Performance analysis and its experiments of turbochargers with 3 types of cooling structures

doi:10.3969/j.issn.1674-8484.2026.02.009

Abstract

Abstract:

A combined simulation and an experimental approach were adopted on a marine power platform and compared the cooling characteristics of three turbocharger exhaust devices: dry-type (DTC), single water-cooled (SWC), and double water-cooled (DWC), to optimize the thermal management strategy of turbochargers and to balance the energy-saving and the emission performances. The results indicate that while the DWC scheme significantly reduces the exhaust pipe outlet temperature by 32 ℃, its filter smoke number (FSN) of 1.6 exceeds the national standard limit of 1.5, and its brake specific fuel consumption (BSFC) of 203.8 g/kWh is approximately 3.8% higher than that of the DTC scheme (196.4 g/kWh). In contrast, the SWC scheme maintains a reasonable exhaust pipe outlet temperature of 418 ℃, achieves an FSN of 1.17 which complies with emission regulations, and has a BSFC of 204.9 g/kWh comparable to the DWC scheme. Consequently, the SWC scheme achieves the best balance among thermal management, emission compliance, and fuel economy, making it the optimal engineering solution with the best comprehensive performance.

Key words: turbochargers, thermal management, cooling performances, smoke emission, fuel economy

CLC Number:

TK421.8

ZHANG Chaowei, LI Song, LÜ Baicang, KANG Xiuchen, DING Kaifang, BAI Yachen, WANG Ziyi. Performance analysis and its experiments of turbochargers with 3 types of cooling structures[J]. Journal of Automotive Safety and Energy, 2026, 17(2): 236-243.

Figures/Tables 18

References 14

[1]	ZHAO Dan, LI Lei. Effect of choked outlet on transient energy growth analysis of a thermoacoustic system[J]. *Appl Energ, 2015, 160*: 502-510. doi: 10.1016/j.apenergy.2015.09.078 URL
[2]	Mezher H, Chalet D, Migaud J, et al. The application of a wave action design technique with minimal cost on a turbocharged engine equipped with water cooled charge air cooler aimed for energy management[J]. *Energy Procedia*, 2013, 36: 948-957. doi: 10.1016/j.egypro.2013.07.108 URL
[3]	SU Jianye, XU Min, LI Tie, et al. Combined effects of cooled EGR and a higher geometric compression ratio on thermal efficiency improvement of a downsized boosted spark-ignition direct-injection engine[J]. *Energ Conv Manag*, 2014, 78: 65-73. doi: 10.1016/j.enconman.2013.10.041 URL
[4]	黄立, 陈晓轩, 李先南, 等. 船用柴油机涡轮增压技术发展现状[J]. 推进技术, 2020, 41(11): 2438-2449.
	HUANG Li, CHEN Xiaoxuan, LI Xiannan, et al. Develop-ment status of turbocharging technology for marine diesel engines[J]. *J Prop Tech*, 2020, 41(11): 2438-2449. (in Chinese)
[5]	Salameh G, Goumy G, Chesse P. Water cooled turbocharger heat transfer model initialization: Turbine and compressor quasi-adiabatic maps generation[J]. *Appl Ther Engi, 2021, 185*: Paper No 116430.
[6]	LU Chunping, LI Jianyu, TAN Dongli. Analysis on the influence mechanism of cooling water on turbocharger and optimum coolant mass flow rate intelligent prediction[J]. *Math Prob Engi*, 2021, 2021(1): 1-12.
[7]	李伟, 李国祥, 白书站, 等. 涡轮增压器水冷中间壳回热改善试验研究[J]. 内燃机与配件, 2021(4): 44-45.
	LI Wei, LI Guoxiang, BAI Shuzhan, et al. Experimental study on heat recovery improvement of water-cooled intermediate shell of turbocharger[J]. *Int’l Combut Engi Acces*, 2021(4): 44-45. (in Chinese)
[8]	Ziad Y, Khalfallah S, Chenafi A, et al. Numerical and experimental investigation of a cooling technique of a turbocharger radial turbine[J]. *J Brazi Soc Mech Sci Engi*, 2024, 46(5): 1-10.
[9]	龚金科, 章滔, 胡辽平, 等. 涡轮增压器水冷轴承体冷却性能仿真研究[J]. 汽车工程, 2014, 36(3): 383-388.
	GONG Jinke, ZHANG Tao, HU Liaoping, et al. Simulation study on cooling performance of water-cooled bearing housing for turbocharger[J]. *Autom Engineering*, 2014, 36(3): 383-388. (in Chinese)
[10]	宁波威孚天力增压技术股份有限公司. 一种轻量化水冷涡轮壳涡轮增压器: CN 222615407 U[P]. 2024.
	Ningbo Weifu Tianli Pressurization Technology Co., LTD. A lightweight water-cooled turbine housing turbocharger: CN 222615407 U[P]. 2024. (in Chinese)
[11]	石永康, 陈振雷, 王勇, 等. 基于流固耦合的涡轮增压器涡轮机温度场分析[J]. 宁波大学学报: (理工版), 2021, 34(3): 7-12.
	SHI Yongkang, CHEN Zhenlei, WANG Yong, et al. Analysis of turbine temperature field of turbocharger based on fluid-structure coupling[J]. J Ningbo Univ (Sci Engi Ed), 2021, 34(3): 7-12. (in Chinese)
[12]	Romagnoli A, Martinez-Botas R. Heat transfer analysis in a turbocharger turbine: An experimental and computational evaluation[J]. *Appl Therm Engi*, 2012, 38: 58-77.
[13]	WU Binyang, JIA Zhi, LI Zhenguo, et al. Different exhaust temperature management technologies for heavy-duty diesel engines with regard to thermal efficiency[J]. *Appl Therm Engi, 2021, 186*: 116495.
[14]	Alaviyoun S, Ziabasharhagh M, Mohammadi A. A three-dimensional conjugate heat transfer model of a turbocharger turbine housing[J]. Iran J Sci Tech (Trans Mech Engi), 2022, 46(1): 71-84.

