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Rotrex Technical Handbook
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Rotrex Technical Handbook,INTRODUCTION 4,1 THE IDEAL APPLICATION DEVELOPMENT CYCLE 5. 2 ROTREX TECHNOLOGY BASICS 7,2 1 SYSTEM OVERVIEW 7. 2 2 SUPERCHARGER INTERNAL STRUCTURE 8,2 3 TRACTION DRIVE PRINCIPLES AND KEY BENEFITS 9. 3 CHOOSING THE RIGHT ROTREX 10,3 1 GENERAL GUIDELINES 10. 3 2 SUPERCHARGER SELECTION EXAMPLE BOOSTING 105HP TO 150HP 11. 4 DESIGNING AND HANDLING INTERFACES 12,4 1 PULLEYS AND OTHER DRIVE TYPES 12.
4 2 BELT DRIVES 13,4 3 BRACKETS 16,4 4 LUBRICATION CIRCUIT 16. 4 4 1 DESIGNING A GOOD LUBRICATION CIRCUIT 17,4 4 2 INSTALLATION STARTUP AND MAINTENANCE 18. 4 5 AIR DUCTING 22,4 5 1 COMPRESSOR HOUSE ADJUSTMENT 22. 4 5 2 DUCTING 23,5 IMPORTANT NOTES AND INFO SOURCES 25. 5 1 TESTING AND VERIFICATION 25,5 2 INSTALLER AND END USER DOCUMENTATION 26.
5 3 CLAIM HANDLING 26,5 4 IMPORTANT INFORMATION SOURCES 27. 6 SUPPORT MATERIAL 28,6 1 PULLEY RING DESIGN GUIDE 28. 6 2 PULLEY RING DRAWING 29,6 3 PULLEY DISASSEMBLY PROCEDURE 30. 6 3 1 STEEL PULLEYS 30,6 3 2 ALUMINUM PULLEYS 31,6 4 BRACKET DESIGN GUIDE 32. 6 4 1 BRACKET DESIGN GUIDE FOR C8 32,6 4 2 BRACKET DESIGN GUIDE FOR C15 33.
6 4 3 BRACKET DESIGN GUIDE FOR C30 34,6 4 4 BRACKET DESIGN GUIDE FOR C38 35. 6 5 NEW APPLICATION DEVELOPMENT FEEDBACK FORM 36,6 6 CUSTOMER CLAIM FORM 37. www rotrex com RTH V1 4,Rotrex Technical Handbook,Revision updates. Version 1 1 Released 29 10 2012,o Original,Version 1 3 Released 16 05 2013. o Corrected the supercharger selection example section 3 2. o Text changed to Incorrect pulley change voids warranty in. section 6 3 to correspond to the latest version of Setup and. Maintenance leaflet V9 0,Version 1 4 Released 04 06 2014.
o Updated oil level checking procedure in section 4 4 2. o Updated maintenance procedure in section 4 4 2, o Updated bracket design guides for the C8 C15 C30 and C38. www rotrex com RTH V1 4,Rotrex Technical Handbook,Introduction. This document is intended for OEM developers and Rotrex distributors For guidance and. information please always contact the company who sold you the Rotrex supercharger or. the company from whom you intend to buy the Rotrex supercharger your Rotrex supplier. Rotrex only deals directly with approved distributors and OEM customers. This document contains important information regarding Rotrex products and services related to. the C range of superchargers C8 C15 C30 and C38 product families It is structured in 6 main. Section 1 The ideal development cycle summarizes how best to develop a successful Rotrex. installation, Section 2 Rotrex technology basics provides essential information on how a Rotrex unit. works and the benefits it brings to you and your customers. Section 3 Choosing the right Rotrex provides a useful guideline to selecting the best Rotrex. unit for a particular application, Section 4 Designing and handling interfaces Provides a series of guides to design. manufacture and installation of critical systems interfacing with the Rotrex unit pulley belt drive. bracket ducting and lubrication systems, Section 5 Important notes and info sources highlights further key considerations and.
