Supercharger in Automobile

Chapter 1
INTRODUCTION
1.1 Introduction
To increase the output efficiency of any engine burn more fuel and make bigger
explosion in every cycle. It has two options for this. One way to add power is to build a
bigger engine. But bigger engines, which weigh more and cost more to build and
maintain, are not always better. Another way to add power is to make a normal-sized
engine more efficient. This can accomplish by forcing more air into the combustion
chamber. More air means more fuel can be added, and more fuel means a bigger
explosion and greater horsepower. This can be done with the help of a supercharger.

A supercharger is basically an air compressor used for forced induction of an internal

combustion engine. It does the same work as that of a compressor, i.e. it compresses the
air being delivered to the combustion chamber of an engine. The greater mass flow-rate
provides more oxygen to support combustion than would be available in a naturally-
aspirated engine, which allows more fuel to be provided and more work to be done per
cycle, increasing the power output of the engine.
Thus a supercharger is extra equipment provided in an engine so as to boost the capacity
and the torque of an engine.

The invention of the internal combustion engine, automotive engineers, speed junkies
and race car designers have been searching for ways to boost its power. One way to add
power is to build a bigger engine. But bigger engines, which weigh more, cost more to
build and maintain, are not always better.

Another way to add power is to make a normal-sized engine more efficient. You can
accomplish this by forcing more air into the combustion chamber. More air means more
fuel can be added, and more fuel means a bigger explosion and greater horsepower.
Adding a supercharger is a great way to achieve forced air induction. In this article, we'll
explain what superchargers are, how they work and how they compare to turbochargers.

A supercharger is any device that pressurizes the air intake to above atmospheric
pressure. Both superchargers and turbochargers do this. In fact, the term
"turbocharger" is a shortened version of "turbo-supercharger," its official name.

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The difference between the two devices is their source of energy. Turbochargers are
powered by exhaust gases driving a turbine. Superchargers are powered mechanically by
a belt or chain drive connected to the engine's crankshaft.

Fig. 1.1 Typical Supercharger

1.2 History
In 1849, [Link] of Birmingham, England began manufacturing a lobe pump compressor
to provide ventilation for coal mines. In 1860, the Roots Blower Company (founded by
brothers Philander and Francis Marion Roots) in the United States patented the design for
an air mover for use in blast furnaces and other industrial applications. This air mover
and Birmingham's ventilation compressor both used designs similar to that of the
later Roots-type superchargers.

In 1878, Scottish engineer Dugald Clerk designed the first supercharger which was used
with an engine. This supercharger was used with a two-stroke gas engine. Gottlieb
Daimler received a German patent for supercharging an internal combustion engine in
1885. Louis Renault patented a centrifugal supercharger in France in 1902. An early
supercharged race car was built by Lee Chadwick of Pottstown, Pennsylvania in 1908
which reportedly reached a speed of 100 mph (160 km/h).

The world's first series-produced cars with superchargers were Mercedes 6/25/40 hp and
Mercedes 10/40/65 hp. Both models were introduced in 1921 and had Roots
superchargers. They were distinguished as "Kompressor" models, the origin of the
Mercedes-Benz badging that continues today.
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On March 24, 1878, Heinrich Krigar of Germany obtained patent #4121, patenting the
first ever screw-type compressor. Later that same year on August 16 he obtained patent
#7116 after modifying and improving his original designs. His designs show a two-lobe
rotor assembly with each rotor having the same shape as the other. Although the design
resembled the Roots style compressor, the "screws" were clearly shown with 180 degrees
of twist along their length. Unfortunately, the technology of the time was not sufficient to
produce such a unit, and Heinrich made no further progress with the screw compressor.
Nearly half a century later, in 1935, Alf Lysholm, who was working for Ljungströms
Ångturbin AB (later known as Svenska Rotor Maskiner AB or SRM in 1951), patented
design with five female and four male rotors. He also patented the method for machining
the compressor rotors.

1.3 Why Supercharger?

A supercharger is used in an engine for various reasons.

 To increases the power of an engine.

 A supercharger spinning at 50,000 RPM translates to a boost of about six to nine

pounds per square inch (psi).

 To increases the torque produced.

 An efficiently working engine with supercharger can achieve the same speed in one

third of the time taken by the same engine without supercharger.

 Necessary in airplanes and jets as they have less oxygen at high altitudes. So they

provide the sufficient amount of air by compressing it to higher pressure. And

ensures complete combustion.

 Higher amount of oxygen in compressed air from supercharger ensures complete

combustion of the fuel.

 Complete combustion reduces pollution to some extent.

