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This paper presents an investigation into the NOx reduction role and turbocharger optimization played by the exhaust manifold by exploring the impact of the exhaust manifold design on turbocharger and engine operation. Exhaust manifold performance is defined as the measure of the exhaust manifold to: (1) optimize cylinder scavenging efficiency and (2) minimize the pressure differential between the compressor discharge and the turbine inlet by exploiting the blow-down pressure pulses and minimizing the static pressure gradient along the exhaust manifold. Pressure pulses in the exhaust manifold have been identified as a plausible mechanism thathinders efficient cylinder scavenging and turbocharger operating range. While modifying the ports and manifold may not be cost effective, a complete understanding of and the ability to address the impact of these pressure waves on turbocharger performance and scavenging efficiency will lead to more reliable engine upgrade projects as the industry approaches the 0.5g/bhp-hr engine. Specifically, the research team used modeling techniques supported by a rich set of field test data to develop a set of guidelines for exhaust manifold designs that: (1) takes advantage of or minimizes the negative impact of blow-down pulses, (2) allows for optimal cylinder scavenging, and (3) minimizes the overall pressure differential between the compressor discharge and turbine inlet to increase the turbocharger operating range. Ultimately, these guidelines will help lead to the concept of first-time/every-time upgrade success.
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