information resources, Section 6 Support material Contains a series of appendices with important drawings. specifications and forms supporting the guidelines. Following the instructions and recommendations contained in this document is vital for a. successful Rotrex installation For the Rotrex warranty to apply all the described requirements. must be followed however throughout this handbook we have further highlighted some of the. more common mistakes to make it as easy as possible to successfully develop a new Rotrex. application, The advice and general guidelines contained in this handbook are mainly directed towards single. boosting solutions If you are considering multi boosting i e twin charged and turbo. supercharged please contact your Rotrex supplier for dedicated guidance and support Multi. boosting delivers excellent results in some applications and the added system complexity calls for. specific and targeted guidance,www rotrex com RTH V1 4. Rotrex Technical Handbook,1 The ideal application development cycle. Rotrex offers technical and commercial support to OEM customers and official Rotrex distributors. along the entire development cycle in order to ensure a proper quality level in all Rotrex based. applications The diagram below represents an ideal application development cycle. Stage Description Milestones, Phase 1 A set of desired specifications for a Naming of project.
particular application Initial base spec,specification. Takes the outcome of phase 1 and Technical analysis. Phase 2 evaluates from technical financial Market analysis. and strategic perspectives the Capability analysis. Feasibility viability of the project The outcome Revised base specification. analysis can lead to approval revision or Project plan. Takes the revised base specification Prototype test run. Phase 3 from phase 2 and verifies the design DVT, The outcome of this phase is the 0 series preparation. Design product specification for production Marketing plan. verification Approval,Implementation of product Documentation package. Phase 4 specification into manufacturing 0 series production. operation Control plan,Production, Evaluation of market response to 0 series feedback report. Phase 5 product 8 months feedback report,1 5 year feedback report.
www rotrex com RTH V1 4,Rotrex Technical Handbook, Phases 2 and 3 in red are the stages where Rotrex expertise is most important since it is here. design feedback can prevent quality and operational issues more effectively Therefore Rotrex. strongly recommends doing the following, A Choose the Rotrex supercharger that best suits your application after identifying a. business opportunity evaluating the market potential and the development. effort investment needed For this purpose you will find useful information in section 3 of. this document, B Design the main interfaces bracket drive ducting and lubrication systems For this. purpose you will find useful information in section 4 of this document. C Inform your Rotrex supplier of the outcome of your technical and market analysis The. purpose is to revise key assumptions to provide constructive feedback aimed to prevent. quality and operational issues Section 6 5 of this document contains a form for this. D Create a revised base specification based on the feedback and adjust your initial design. accordingly, E Create a project plan including test validation program and estimated product launch date. and send a summary copy to your Rotrex supplier in order to coordinate joint efforts and. synchronize key events, F Design and implement a proper approval process for the application including testing and.
documentation verification ensuring product quality For this purpose you will find useful. information in section 5 of this document, G Send regular updates along the process In case of any doubt or difficulty don t hesitate to. contact your distributor or Rotrex,www rotrex com RTH V1 4. Rotrex Technical Handbook,2 Rotrex technology basics. 2 1 System overview, The picture above shows a standard Rotrex C type supercharger system highlighting main. components and their location, Supercharger Centrifugal air compression through high speed traction drive featuring.
internal dry sump dual action oil vane pump,Oil cooler Acting as main cooling element. Canister Allowing service De foaming and venting of oil system Acting as a secondary. oil cooling element, Filter Protecting traction drive from any particles through cellulose and magnetic filtering. Pulley Connecting the supercharger to crankshaft via belt. www rotrex com RTH V1 4,Rotrex Technical Handbook,2 2 Supercharger internal structure. As the cross section above shows the supercharger contains three internal subsystems. A Input pump Connecting the pulley drive to the traction drive and powering the dual. action vane pump The dual action vane pump sucks oil from the canister pumps it into. the traction drive sucks oil from the unit sump and pumps it back out into the canister. through the cooler, B Traction drive Multiplying input speed powering the centrifugal compressor The traction. drive is covered in detail in the section traction drive principles. C Centrifugal compressor Providing boost through high efficiency turbo compressor. These interdependent subsystems work together supported by the lubrication circuit in order to. deliver optimum performance and reliability,www rotrex com RTH V1 4.