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Chapter 2
PRINCIPLE OF WORKING
2.1 Working
“More fuel + More air = Bigger explosion=Greater horsepower”.
Every supercharger works on the same above mentioned tagline.
It is quite evident that to get more output from any engine we need to burn more fuel.
More fuel will result in a bigger explosion in every cycle, which will then push the piston
with more thrust, and consequently this thrust will be transmitted to the wheels with the
help of crank and shaft. Wheels will rotate faster and with more power and that is how it
works.

But, to burn more fuel in an engine, we need more air in it (The chemically correct
mixture – (14: 1:: air : fuel) – is essential for an engine to operate perfectly). Thus a
supercharger compresses the air being delivered to the engine so as to supply more air in
the same, limited volume of the cylinder. This ensures complete combustion of the fuel
and no unburnt fuel comes out of the exhaust. Thus the supercharger increases the power
output of any engine.

Fig. 2.1 Working engine equipped with a supercharger

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Chapter 3
CLASSIFICATION OF SUPERCHARGERS
Based on method of compression, Superchargers can be classified as

1. Positive-displacement type, which deliver a nearly-fixed volume of air per

revolution at all speeds and a fairly constant level of boost regardless of engine
speed.

2. Dynamic compressors rely on accelerating the air to high speed and then
exchanging that velocity for pressure by diffusing or slowing it down & deliver
increasing boost with increasing engine speed.

A supercharger comes in two different variations:

Positive displacement and dynamic compressors.

A positive displacement supercharger pushes air into the engine at a constant speed,
while a dynamic supercharger uses velocity to manipulate the pressure in the air.

In either case, oxygen is compressed as it is delivered to the engine, allowing more power
to be gained from every explosion in the combustion chambers.

Fig. 3.1 Types of supercharger

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3.1 Commonly Used Superchargers

Nowadays, there are several types of superchargers used in the engines.

Following are some of the most commonly used superchargers in the market.

 Roots Superchargers

 Twin-Screw Superchargers

 Centrifugal Superchargers

3.1.1 Roots Supercharger

Constructional features: The roots supercharger is among the oldest designs for
pumping air. First implemented in early 1900, it was used as an industrial air-moving
device. In the past thirty years however, it has been used on many vehicles as a
supercharger.
The roots type supercharger is two counter-rotating meshed lobed rotors. The two rotors
trap air in the gaps between rotors and push it against the compressor housing as they
rotate towards the outlet/discharge port. During each rotation, a specific fixed amount of
air is trapped and moved to the outlet port where it is compressed, which is why the roots
type supercharger falls under the broader category of fixed-displacement superchargers
(like the twin screw supercharger). As with all positive displacement blowers, boost is
directly related to the speed of the lobes.
The roots supercharger is known for its high levels of low-rpm boost. Used often in high
torque applications such as towing, the roots blower has also seen much use in top-fuel
dragsters. The simplicity and low-rpm of the design make it a very reliable compressor.

Working of Roots Supercharger: As the meshing lobes spin, air trapped in the
pockets between the lobes is carried between the fill side and the discharge side & large
quantities of air move into the intake manifold and "stack up" to create positive pressure.
This pressurized air is received at the discharge side.
 Roots superchargers are usually large and sit on top of the engine.
 Roots superchargers are the least efficient supercharger for two reasons:
1. They add more weight to the vehicle.

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 Supercharger in Automobile

2. They provide air in discrete bursts instead of providing in a smooth &

continuous manner.

3.2 2D view of Root supercharger

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Fig. 3.3 Root supercharger

3.1.2 Twin-Screw Supercharger

Constructional features: Twin-Screw Superchargers consist of two meshing lobes

that resemble a set of worm gear. The two gears meshes in such a way that the air
pockets between them goes on decreasing as air moves ahead.
Twin Screw Supercharger also works same as other superchargers and driven from the
engine’s crankshaft via a belt or gear drive. Twin screw name has given because, it uses a
pair of spiral rotor which is identical and both are in the shape of screw. It comes under
the positive displacement device and more efficient than the roots type. It is used for
increasing air quantity in the engine cylinder for more combustion which actually leads
to more horsepower and torque from the engine. Air suction and compression process is
done in a very unique way whereas in other devices, just air gets sucked at the inlet side
and pushed at the discharge side. It looks similar to roots supercharger

Working of Twin Screw Supercharger: A twin-screw supercharger operates by

pulling air through a pair of meshing lobes that resemble a set of worm gears.
The rotors have a conical taper, which means the air pockets decrease in size as air
moves from the fill side to the discharge side. Thus a twin-screw supercharger
compresses the air inside the rotor housing.
This device starts its function from driving pulley and power transmitted to input shaft
that makes the rotors to move in the opposite direction. One of its rotors has taper teeth
section and second rotor has warm gear teeth section.
When both side of rotor pocket meshes together, air gets squeezed between them. When
air get start to compress by both side of rotor’s pockets the air flow in auxiliary motion at
inlet and transported horizontally all the way to discharge side in radial motion.
From the discharge side, the compressed air goes to intercooler, here it decreases the high
temperature to a desired low temperature and pressurized air goes into the inlet manifold
of the engine. At less temperature of the air the density of air will be greater so, more air
molecules mean more oxygen to burn more fuel to achieve more power and torque from
the engine.
As the air pockets shrink, the air is squeezed into a smaller space.