参数名称	符号	定义标准
涡轮进口温度	θ_tur,in	SAE J1828
涡端进口温度	θ_t,in	SAE J1828
涡轮出口温度	θ_t,out	SAE J1828
排气管出口温度	θ_ex,out	ISO 15550∶2016
进出口温差	Δθ_tur,ex	SAE J1828
冷却水入口温度	θ_cw,in	ISO 15550∶2016
冷却水出口温度	θ_cw,out	ISO 15550∶2016
中冷后气体温度	θ_ic,out	ISO 15550∶2016
中冷后气体压力	p_ic,out	ISO 15550∶2016
进口压力	p_in	SAE J1828
出口压力	p_out	SAE J1828
整机压损	Δp_total	SAE J1828
膨胀比	π	ISO 3046-1∶2002
燃油消耗率	BSFC	ISO 3046-1∶2002
滤纸式烟度	FSN	ISO 10054∶1998

参数名称	符号	定义标准
涡轮进口温度	θ_tur,in	SAE J1828
涡端进口温度	θ_t,in	SAE J1828
涡轮出口温度	θ_t,out	SAE J1828
排气管出口温度	θ_ex,out	ISO 15550∶2016
进出口温差	Δθ_tur,ex	SAE J1828
冷却水入口温度	θ_cw,in	ISO 15550∶2016
冷却水出口温度	θ_cw,out	ISO 15550∶2016
中冷后气体温度	θ_ic,out	ISO 15550∶2016
中冷后气体压力	p_ic,out	ISO 15550∶2016
进口压力	p_in	SAE J1828
出口压力	p_out	SAE J1828
整机压损	Δp_total	SAE J1828
膨胀比	π	ISO 3046-1∶2002
燃油消耗率	BSFC	ISO 3046-1∶2002
滤纸式烟度	FSN	ISO 10054∶1998

工况	n / (万r·min^-1)	气体域			冷却水域
工况	n / (万r·min^-1)	q_m_,in / (kg·s^-1)	θ_tur,in / ℃	出口条件	q_m_,in / (kg·s^-1)	θ_tur,in / ℃	p_out / kPa
额定	7.0	0.20	750	自由流出	7.0	73	200
怠速	5.0	0.15	650	自由流出	7.0	73	200

工况	n / (万r·min^-1)	气体域			冷却水域
工况	n / (万r·min^-1)	q_m_,in / (kg·s^-1)	θ_tur,in / ℃	出口条件	q_m_,in / (kg·s^-1)	θ_tur,in / ℃	p_out / kPa
额定	7.0	0.20	750	自由流出	7.0	73	200
怠速	5.0	0.15	650	自由流出	7.0	73	200

工况	结构	θ_tur,in / ℃	θ_t,out / ℃	θ_ex,out / ℃	Δθ_tur,ex / ℃
额定	DTC	752	667	436	316
	SWC	752	613	387	365
	DWC	752	596	334	418
怠速	DTC	648	563	323	325
	SWC	648	523	295	353
	DWC	648	507	264	384