Experimentally Validated Extension of the Operating Range of an Electrically Driven Turbocharger for Fuel Cell Applications

From an aerodynamic point of view, the electric turbocharger for the air supply of an automotive fuel cell faces difficult requirements: it must not only control the pressure level of the fuel cell, but it also has to operate with very high efficiency over a wide range. This paper explores features for the compressor and the turbine of an existing electric turbocharger, which are intended to meet the specific requirements of a fuel cell in an experimentally validated numerical study. Adjustable diffuser or nozzle vanes in the compressor and turbine achieve wider operating ranges but compromise efficiency, especially because of the necessary gaps between vanes and end walls. For the turbine, there are additional efficiency losses since the pivoting of the nozzle vanes leads to incidence and thus to flow separation at the leading edge of the nozzle vanes and the rotor blades. An increase in the mass flow and a slight efficiency improvement of the turbine with the low solidity nozzle vanes counteracts these losses. For the compressor, a reduction in the diffuser height and its influence over the operating range and power consumption yields an increase in surge margin as well as in maximum efficiency

Use of High-Order Curved Elements for Direct and Large Eddy Simulation of Flow over Rough Surfaces

In the present study, the curved element capabilities of a high-order solver are scrutinized for use in scale-resolving simulations regarding roughness. The approach devised not only suggests a plausible way to adopt a body-fitted grid approach as an alternative to immersed boundary method (IBM), but also enables performing LES instead of DNS without under-resolving the roughness. The method is first tested using various polynomial degrees. Then, it is validated against reference DNS-IBM results from a rough channel flow setup having various Reynolds numbers corresponding to the entire roughness range. The results confirm the validity of the new approach. Finally, a highly loaded low-pressure turbine cascade is simulated under LES resolution with and without the roughness patch. Although a rougher surface is needed for producing a more pronounced impact on the flow, the viability of this method also for pressure-gradient boundary layers is proven

Aerodynamic and aeroelastic effects of design-based geometry variations on a low-pressure compressor

In modern aircraft engines, the low-pressure compressor (LPC) is subjected to a flow characterized by strong wakes and secondary flows from the upstream fan. This concerns ultra-high bypass ratio (UHBR) turbofan engines, in particular. This paper presents the aerodynamic and aeroelastic sensitivities of parametric variations on the LPC, driven by the design considerations in the upstream fan. The goal of this investigation was to determine the influence of design-based geometry parameter variations on the LPC performance under realistic inlet flow distributions and the presence of an s-duct. Aerodynamic simulations are conducted at the design and off-design operating points with the fan outflow as the inlet boundary conditions. Based on the aerodynamic results, time-linearized unsteady simulations are conducted to evaluate the vibration amplitude at the resonance operating points. First, the bypass ratio is varied by reducing the channel height of the LPC. The LPC efficiency decreases by up to 1.7% due to the increase in blockage of the core flow. The forced response amplitude of the rotor decreases with increasing bypass ratio due to increased aerodynamic damping. Secondly, the fan cavity leakage flow is considered as it directly affects the near hub fan flow and thus the inflow of the LPC. This results in an increased total-pressure loss for the s-duct due to mixing losses. The additional mixing redistributes the flow at the s-duct exit leading to a total-pressure loss reduction of 4.3% in the first rotor at design point. This effect is altered at off-design conditions. The vibration amplitude at low speed resonance points is increased by 19% for the first torsion and 26% for second bending. Thirdly, sweep and lean are applied to the inlet guide vane (IGV) upstream of the LPC. Despite the s-duct and the variable inlet guide vane (VIGV) affecting the flow, the three-dimensional blade design achieves aerodynamic and aeroelastic improvements of rotor 1 at off-design. The total-pressure loss reduces by up to 18% and the resonance amplitude more than 10%. Only negligible improvements for rotor 1 are present at the design point. In a fourth step, the influence of axial gap size between the stator and the rotor rows in the LPC is examined in the range of small variations which shows no distinct aerodynamic and aeroelastic sensitivities. This finding not only supports previous studies, but it also suggests a correlation between mode shapes and locally increased excitaion with increasing axial gap size. As a result, potential design improvements in future fan-compressor design are suggested. © 2020 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY-NC-ND) license (https://creativecommons.org/licenses/by-nc-nd/4.0/)

Virtual Process for Evaluating the Influence of Real Combined Module Variations on the Overall Performance of an Aircraft Engine

