearance configuration. The efficiency and MFR were increased at the minimum and 25% stator vane position. At the design point, the efficiency and MFR were decreased. The CFD investigation showed that the incidence angle was improved at the off-design conditions for the back swept rotor. This reduction in the positive incidence angle, along with the improvement caused by the stator vane tip leakage flow, reduced flow separation on the suction surface of the rotor. At the design point, both the tip leakage flow of the stator vanes and the back swept blade angle caused flow separation on the pressure surface of the rotor. This resulted in additional blockage at the throat of the rotor reducing MFR and efficiency.

Effects of Inlet Temperature Uniformity and Nonuniformity on the Tip Leakage Flow and Rotor Blade Tip and Casing Heat Transfer Characteristics

High thermal load appears at the blade tip and casing of a gas turbine engine. It becomes a significant design challenge to protect the turbine materials from this severe situation. As a result of geometric complexity and experimental limitations, computational fluid dynamics tools have been used to predict blade tip leakage flow aerodynamics and heat transfer at typical engine operating conditions. In this paper, the effect of turbine inlet temperature on the tip leakage flow structure and heat transfer has been studied numerically. Uniform low (444 K) and high (800 K) inlet temperatures and nonuniform (parabolic) temperature profiles have been considered at a fixed rotor rotation speed (9500 rpm). The results showed that the change of flow properties at a higher inlet temperature yields significant variations in the leakage flow aerodynamics and heat transfer relative to the lower inlet temperature condition. Aerodynamic behavior of the tip leakage flow varies significantly with the distortion of turbine inlet temperature. For more realistic inlet condition, the velocity range is insignificant at all the time instants. At a high inlet temperature, reverse secondary flow is strongly opposed by the tip leakage flow and the heat transfer fluctuations are reduced greatly.

Design and testing of transonic linear cascade tunnel with optimized slotted walls

In linear cascade wind tunnel tests, a high level of pitchwise periodicity is desirable to reproduce the azimuthal periodicity in the stage of an axial compressor or turbine. Transonic tests in a cascade wind tunnel with open jet boundaries have been shown to suffer from spurious waves, reflected at the jet boundary, that compromise the flow periodicity in pitch. This problem can be tackled by placing at this boundary a slotted tailboard with a specific wall void ratio s and pitch angle a. The optimal value of the s-a pair depends on the test section geometry and on the tunnel running conditions. An inviscid two-dimensional numerical method has been developed to predict transonic linear cascade flows, with and without a tailboard, and quantify the nonperiodicity in the discharge. This method includes a new computational boundary condition to model the effects of the tailboard slots on the cascade interior flow. This method has been applied to a six-blade turbine nozzle cascade, transonically tested at the University of Leicester. The numerical results identified a specific slotted tailboard geometry, able to minimize the spurious reflected waves and regain some pitchwise flow periodicity. The wind tunnel open jet test section was redesigned accordingly. Pressure measurements at the cascade outlet and synchronous spark schlieren visualization of the test section, with and without the optimized slotted tailboard, have confirmed the gain in pitchwise periodicity predicted by the numerical model. Copyright © 2006 by ASME.

Multi-Fidelity Multidisciplinary Whole Engine Thermo-Mechanical Design Optimization

Traditionally, the optimization of a turbomachinery engine casing for tip clearance has involved either twodimensional transient thermomechanical simulations or three-dimensional mechanical simulations. This paper illustrates that three-dimensional transient whole-engine thermomechanical simulations can be used within tip clearance optimizations and that the efficiency of such optimizations can be improved when a multifidelity surrogate modeling approach is employed. These simulations are employed in conjunction with a rotor suboptimization using surrogate models of rotor-dynamics performance, stress, mass and transient displacements, and an engine parameterization.

Meanline Modeling of Inlet Recirculation in Automotive Turbocharger Centrifugal Compressors

This study provides a novel meanline modeling approach for centrifugal compressors. All compressors analyzed are of the automotive turbocharger variety and have typical upstream geometry with no casing treatments or preswirl vanes. Past experience dictates that inducer recirculation is prevalent toward surge in designs with high inlet shroud to outlet radius ratios; such designs are found in turbocharger compressors due to the demand for operating range. The aim of the paper is to provide further understanding of impeller inducer flow paths when operating with significant inducer recirculation. Using three-dimensional (3D) computational fluid dynamics (CFD) and a single-passage model, the flow coefficient at which the recirculating flow begins to develop and the rate at which it grows are used to assess and correlate work and angular momentum delivered to the incoming flow. All numerical modeling has been fully validated using measurements taken from hot gas stand tests for all compressor stages. The new modeling approach links the inlet recirculating flow and the pressure ratio characteristic of the compressor. Typically for a fixed rotational speed, between choke and the onset of impeller inlet recirculation the pressure ratio rises gradually at a rate dominated by the aerodynamic losses. However, in modern automotive turbocharger compressors where operating range is paramount, the pressure ratio no longer changes significantly between the onset of recirculation and surge. Instead the pressure ratio remains relatively constant for reducing mass flow rates until surge occurs. Existing meanline modeling techniques predict that the pressure ratio continues to gradually rise toward surge, which when compared to test data is not accurate. A new meanline method is presented here which tackles this issue by modeling the direct effects of the recirculation. The result is a meanline model that better represents the actual fluid flow seen in the CFD results and more accurately predicts the pressure ratio and efficiency characteristics in the region of the compressor map affected by inlet recirculation.