Rotrex Technical Handbook,2 3 Traction drive principles and key benefits. A traction drive transmits power through friction forces between rolling elements High speeds. low noise and high efficiency are just some of the advantages of traction drives over traditional. gear transmissions, The Rotrex patented traction drive uses a steel annulus with a small pre span to secure contact. between the roller planets and the sun shaft with a reasonable force The ramp or wedge effect. increases efficiency and reliability in the transmission by regulating the torque transfer capability. on demand through self adjusting planet geometry This is a key operational feature since friction. is highly dependent on surface pressure slip and temperature conditions in the traction fluid. Developed specially for its use in Rotrex superchargers the special traction fluid momentarily. increases viscosity under high surface pressure enhancing the traction drive performance by. securing the optimum friction between rolling elements while cooling and protecting the system. The diagram below represents the dynamics explained above. Power is transmitted through,friction forces between rolling. elements Friction given by,special traction fluid depends. Slip Pressure and slip are,Temperature kept under optimum.
conditions through the,patented ramp effect,within allowed speed. Temperature is kept within,optimum range through oil. circuit cooling cleaning,and de foaming, This unique traction drive delivers the following key benefits. Speed capability released up to 240 000 RPM depending on model. Allowing reliable utilization of highly efficient impellers delivering improved boost. conditions, Great power density around 20 kW kg resulting in unparalleled compactness. Accelerating application development and simplifying installation lower costs. Improving customer satisfaction,High efficiency,Causing less heat and requiring less energy.
www rotrex com RTH V1 4,Rotrex Technical Handbook,3 Choosing the right Rotrex. 3 1 General guidelines,Supercharger comparison table. Air inlet Air outlet,Input Max impeller, hose hose Max pressure Max flow Power range1 Max adiabatic. Model rotation speed,diameter diameter ratio kg s engine kW efficiency. direction rpm,C8 6 CCW2 34 28 240 000 1 97 0 048 20 40kW 79.
C8 8 CW2 34 28 240 000 2 23 0 065 74,C8 8 CCW2 34 28 240 000 2 23 0 065 30 55kW 74. C15 16 CW3 60 45 201 500 2 46 0 15 60 125kW 70,C15 20 CW3 60 45 180 000 2 94 0 15 75. 3 90 175kW,C15 60 CW 60 45 150 000 2 34 0 22 74,C30 64 CW3 60 50 120 000 2 68 0 28 72. C30 74 CW3 60 50 120 000 2 82 0 31 135 255kW 72,C30 84 CW3 76 50 120 000 2 82 0 32 140 265kW 72. C30 94 CW3 76 50 100 000 2 52 0 39 71,C38 61 CW3 76 63 90 000 2 90 0 48 73.
C38 71 CW3 76 63 90 000 2 82 0 55 75,C38 81 CW3 76 63 90 000 2 85 0 58 220 485kW 72. C38 91 CW3 76 63 90 000 2 94 0 63 75,3 260 530kW,C38 92 CW 89 63 90 000 2 94 0 63 75. Power output is dependent on engine type cooling of charge air cam profile and timing compression ratio etc. CCW Counter Clock Wise rotation direction seen from the pulley side. CW Clock Wise rotation direction seen from the pulley side. The amount of air delivered by the supercharger and consequently the boost pressure is. determined by the supercharger model and the impeller speed in conjunction with the engine size. and speed The comparison table above shows the working area of each supercharger model. within the C range For compressor maps please refer to the technical datasheets see section. 5 4 If in doubt please contact your Rotrex supplier. Regardless of the supercharger type and model always make sure to run it within its appropriate. operating speed range specified in the technical datasheet Exceeding these speed values will. void warranty, The optimum supercharger for a given application will depend on lots of variables of which many. are hard to know accurately i e volumetric efficiency or how this will be affected under boost. conditions This can very well be modelled using advanced engine calculation tools and theory. However using a simple rule of thumb along with the information provided here and in the. flowcharts will be adequate in many cases,www rotrex com RTH V1 4. Rotrex Technical Handbook, 3 2 Supercharger selection example boosting 105hp to 150hp.
The following example runs through the process for a given engine in order to provide a more. detailed explanation of how to choose the best supercharger fit for a given application This. example is to be seen as a basic guideline and may vary depending on engine variables. The key to selecting the right supercharger is to know what air flow and pressure ratio you will be. Rotrex Technical Handbook www rotrex com RTH V1 4 10 3 Choosing the right Rotrex 3 1 General guidelines 1 Power output is dependent on engine type cooling of charge air cam profile and timing compression ratio etc 2 CCW Counter lock Wise rotation direction seen from the pulley side

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