 Thus twin-screw superchargers are more efficient compared to roots supercharger.

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 Supercharger in Automobile

 They cost more because the screw-type rotors require more precision in the
manufacturing process.
 They also make a lot of noise.
 The compressed air exiting the discharge outlet creates a whine or whistle that must
be checked with noise suppression techniques.

Fig. 3.4 Twin-screw supercharger

3.1.3 Centrifugal Superchargers

Constructional features: This type of super charger is most commonly used in
automotive engines. It consists of an impeller made of alloy steels and rotates at high
speeds (about 80,000 rpm) inside a closely fitted casting. I he air enters axially at the
centre of impeller and radial vanes deflect air flow by 90°. Due to centrifugal action, high
velocity air from tip of radial vanes is passed to a diffuser or volute where air pressure
increased and then high pressure air is supplied to the engine.
This super charger is driven by engine through V-belt. Due to entry of high pressure air,
30% more air fuel mixture can be forced in to combustion chamber.

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The supercharger consists of an inlet port, an impeller, a scroll, and a discharge port. The
air comes in the inlet port, and is hit by an impeller. The impeller must spin at speeds of
40,000 - 60,000 rotations per minute in order to create boost.
Working of Centrifugal Supercharger: As the air is drawn in the hub of the
impeller, centrifugal force causes it to radiate outward. The air leaves the impeller at high
speed, but low pressure. A diffuser converts the high-speed, low-pressure air to low-
speed, high- pressure air. Thus pressurized air is achieved.

 Impeller speeds can reach ‘50,000 to 60,000 RPM’.

 Centrifugal superchargers are the most efficient and the most common induction

systems.

 They are small, lightweight and attachable to the front of the engine.

At idle speeds, the impeller does not have enough rotational speed to produce any boost.
The impeller utilizes centrifugal forces in order to produce boost.

The impeller is the integral part of the centrifugal supercharger (depicted as black fins).
As the air comes in at the centre of the compressor blades, the impeller grabs the
incoming air from the inlet port. Fig.3.4 (1).

Since the impeller is turning at tens-of-thousands of revolutions per minute, the air is
naturally thrown back and towards the outskirts of the fins due to centrifugal forces
created by its rotational inertia. Fig.3.4 (2 &3).
"At the outside of the blades, a "scroll" is waiting to catch the air molecules. Just before
entering the scroll, the air molecules are forced to travel through a venture (depicted as
the larger grey circle), which creates the internal compression, as the air travels around
the scroll. Fig.3.4 (4).
The diameter of the scroll increases, which slows the velocity of the air, but further
increases its pressure. Fig.3.4 (5).
While a centrifugal supercharger is capable of very high levels of boost and high levels
of horsepower increase, the boost doesn't occur until high RPMs are reached (normally
the supercharger starts creating boost around 3000 RPMs).

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Fig. 3.4 Centrifugal supercharger

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Chapter 4
DRIVES USED IN SUPERCHARGERS
Drives are basically the equipments that are used to transfer power from one shaft to
another shaft. In a supercharger, drives are used to transfer part of engine power to the
supercharger. There are several types of drives used to empower a supercharger.

4.1 Mechanical:
 Belt drives (V belt, toothed belt & Flat belt).
A belt drive is one of the most popular types of power transmission methods besides gears,
chain drives, shaft couplings and lead screws.

Fig. 4.1 Belt drive

 Gear drive
Gear drives are packaged units used for a wide range of power-transmission applications.

Fig. 4.2 Gear drive

 Chain drive
Chain drive is a way of transmitting mechanical power from one place to another.

Fig. 4.3 Chain drive

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Chapter 5
SUPERCHARGER AN EDGE OVER
TURBOCHARGER
Superchargers do not suffer lag: Superchargers have no lag time because they are
driven directly by the crankshaft, whereas Turbochargers suffers lag because it takes a
few moments before the exhaust gases reach a velocity that is sufficient to drive the
impeller/turbine.
Since the superchargers are directly empowered from the engine, so as the engine starts,
the superchargers can be activated. But in the case of turbochargers they take some time
for the accumulation of exhaust gases.

Modification of the exhaust system: Installing a turbocharger requires extensive

modification of the exhaust system, but superchargers can be bolted to the top or side of
the engine, that makes them cheaper to install and easier to service and maintain.
So this becomes a problem in the case of turbochargers. It becomes a tough task to
modify the exhaust system as well as it adds an extra cost in the vehicle.

