SUPERCHARGING & TURBOCHARGING

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 INDEX
Ser No Topic
1 Introduction
2 Purpose of Supercharging
3 Supercharger
4 Limitation of Supercharger
5 Components of Turbocharger
6 Construction of Turbocharger
7 Layout & Working of Turbocharger
8 Cooling of Charge
9 Advantages
10 Latest Trends
11 Symptom, Faults & Remedies
12 Difference Between Petrol & Diesel Engine
No of Slides - 26
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 INTRODUCTION
 In exhaust gas turbocharger, part of exhaust gas
energy, which would normally be wasted is used to drive a
turbine.

 The turbine shaft is connected to a compressor, which

draw air, compresses it, and then supply it to the engine.

 The increased air supply enables more fuel to be

burnt, hence the engine develops higher power. Increased
air availability improves combustion of fuel, thus leading
to lower fuel consumption and less emission.

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 PURPOSE OF SUPERCHARGING
 To raise the density of the air charge in the
cylinder.

 To raise engine power output.

 To compensate for the loss of power due to

altitude.

 To increase the engine volumetric efficiency.

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 SUPERCHARGER

 Supercharger takes drive

from engine pulley through V
belt.

 Impeller runs at high

speeds (80,000 RPM).

 About 30% more charge

can be forced into
combustion chamber.

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 LIMITATIONS OF SUPERCHARGING
 Consumes engine power

 Increases the strain on the engine

 Increases the engine size

 High noise

 Detonation tendency increases in SI engine

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 MAIN COMPONENTS OF TC
 Turbine wheel with shaft

 Central housing

 Compressor wheel

 Turbine body

 Compressor body

 Heat shield plate

 Bushes

 Oil ring both side

 Actuator assy

 Oil deflector
AUTO MECH
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 CONSTRUCTION OF TURBOCHARGER
 Turbocharger is fitted on the exhaust manifold.

 There are two drive wheel, one is turbine wheel and other is compressor
wheel.

 Both wheels are mounted on one shaft.

 Shaft is mounted through centre housing by two general bushes.

 A heat shield plate is fitted on turbine wheel side to absorb the heat.

 Two oil ring are provided on both end of the shaft to prevent from the
leaking of lubricating oil.

 A oil deflector is provided in the centre body to change the direction of oil.

 The waste gate mechanism is provided to reduce boost pressure of the

inlet manifold.
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CONSTRUCTION OF TURBOCHARGER

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LAYOUT OF TURBOCHARGER

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 WORKING OF TURBOCHARGER
 A turbocharger is a small radial fan pump driven by the engine
exhaust gases.

 A turbocharger consist of a turbine wheel and a compressor wheel

on a common shaft.

 The engine exhaust gas is used to drive a turbine

 The turbine wheel drives a compressor wheel which draw filtered

air from air filter and feeds to engine at higher pressure.

 This enable more fuel to be burnt with a greater mass of charge air.

 Better air availability enhances better combustion , thus leading

lower fuel consumption and less emission.

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 COOLING OF CHARGE
 Compressed charge is hot.

 Supercharging increasing
temperature of boost pressure.

 Density reduces when air is

heated.

 Intercooler used to cool

compressed air.

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 ADVANTAGES OF TURBOCHARGER

 Horsepower and torque are improved

 Increasing engine volumetric efficiency
 Reduce exhaust emissions
 Lower fuel consumption
 Lower weight and a smaller engine package
 Lower engine noise
 Reduced power loss at high altitude
 No drive required from engine

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 INTERNAL COMBUSTION ENGINE

Inlet valve Exhaust valve

Inlet port
Exhaust port

Connecting rod
Fuel Crank shaft
+ Air

2 Stroke engine 4 Stroke engine

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TWO STROKE

Suction stroke

Compression stroke

Power stroke

Exhaust stroke
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TWO STROKE

 Upward stroke

 Suction stroke

 Compression stroke

 Downward stroke

Power stroke
Exhaust stroke

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 TWO STROKE ENGINE
 In two stroke engine, there are two strokes in one
cycle of operation. There is one power stroke for every one
revolution of the flywheel.

