Turbocharger Air Bearing Retrofit by New Way
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- Опубликовано: 10 дек 2024
- A Volvo Turbocharger for D12 engine is retrofitted with New Way Air Bearings. Hear why eliminating oil, friction and reducing tip clearances via air bearings will set the stage for the next generation of turbochargers.
New Way Air Bearings: www.newwayairbe...
Bently Bearings: www.bentlybeari...
New Seal: www.new-seal.com
New Valve: www.new-valve.com
Love your videos. I’m hoping air bearings become more and more accessible for consumer products & retrofitting. Converting a wood lathe to air bearings for higher precision/surface finish, lower noise, and rock solid indexing when stopped, for example. Or a vinyl turntable with linear tracking that is an order of magnitude less expensive than the current options on the market.
Nice idea new way, I miss you all.
My primary concern would be how the air bearing can handle thrust loads. If you completely blocked exhaust gasses and compressed air from getting to the back of each wheel, you would largely negate thrust loads, so that could be a solution. You would then be dealing with only the much smaller thrust loading caused by the pressure on the outward faces of the compressor and turbine wheels. These could still be substantial given the possible pressure differentials, so that would need to be handled.
Nice!! Serious question? How do I get some for my Tesla turbines?!?
Awsome video en explanation! I'm really interested in how much air it uses at what pressure for the smaller version of the turbo charger, en if it's depending on the mass of the rotor how Much pressure is needed
How many thousands of hours of dyno testing has the retrofitted turbo setup done? The bench is one thing a running engine with constant changing temps, pressures and environments is totally different.
Nice job
How would you supply the air bearings with air in the D12 turbo?
The turbo itself
outstanding
Now this looks like stuff that I want to do an have a reason to get excited about 😮😊😮😊
Might be ok for trucks but cars you need a powerful compressor to run permanently which will drag power and add to the cost
Compressor wheels with flat backing are outdated designs, reason they are nit flat is you are trying to push as much rpm into the wheel as possible, and with raised back the rpm can double in some turbos so you want to avoid flat backed compressor and Turbine
Impellers with flat backs and our externally, pressurized gas bearings running on them reduce clearances that are typically required between the impeller and the rest of the state or housing. Turbo chargers should spool up quickly. The oil shear at high speed is a surprising drag on the ability of turbo chargers to spool up, this has a much bigger effect than the geometry of the impeller.
@@drewdevitt I think what he was trying to say is that the superback design is necessary for structural integrity of the compressor wheel at high speeds. It is not about sealing of any kind. However, even a superback design could obviously implement a flat area or whatever is required for sealing.
Not here to spew doubt, but my concern here is not the bearing material, well, the porous matrix to be precise, the air is the bearing material in a way, but my concern is not the capacity of the matrix to withstand the hot side, my concern lies more in the direction of the fact that as an air bearing, sure, its somewhat cooled by the air itself, but the shaft is no technically suspended, contacting absolutely nothing, as per the function of the air bearing... In such conditions, the hot side, which can get real damn hot, will heat up the impeller, thus through it, it will heat up the shaft, which being steel, will expand... How much can the ceramic or whatever matrix used, contend with steel`s thermal expansion without it becoming an issue... Being isolated, the heat can only rely on the air current to cool it somewhat, which i dont see as being adequate to cool down, what is supposed to be an ultra high precision shaft-bearing-bore system, and maintain the clearances, which as you state, should be minimal, both to run an air bearing sys, and to as you say, improve the efficiency of the turbo itself... Oil is troublesome, but it themally couples the shaft with its rotors and bearings to the housing of the turbo, which often has extra routing for engine coolant, which makes it quite a decent thermal sponge... Without oil, you dont just lose the cooling provided by the oil, but you lose the fluid coupling that allows the shaft to quickly shed heat and maintain its tolerances...
Speaking of tolerances, if you run air bearings, they require pretty high precision, or minimal tolerances... One side is cold, which will when running reduce the clearances on that end, and the other is hot, which will loosen the clearances on that end... The shaft being insulated by air, will undoubtedly suffer from that situation even more, so how do you plan on contending with that issue? The healthy turbo range is quite varied, and the clearances have to be adequate for both support of the componentry and for adequate sealing and free running... With oil, that is less of a problem, as it has some properties that are greatly reduced or not present with the air as a bearing film medium...
