Project was divided into 5 workpackages:
Work Package 1: Definition Phase
This work package laid foundation to the project. Following requirements’ analysis and review of the state of the art technologies preliminary specification of the turbocharger, preliminary validation plan and project plan were created.
Work Package 2: Engineering
This work package included engineering activities necessary to create set of documents necessary to launch production of the turbocharger prototype: 3D models and drawings of all components, supporting specifications, inspection and assembly instructions and control plans, details of test plan together with requirements for test facility and production and testing tooling and equipment.
Engineering activities were grouped into 2 phases: Concept Development and Detailed Design and Analysis. Former was devoted to creating detailed technical specification which would allow meeting performance, reliability and durability targets, latter on creating detailed definition of the components. Both phases relied heavily on numerical simulations (like Computational Fluid Dynamics, Finale Elements Analysis and Rotordynamics) and thoughtful risk assessment.
Emphasis was put onto assuring design flexible enough to make it applicable for both 4 and 6 cylinder engines being developed by SMA.
Work Package 3: Manufacturing of turbocharger prototypes
Within this work package manufacturing and production of turbocharger prototypes took place.
Manufacturing methods and suppliers were chosen with the aim on simplifying transition from prototype to production. Consultation with SMA to assure planned production volumes were properly accounted for took place.
Work Package 4: Testing and analysis
Turbocharger prototype testing and post-test analysis took place here. Activities focused on verifying turbocharger prototype functionality, performance and efficiency. Testing was performed at hot gas stand, all tests were passed successfully, and subsequent hardware inspection shown prototype being in good condition.
Work Package 5: Project Management
This work package, spanned across whole duration of the project, covered all activities related to managing project’s tasks, coordinating efforts of involved participants and reporting project status and progress to EU.
Apart from aforementioned duties this actions focused on dissemination and exploitation of the results and communication activities were included.
Two comprehensive technical reports, providing details of Concept Development and Detailed Design and Analysis, serve as a good example here.
Below summary presenting key results:
• High compression ratio. Required 3.9:1 achieved without overspeeding turbocharger.
• High corrected compressor air flow. Requirements asked for 320 grams per second, 380 achieved.
• Design is able to cover all required operating points without the need to use wastegate, as required
• Requirements specified weight to be below 7.0 kg, developed prototype was 6.4 kg.
• Aeronautical certficability. SMA confirmed design is capable to fulfill requirements.
Results of the project were convincing enough for SMA to kick-start discussion about further development of the turbocharger prototype, with the goal of taking it into production.
SMA was also pleased with Pankl Turbosystems testing capabilities, so much that Pankl Turbosystems was nominated as SMA’s supplier and is providing testing services.
Last but not least - this project allowed Pankl Turbosystems to build knowledge and understanding of specific requirements of aviation turbochargers. Company was able to make inroads into General Aviation market, several projects are already ongoing, and several others are being discussed.