First stroke (suction and compression stroke)

 During the first stroke, as the piston moves up from the

BDC, it closes all three ports, namely the inlet, transfer,
and exhaust ports.

 The piston compresses the mixture of petrol and air

inside the cylinder.
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 TWO STROKE ENGINE
 When the piston is near the TDC, the petrol mixture is
fully compressed.

 The spark plug then ignites the mixture.

 Power is produced with the burning of this mixture.

 This power is transmitted to the crankshaft through the

connecting rod during the stroke, partial vacuum is
produced inside the crankcase.

 The inlet port is opened and the petrol mixture enters

through it into the crankcase.

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 TWO STROKE ENGINE
 Second stroke (power and exhaust stroke)

 During the second stroke, the piston moves down

from the TDC and the inlet port is closed.

 The fuel mixture is compressed by the bottom of the

piston and the crank gets pushed into the cylinder
through the transfer port.

 Since the exhaust port is open the exhaust gas leaves

the cylinder through it.

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 TWO STROKE ENGINE
 Some exhaust gas may however, remain inside the
cylinder.
 The special shape of the piston head deflects the
fresh charge of the fuel mixture up into the cylinder.
 The mixture then flows down and pushes the exhaust
gas through the exhaust port.
 This process is called scavenging. Once the flywheel
has completed one revolution, the cycle of operation is
repeated.

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FOUR STROKE

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 DIESEL ENGINE VS PETROL ENGINE
Petrol engine Diesel engine
 Works on Otto cycle  Works on diesel cycle
 Fuel-air mixture is admitted  Fuel is injected at the end of
during suction stroke compression stroke
 Spark ignition  Compression ignition
 Low compression ratios  High compression ratios
 Lower engine efficiency  Higher engine efficiency
 Higher fuel consumption  Lower fuel consumption
 Lower engine vibrations and  Higher engine vibrations and
noise noise
 High running cost  Low running cost
 Light duty application  Heavy duty application
 Lighter  Heavier
 Lower maintenance cost  Higher maintenance cost
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 LATEST TRENDS

 Turbocharger with waste gate mechanism

 Twin scroll turbo
 Variable geometry turbocharger
 Variable twin-scroll turbo
 Electric turbocharger

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 SYMPTOM, FAULTS & REMEDIES
S.No Symptom Faults Remedies
Replace
Worn-out turbo shaft bush .
Adjust play
Excessive axial, radial play in
turbine shaft.
Restriction in intake manifold. Repair
Air leaks between turbo and Repair/Replace
inlet manifold.
1 Turbocharger noisy
Leakage of exhaust between Repair/Replace
manifold and cylinder head.
Loose mounting of hose Tightening
clamps or other components
Foreign particle in the exhaust Check &remove
manifold or intake duck to
compressor

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 SYMPTOM, FAULTS & REMEDIES
S.No Symptom Faults Remedies

Clogged Air cleaner. Replace

Turbo charger damaged. Replace

Restriction in intake manifold. Check & Repair
Air leaks between turbo and inlet Check & Repair
low power
1 manifold.
generation
Exhaust system restriction Check & Repair
Waste gate stuck in open position. Repair/Replace

Leakage of exhaust between Check & Repair

manifold and Cylinder head.

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 SYMPTOM, FAULTS & REMEDIES
Ser No Symptom Faults Remedies
Restriction in turbo oil drain Check/Repair

Engine crank case breather Check/Repair

Oil leakage from restriction
1
turbine Thick oil sludge or coke in turbo Check oil
center housing
Worn out valves, seats, Piston Replace
ring, liners.
Waste gate stuck in closed Repair/Replace
position
Snapped connection between Check/Repair
Boost pressure intake manifold and boost cyl.
2
is too high
Defective boost cylinder, piston Replace
jammed, piston seal leaky

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UPDATED BY

 Sub Rajesh Sangwan

 Dt – 30 Sep 2020
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