Im not outright denying the idea or calling it a scam, i just see some aspects from the technical standpoint which rise some questions... Not just that, but speaking of heat and tolerances, you said the thrust clearance thermal growth can be eliminated... I dont see how... The shaft is going to be heated up through the hot side rotor, no matter what you do - the air bearing air flow cooling wont be enough to impact that... That in turn will render your shaft longer, regardless of its shrinkage on the cool side... cool side is not too cool, but hot side is extremely hot, which is bound to extend and expand the shaft during running... That will affect your thrust clearances without a doubt... And again, the shaft being suspended in air, not being actively cooled by a liquid, will not benefit from any housing cooling system... You can run liquid nitrogen as coolant through the housing(ridiculous, but im just giving an overkill situation) and it will cool the housing(thus reducing your clearances on the bore - matrix surface, but the isolated shaft wont benefit from it, it will only be heated up by the hot side and minimally cooled by the air flow and the cold side... An air bearing is not an air motor, which greatly benefits from cooling air, the bearing relies on high pressure and relatively low flow, so its self-cooling capacity is quite minimal... Which normally isnt a problem, as there is no contact or friction to induce heat which would have to be lowered...
Air bearings are amazing, as a machinist, i love the concept, just as with hydra-bearings, but as a machinist, i know that some things are not used in some scenarios, exactly because of their inherent benefits that in some situations turn into absolute detriments... You know, ice skating is cool, and ice`s properties that allow you to skate are amazing, but they really fucking suck when you are trying to just walk or drive... As said, i dont want to call shit out as anything, but i do have some concerns, and those have been written down above...
Marrow porous pads mounted on springs holding the shaft
I appreciate your comments.
Especially the ones concerning thermal growth. Actually, the shaft will expand more than the poorest media so the clearance is reduce in the hot area and expand in the cool areas, especially in cryogenic Turbo machinery. 90% of turbo chargers have a shaft that’s less than half an inch in diameter and most of those are on the order of a quarter inch so even with large temperature swings the thermal growth is not great. Also the turbo chargers heat up quite quickly because of the hot exhaust gases, so we just leave enough clearance to accommodate the growth which happens quite quickly.
The ultra fast pull up and efficiency improvements by avoiding oil shear drag are huge improvements for turbo chargers. Plus, there is no oil to Coke improving the reliability and longevity of turbocharged systems.
@@drewdevitt Most glad to hear back from ya! Great, glad to hear your analysis of the system... As said, i was speculating, i know that the growth ain`t much, but being that i am not the one designing this nor researching the specific materials and applications, i still am lacking specific insights into performance of this system, especially on the long run and in the ``field``... Sure, oil/grease shear is a major drag contributor, no doubt there... Hell, even air has shear of sorts, or rather, a sort of molecular friction when it passes near something, so yeah, switching from lubricant shear to what is essentially a jig grinder spindle with the ridiculous bearing efficiency is a major deal...
As said, i didn`t come to shit on this, on the contrary, i was curious and unsure as to how well the system would operate ``not on the clean room table``... As a machine fetishist, i am aware that the field and clean room perform a lot differently, so i had to ask... And now i am glad that i did... I wonder what is the running, full temp - clearance of the spindle in those bearings, or the shaft in this case... Cant be far from a micron of few, in which case, i wonder what`s the clearance of the same part when cold...
Hell, i would love to see the dynamic graphic display of the system fluidity and fluctuation as it goes from 0-100, or rather from env. temp to full operating conditions... That would be a damn cool sight with modern cad display capacities of computers...
At any rate, i wish you all the best and you have my kindest regards!
Steuss
I've said this for years, but I've yet to understand why nobody in the industry is listening 🤦♂️
Hi James,
Yes, I have a hard time seeing why people don’t understand the advantages of gas bearings, and turbo chargers
Thanks for your reply
@drewdevitt - I see why many applications can't/don't use them. Ancillary requirements, packaging dynamic load resistance, etc... but there are sooooo many applications where these are overwhelmingly applicable, yet aren't being implemented. Turbochargers are a fine example. Integrated air supply.
It will fail
Give me job, I work for food and housing and student loans/ debts paid 😮
WHY DO YOU EXPERTS. CALL A TURBINE A TURBAN. A TURBAN IS WHAT YOU WHERE ON YOUR HEAD OK .
Wear. You wear a turban.
@@snorttroll4379 😂😂😂 YES THATS WHY I KNOW ITS A TURBINE. HOPE THAT HELPS YOU YOUNG MAN . ALL THE BEST TO YOU AND YOUR FAMILY.
You are ruining that granite surface plate. It’s for precision metrology. I hope that’s not the plate you’re using to measure your machined products off of
Where's your link? The link to your video where we can see your granite surface plate.