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Blower Briefing
The term
"supercharger" is quite descriptive. Inside normally-aspirated or
"atmospheric" engines, when the intake valve opens, downward
movement of the piston creates lower pressure and the difference
between that and atmospheric pressure causes air to flow into or
"charge" the cylinder. In fact, automotive engineers describe what
flows into the cylinder as "charge air".
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After
150+ years the Roots blower is still the best thing to
use on a Nitro Class drag racing engine. On the top of
this Top Fuel Dragster's 500-in. BAE Hemi is a
state-of-the-art, Gibson-Miller supercharger. This
engine produces about 8000-hp@8200rpm. The supercharger
takes about 500-hp of that to run when it's making high
boost. If the Roots Brothers were alive today, they'd
probably fall-over in astonishment at this use of their
invention or, at least, they'd be deafened by the noise
a Top Fueler makes. Image: Author. |
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If we
increase the intake manifold pressure above atmospheric such
that the pressure differential between it and inside the
cylinder is greater, causing a larger mass of air tp flow into
the cylinder than could by atmospheric pressure, alone; we'd
be "super" charging the cylinders so, when an engine is
"supercharged", there's usually some external device
increasing the mass of, or compressing, the charge air going
into the engine. Of course, with that extra air, we can burn
more fuel and the result is more power–of which we can never
get enough, right?
How much
compression occurs is sometimes expressed in
pounds-per-square-inch (psi) above atmo-spheric pressure and is
called "boost", ie: "five pounds boost" pressurizes the
engine's intake tract five psi above atmospheric. The maximum
boost made by most superchargers on production-based,
street-driven gasoline automotive engines is 5-10 pounds. With
the addition of a supercharger, making 7 psi, to most
gasoline-fueled, automotive engines, a 50% increase in torque
output is common and 75% is not unusual. In the case of a THR
Supercharged Silverado the increase is about 60%
There are several types of superchargers: |
"Roots", "Lysholm
screw", "centrifugal" and "axial-flow", all of which are
engine-driven, and "turbosupercharger" in which exhaust gas flow
spins a turbine joined to the impeller of a centrifugal
supercharger. For this briefing, we're concerned with the Roots
because that’s what the Magnuson Radix, used on Tom Henry Racing
Supercharged Silverados, is.
A common, but
perhaps more correct, term for a Roots supercharger is "blower. One
defining characteristic of a Roots is that charge air compression
occurs outside the supercharger, in the space between it and the
intake valves. In effect, it blows air into the intake manifold
where it becomes compressed due to the system's pushing more air in
than can flow out.
The Roots blower
was patented in 1860 by two brothers, Philander and Francis Roots,
as a ventilating device for blast furnaces, grain elevators and coal
mines. In the last half of the 19th century they were quite common
in those applications and that ancestry is key to understanding that
a Roots is a device which moves air rather than compresses it.
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In the early part
of the 20th Century, engineers perfected supercharging in
motorsports and aircraft applications using primarily centrifugal
superchargers. In the '30s, Roots blowers gained acceptance in Grand
Prix and Indianapolis racing and on some expensive, high-performance
sports cars of the period. Starting in the late-'30s, General Motors
began using large Roots blowers on the diesels it built for its GMC
heavy-duty trucks, its marine customers and its Electromotive
Division locomotives. In the 1950s, drag racers and Bonneville Salt
Flats competitors adapted GMC blowers to racing engines. Today,
Roots blowers are still quite common in motorsports, especially drag
racing.
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The Magnuson
"Radix" supercharger in GM, Vortec truck engine trim.
Magnuson makes both the intake manifold and the blower case. The
drive and the guts of the blower are Eaton parts used in Eaton's
model-M112 supercharger, the largest unit Eaton makes for O.E.s.
Image: Magnuson Products. |
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Later, the Roots
idea transferred to the street high-performance aftermarket and the
Eaton Corporation developed a small, compact Roots blower for
original equipment use on some performance cars, luxury sedans and,
yes, pick-up trucks. Buick, Pontiac, Ford, Lincoln, Jaguar and
Mercedes Benz are just a few brands using the Eaton blower, the
design of which is now in its fifth-generation.
