DAMON JURKIEWICZ
Industrial Design
WASTE EXHAUST TURBO ENGINE ACCESSORY DRIVE
This pile of precisely machined, modified and matched parts assembles into a unit that takes potentially useful thermally expanded waste exhaust gasses and puts them to use doing work around the engine compartment. The investigation was targeted at using two of these devices on a Humvee to drive the engine accessories through the main serpentine belt. Theoretically they would provide a 10 horsepower boost per unit. The unit is made from an off the shelf T04 turbo hot side and center section, we utilized an oil cooled and lubricated gearless reduction drive from a modern supercharger and my own adaptive parts to put it all together. I'm happy to report the thing actually worked!
This was a super critical fit. The turbine output shaft is a light press fit into the connector shaft. The shaft is threaded internally to draw the parts together and they self tighten due to the direction of rotation. These tolerances need to be within .0002" of perfect parallelism and concentricity in order not to explode.
The next steps are adding the spacer body and reduction drive. There is very limited end float to work with on the turbo end of this assembly so shaft length and spacer length are very critical. The needed to be held within .002" total stack up in one direction to prevent binding once they are all fitted together.
Here is the assembled unit ready for installation. I'm still waiting for pictures of the on vehicle tests, since this was a Department Of Defense project I'm not sure when I will be seeing those pictures but i was told that both units worked as expected. I'm still trying to understand why this approach was chosen over a more efficient turbo driven alternator. That would have been lighter weight, much easier to situate anywhere you might want to put it and it plugs right into your regen/hybrid system.