Turbochargers are used to make internal combustion engines more efficient – ​​but their benefits aren’t limited to just those engines. Fuel cells also require compressed air, which is provided by the turbocharger.

Our Key Technology: Turbochargers

The turbocharger is an integral component of the engine design concept. It shapes the characteristics of the engine more than almost any other system, as it affects its economy, dynamics and emissions characteristics. That’s why turbocharging is one of MTU’s key technologies. MTU has a tradition of maintaining in-house expertise in developing and manufacturing turbochargers. The range of mtu turbochargers covers engine power ratings from 400 to 10,000 kW. Turbochargers are purchased for engine designs that can use synergy effects with the commercial vehicle industry. The global market for turbochargers is dominated by automobile and commercial vehicle applications. In comparison, the number of turbochargers installed on industrial engines is insignificant. As a result, turbocharger manufacturers rarely produce custom designs for industrial engine manufacturers. Where customers’ engine requirements cannot be met with purchased turbochargers, mtu develops and manufactures turbochargers itself.

Considering all engine lines, MTU produces approximately 50 percent of its turbochargers in-house. The current MTU turbocharger range covers five series, ZRT 12, ZRT 13, ZRT 35, ZRT 36 and ZRT 57 (see Figure 1) and is based on the concept of using as many common parts as possible. For example, for the new Series 4000 engine with regulated two-stage turbocharging, all three turbochargers in the system are identical. This simplifies logistics in production and spare parts supply.

Current MTU turbocharger program (ZRT 12, 13, 35, 36, 57) MTU’s current turbocharger family consists of five series and is based on the concept of using as many common parts as possible.

Using three-dimensional calculation procedures to simulate airflow and mechanical structural loads to optimize turbocharger performance Turbochargers must maintain the required characteristics throughout their entire service life. To this end, MTU works with three-dimensional calculation procedures to simulate air flow and mechanical structural loads.

Our Developing Turbocharger Technology

In recent years, the working conditions of some applications have become more challenging. Power units are subjected to numerous load cycles, which affects the service life of turbochargers. MTU has taken these changes into account in the development of its turbochargers, further optimizing the time between overhauls (TBO) and adapting it to the engines. For example, in the case of the 4000 Series rail engines, the turbocharger TBO can be as high as 15,000 hours, depending on the number of load cycles per hour. This means shorter maintenance times and lower costs, which also applies to turbochargers. In the development processes of turbochargers, MTU takes advantage of the possibilities offered by efficient calculation and simulation tools.

When a new turbocharger is produced, it undergoes a series of analytical optimization processes in terms of thermodynamics, structural mechanics, durability, and containment strength, for example, when placed on a test bench. The analysis primarily involves the optimization of the component using three-dimensional calculation procedures to simulate airflow and mechanical structural loads (see Figure 2). In this way, MTU ensures that turbochargers have the necessary features when they finally enter service and maintain these features throughout their entire service life.