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These are the
rotors from the fifth-generation Eaton supercharger. The
frosty-looking, matte-black color is the APC with partially-abrades
away during break-in leaving an enhanced lobe-to-lobe seal. The
lobes mesh as they turn and that pulls the air through the
supercharger. Image: Author |
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There are some
concerns with blowers and one is cost. A properly developed,
aftermarket supercharger kit runs several thousand dollars. Add
installation labor and you're past five large pretty quick. Because
a supercharger increases both the engine's cylinder pressure and
charge air temperature, two causes of detonation or "knock", blowers
mandate use of at least 91-octane fuel which may increase operating
cost. A "boosted" engine produces a higher volume of exhaust gases,
so engines equipped with superchargers usually need a
low-restriction exhaust system.
With aftermarket
superchargers on computer-controlled engines, the
"calibration" in the computer, software which tells |
the computer how to set the fuel
curve, spark curve, emissions controls operation and a host of other
operational parameters, can be a significant development issue. In
fact, proper engine controls calibration of a aftermarket
supercharger system requires almost as much work as developing the
supercharger hardware, itself, so a key factor in the difference
between a good aftermarket blower kit and a bad one is, often,
calibration. Lastly, don't be surprised if there is a reduction in
fuel economy. How much depends on how the engine is driven. If
boosted operation is infrequent and the blower has a bypass (which
we'll discuss momentarily), fuel mileage will be close to stock. If
you're "on boost" regularly, expect a noticeable decrease in
mileage.
Let's take a
closer look at some features of the Magnuson Radix Supercharger as
used on the THR Silverados. The word "Radix" is Latin for "root" or
"origin," an appropriate name, indeed. Radix are based upon Eaton,
fifth-generation, M112 superchargers but they're not simply "rebadged"
Eatons. Magnuson uses many of Eaton's internal pieces but
manufactures its own supercharger case, intake manifold, charge air
cooler and drive system.
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What actually
moves the air through a Roots blower is a pair of contrarotating,
tri-lobe rotors which mesh as they turn. The tighter the fit of the
lobes, the more efficient the blower is, however, there must be some
clearance or the rotors won't turn. If the clearance is too great,
the supercharger is inefficient because of leakage past the lobe
edges. If the clearance is too tight, there is a high level of
resistance to rotation. To both tighten rotor clearance and reduce
friction, one trick Eaton began using with its fifth-generation
Roots is to coat each rotor with an abradable powder coating or (APC).
During the break-in period, in the first few hundred miles of
operation, a small portion of this coating abrades away, leaving the
contact areas at the tips of the rotor lobes perfectly matched to
each other and able to run extremely close. |
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This is
Magnuson's Radix case. At top left, just inside the
blower inlet is the bypass valve butter fly. At lower
right, on the side of the blower case if the vacuum
motor that operates the valve. Image: Magnuson Products. |
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Eaton rotors are
twisted 60 degrees. Helical rotors, along with specially designed
inlet and outlet port geometry in the blower case, help to reduce
pressure variations resulting in a smooth discharge of air and a
lower level of noise during operation. This arrangement, also,
improves efficiency. With helical rotors, the supercharger can run
at up to 14,000 rpm, making for a small blower for a given boost and
air flow output. The Eaton's axial intake further reduces package
size.
Another "secret
of the Radix" its bypass valve. This small valve, between the the
throttle body and the intake manifold, increases fuel economy and
reduces parasitic power loss. The bypass is operated by a vacuum
actuator and is normally closed. When manifold pressure is low (high
vacuum typical of light throttle operation) the actuator opens the
valve, allowing charge air to flow from the throttle body directly
into the intake manifold, bypassing the blower and equalizing
pressure in the system. The bypass valve open at low manifold
pressure eliminates parasitic loss in a practical sense. Magnuson
superchargers running with an open bypass consume only about one
horsepower. When the supercharger begins to make boost, the bypass
valve snaps closed, allowing pressure to build in the intake ports.
All Radix used in
THR applications have a "charge air cooler" which some call an
intercooler. During compression, charge air temperature rises.
Because a temperature increase reduces air density, negating some of
the effect of compression, and makes the engine more prone to
detonation; there is an advantage in cooling the air after it exits
the blower but before it goes into the cylinders. The Radix charge
air cooler is built into the intake manifold.
Lastly, Radix
systems used on THR Supercharged Silverados are approved by the
California Air Resources Board. The CARB "E.O. number" makes them
street-legal in all 50 states, including California with its
stringent "Smog Check" program.
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