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The Turbocharger: The Exhaust Drives the Compressor
An engine throws away a large part of its fuel's energy as hot exhaust. In 1905–06 the Swiss engineer Alfred Büchi proposed putting a turbine in the exhaust to drive a compressor that forces extra air into the cylinders — so the engine can burn more fuel for the same size. His US patent of 1911 calls it a 'Hydrocarbon Power Plant'.
It is a small gas turbine that borrows its heat from the engine. Its compressor heats the air it compresses, which is why a charge-air cooler usually follows it; and its wheels turn at tens of thousands of revolutions per minute.
This rung works out the density gain with and without a cooler, and reads a real compressor wheel.
Intermediate
About 3 hours
Instructions
1
1
Büchi's loop
Büchi's loop
Blockly Workspace
Loading Blockly workspace...
2
2
Read the 1906 application
Read the 1906 application
US 1,006,907, 'Hydrocarbon Power Plant', Alfred Büchi, filed 30 October 1906, granted 24 October 1911. The drawing shows piston cylinders, a working turbine fed by their exhaust, and *"a turbine-compressor"* that *"draws"* the charging mixture and *"forces"* it into the cylinders. The specification talks of the charging mixture being *"cooled"* — the charge-air cooler is in the idea from the start.
3
3
Density gain and wheel speed
Density gain and wheel speed
Loading Jupyter Notebook...
4
4
Read a compressor wheel
Read a compressor wheel
Take a turbocharger compressor wheel and measure it with calipers: the **inducer** (the small diameter where air enters, at the nose), the **exducer** (the full diameter at the back), and the blade height at each.
Look at the blades from the front. They lean into the direction of rotation at the inducer, to scoop the air in, and at the exducer they sweep backward — a backward-curved centrifugal wheel, like the pump impeller in batch 150 but made for air and for enormous speed. Count the full blades and the shorter splitter blades between them: splitters add blade area at the rim without choking the inlet.
Put the exducer diameter into the notebook's speed table.
Tools needed:
Digital Caliper 6-Inch
Steel Ruler
Turbocharger Compressor Wheel5
5
Low boost: find out why
Low boost: find out why
The usual causes of a turbocharger that will not make its boost, in order.
Flow
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6
6
History and context
History and context
**US 1,006,907, 'Hydrocarbon Power Plant', Alfred Büchi; filed 30 October 1906, granted 24 October 1911.** Büchi went on to apply exhaust turbocharging to large diesel engines, where it became standard; aircraft engines used turbochargers to hold their power at altitude; and today most car and truck diesels are turbocharged.
**Honest limits.** Turbo lag: at low engine speed there is little exhaust and little boost. The turbine side runs very hot and the bearings depend on clean oil. Boost raises cylinder pressures and temperatures, so the engine must be built for it. **A running turbocharger is a hazard** — its wheels can suck in a hand-held object or fingers and fail explosively.
Tools Required
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