It derives power from the engine itself: Crankshaft drives superchargers so they steal
some of the engine's horsepower. A supercharger can consume as much as 20 percent of
an engine's total power output. So it can be considered as a loss of engine power.
(But because a supercharger can generate as much as 46 percent additional horsepower)
Whereas this is not the case in turbochargers, it empowers itself from the exhaust gas of
the engine, which is mainly a waste of the engine.

Shutdown procedure: No special shutdown procedure is required with superchargers as

they are not lubricated by engine oil. They can be shut down normally. Whereas
turbochargers must idle for about 30 seconds or so prior to shut down so the lubricating
oil has a chance to cool down.

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Chapter 6
ADVANTAGES, DISADVANTAGES AND
APPLICATIONS
6.1 Advantages
 Increased horsepower: adding a supercharger to any engine is a quick solution to
boosting power.
 No lag: the supercharger’s biggest advantage over a turbocharger is that it does
not have any lag. Power delivery is immediate because the supercharger is driven
by the engine’s crankshaft.
 Low RPM boost: good power at low RPM in comparison with turbochargers.
 Supercharger are relatively easy to install and don't require any major
modifications to the engine.

 Price: cost effective way of increasing horsepower.

 Higher power output.
 Better atomization of fuel.
 Better mixing of fuel and air.
 Quick acceleration of vehicle.
 Complete and smooth combustion.
 Improved cold starting.
 Reduced exhaust smoke.
 Reduced specific fuel consumption.
 Increased mechanical efficiency.

6.2 Disadvantages
 Supercharged engines produce more heat

 It required an efficient cooling system.

 They require more maintenance than turbochargers.

 If the engine is not tuned correctly, it can cause damage to the engine.

 The added weight of the supercharger can make the car harder to handle.

 More fuel consumption.

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6.3 Applications
 Superchargers are responsible for reducing the per horsepower weight of the
engines as per the requirement of the aero engines.

 In order to decrease the space which is occupied by the engine as necessitated in

the marine engines.

 In order to maintain the power of a reciprocating aircraft engine at high altitudes

supercharger is quite helpful where there is less oxygen available for combustion.

 Superchargers are used in order to improve the volumetric efficiency of

an engine at a comparatively high altitude, as in the aero engines and at high
speeds as in the racing cars.

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 Supercharger in Automobile

SUMMARY
Superchargers increase intake by compressing air above atmospheric pressure without
creating a vacuum. This forces more air into the engine, providing a boost. With the
additional air, more fuel can be added to the charge, and the power of the engine is
increased. Supercharging adds an average of 46 percent more horsepower and 31 percent
more torque. In high-altitude situations, where engine performance deteriorates because
the air has low density and pressure, a supercharger delivers higher-pressure air to the
engine so it can operate optimally.
Superchargers can result in power increase of 50 to 80 percent, making them great for
racing, towing heavy loads or just adding excitement to the typical driving experience. It
is a must use component in an airplanes. As superchargers ensure complete combustion,
it greatly reduces the pollution problem. With the use of high octane premium-grade gas,
I think it is a miracle invention for speed junkies.

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REFERENCES

[1] Vidit Saxena, Shivpratap Singh Hada, Sourabh Jain ”Performance Analysis of
Super Charger and Turbo-Charger using Ethanol Gasoline Blend”. International
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No.04,April 2016.

[2] Quijun Tang, Jianqin Fu, Jing Ping Liu, Benoit Boulet, Ligang Tan, Zhichao Zhao
“Comparison and Analysis of the Effects of various Improved Turbo-Charging
Approaches on Gasoline Engine transient performances ” 2015.

[3] Aniruddh H, Bulbule, [Link] A Pawar, ”Two Stage Turbo-Charger, Its

Matching and subsequent emission control of Diesel Engine”. International Journal
of Advanced Technology in Engineering and Science/III/IV/July-Sept 2014/55-58,
2014.

[4] Jianqin Fu, Jingping Liu, Yong Wang, Banglin Deng, Yanping Yang, Renhua
Feng, Jing Yang “A Comparative Study on various Super Charging Approaches
based on IC Engine Exhaust gas Energy Recovery”, 2013.

[5] Mohd Muqeem, “Supercharging Assisted Intercooler”, ISRO Journal of

Mechanical Engineering (IOSRJMCE), 2012.

[6] Wladyslaw Mitianiec and Lukasz Rodak, “Control Problems in a Supercharged

Spark-Ignition Engine” Journals of KONES Powertrain and Transport, 2011.

[7] [Link], C.H. Onder, L. Guzzella “EGR control of pressure wave supercharged
IC engine” 2007.

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