The effects of real combined variances in components and modules of aero engines, due to production tolerances or deterioration, on the performance of an aircraft engine are analysed in a knowledge-based process. For this purpose, an aerothermodynamic virtual evaluation process that combines physical and probabilistic models to determine the sensitivities in the local module aerodynamics and the global overall performance is developed. Therefore, an automatic process that digitises, parameterises, reconstructs and analyses the geometry automatically using the example of a real turbofan highpressure turbine blade is developed. The influence on the local aerodynamics of the reconstructed blade is investigated via a computational fluid dynamics (CFD) simulations. The results of the high-pressure turbine (HPT) CFD as well as of a Gas- Path-Analysis for further modules, such as the compressors and the low-pressure turbine, are transferred into a simulation of the performance of the whole aircraft engine to evaluate the overall performance. All results are used to train, validate and test several deep learning architectures. These metamodels are utilised for a global sensitivity analysis that is able to evaluate the sensitivities and interactions. On the one hand, the results show that the aerodynamics (especially the efficiency hHPT and capacity m˙ HPT ) are particularly driven by the variation of the stagger angle. On the other hand, hHPT is significantly related to exhaust gas temperature (Tt5), while specific fuel consumption (SFC) and mass flow m˙ HPT are related to HPC exit temperature (Tt3). However, it can be seen that the high-pressure compressor has the most significant impact on the overall performance. This novel knowledge-based approach can accurately determine the impact of component variances on overall performance and complement experience-based approaches.</jats:p

Operational Modal Analysis of an Axial Compressor Rotor and Casing System for the Online Identification of a Digital Twin

Modal parameter identification can be a valuable tool in mechanical engineering to predict vibrational behaviour and avoid machine damage during operation. Operational modal analysis is an output-only identification tool motivated by the structural identification of civil engineering structures, which are excited by ambient conditions. This technique is increasingly applied in mechanical engineering in order to characterise the system behaviour during operation as modal parameters can vary under operating conditions. The following study investigates the application of operational modal analysis on an axial compressor under operating conditions. Since the modal parameters of the system change depending on the life history and during the operation of the system, a corresponding data analysis might allow us to identify the present status of the system. Eigenfrequencies and eigenvectors are studied for the use of structural health monitoring approaches. According to the analysis, eigenfrequencies represent robust parameters for the studied purpose. Eigenvectors are sensitive to damages but need further investigation, especially for rotating machinery. This study will help the user to set up a virtual model, which describes the system behaviour for different boundary conditions. This in turn, will provide an accurate prediction of the vibrational behaviour in order to assure a safe operation

Low-inertia centrifugal compressor wheels: Aerodynamic and mechanical design

A new centrifugal compressor impeller design approach is presented, focusing on electrically driven compressors for gasoline engine and fuel cell applications. The performance and mechanical integrity are evaluated based on numerical simulations. Additionally, the numerical model is applied to several variations of the diffuser and volute geometries, in order to evaluate stage characteristics for diffuser area ratios of 110% and 150%, volute area ratios from 60% to 90%, and diffuser pinch ratios from 60% to 80%. The preliminary performance results show the capability to achieve a flow range comparable to a larger state-of-the-art impeller, with minor penalties regarding stage efficiency and near surge operating stability

Experimentally Validated Extension of the Operating Range of an Electrically Driven Turbocharger for Fuel Cell Applications

From an aerodynamic point of view, the electric turbocharger for the air supply of an automotive fuel cell faces difficult requirements: it must not only control the pressure level of the fuel cell, but it also has to operate with very high efficiency over a wide range. This paper explores features for the compressor and the turbine of an existing electric turbocharger, which are intended to meet the specific requirements of a fuel cell in an experimentally validated numerical study. Adjustable diffuser or nozzle vanes in the compressor and turbine achieve wider operating ranges but compromise efficiency, especially because of the necessary gaps between vanes and end walls. For the turbine, there are additional efficiency losses since the pivoting of the nozzle vanes leads to incidence and thus to flow separation at the leading edge of the nozzle vanes and the rotor blades. An increase in the mass flow and a slight efficiency improvement of the turbine with the low solidity nozzle vanes counteracts these losses. For the compressor, a reduction in the diffuser height and its influence over the operating range and power consumption yields an increase in surge margin as well as in maximum efficiency