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Welcome. Final Presentation. April 22, 2008. Turbocharger Test Stand Development Team. 2 Tobi. Outline. Introduction Goals for Turbo Team CAGI Competition & Results CAGI Teams Engine Throttle Cable Bearing Tests & Equipment. 3 Tobi. Outline. Test Stand Development

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  1. Welcome

  2. Final Presentation April 22, 2008 Turbocharger Test Stand Development Team 2 Tobi

  3. Outline • Introduction • Goals for Turbo Team • CAGI Competition & Results • CAGI Teams • Engine • Throttle Cable • Bearing Tests & Equipment 3 Tobi

  4. Outline • Test Stand Development • Sensors and Measurements • Temperature Measurements • Flow and Pressure • Test Stand Construction/Assembly • Recirculation Line • Rig and Custom Adapter Pieces • Piping, gauges, boost, exhaust 4 Tobi

  5. Outline • Results – Test Stand • PR – Readings, • Future of the Test Stand • Issues Still Present, and Potential Resolutions • Improving – Testing Bearings on Test Stand 4 Tobi

  6. Goals of Turbocharger Test Team Research Goals: Test different bearing designs on a turbocharger to find those causing the fewest vibrationsLess emissions Longer durability ` ` Analyze turbo shaft vibrations: On a Diesel engine On a test stand powered by compressed air ` ` 5 Tobi

  7. CAGI Competition What is it? • CAGI = Compressed Air and Gas Institute • Awards Student Teams for Innovative Design Solutions Using Compressed Air Why did the team choose to participate? • Research Money • Publicity • Contact with experienced researchers in the field of compressed air • How did the team perform? • Second Place! 6 Tobi

  8. The CAGI-Teams ● Air Flow Team Francis Robert Jablonski Angela Gail Overstreet● Air Pressure Team Thomas William Goodrich Carter Keyes McGowan Tobias Mueller ● Test Stand Design Team Charles Jackson Clarke Jason William Ruhe● Marketing Team Abhishek Chowdhary Andrew Samuel Newman ● Heat and Moisture Team James Thomas East William John Papke 7 Tobi

  9. Throttle Control - Previous To operate the throttle, someone had to be in the dyno room during the run. To improve safety and convenience, the team investigated purchasing a throttle control cable. The team determined that a mechanical cable would be the best solution.

  10. Throttle Control – Current A mechanical throttle cable was ordered for under $40. The throttle controller was modified and mounted to the data acquisition cart. The cable arrived and was installed. Many successful runs have been made. Throttle controller Throttle cable

  11. Bearing Puller Design Puller required to remove o-ring bearings O-ring bearings are a tight fit Each team member submitted a design 13 Drew

  12. Final Puller Design Decided to first try a design using a rubber expanding bushing Has only 5 parts Easy to machine 14 Drew

  13. How it works: Bushing is inserted into bearing Bearing removed by pulling handle 15 Drew

  14. Bearing Test Results 36 Jason

  15. Engine Sensors • Exhaust Pressure Pre Turbo • Exhaust Gas Temperature Pre Turbo • Wideband O2 Sensor 8 Bill

  16. Why these Sensors? • Exhaust Pressure Pre Turbo • Used to see how restrictive the turbocharger turbine is • Used to calculate the density of the exhaust gas • Exhaust Gas Temperature Pre Turbo • Used to monitor the health of the engine • Used to calculate the density of the exhaust gas • Wideband O2 Sensor • Used to monitor the air-fuel ratio of the engine under different speed and load conditions • Used to calculate the actual airflow of the engine 9 Bill

  17. Exhaust Pressure Pre Turbo • First the pressure gauge had to be mounted: • Drilled and tapped exhaust manifold • Mounted copper tube to exhaust manifold • Connected other end of copper tube to oil pressure gauge • The pressure measured pre turbo was 15-20 psig, fluctuation due to exhaust pulses • Considering that the engine boost pressure is 19.2 psi this pressure measurement pre turbo is acceptable 10 Bill

  18. Exhaust Gas Temperature Pre Turbo Mounted the EGT probe using the tapped hole for the pressure gauge Measured an exhaust gas temperature of about 1280ºF at operating point, 570ºF at an unloaded 2500 RPM, and 270ºF at idle Can use the exhaust gas temperature and the pressure of the exhaust pre turbo to find the density of the exhaust gas entering the turbine of the turbocharger 11 Bill

  19. Wideband O2 Sensor To install the wideband O2 sensor, first a bung was welded onto the exhaust and the sensor was screwed into this bung Then the wideband O2 sensor controller was wired up Team laptop is used to view the air-fuel ratio of the engine under all operating conditions Under operating conditions, the Cummins engine showed an air-fuel ratio of about 22.8:1 12 Bill

  20. Temperature Analysis • Engine Temperatures • Test Stand Temperatures • Temperature Conflicts • Test Stand Solutions 16 JT

  21. Engine Temperatures • Engine Air Flow System Temperatures • Turbine Inlet Temp. : 1280F • Turbine Outlet Temp. : 1030F • Engine Oil System Temperatures • Inlet Temp : 150-225F • How do the high temperatures effect the turbo? The change in temperature increases work due to energy from enthalpy. 17 JT

  22. Test Stand Temperatures Test Stand Air Flow System Temperatures Turbine Inlet temperature : 75 Turbine Outlet Temperature : 40-50 Test Stand Oil System Temperatures Inlet Temp : 180F Why are these temperatures so low? Because the turbo inlet air is ambient, unlike the exhaust gasses of the engine; less energy. 18 JT

  23. Temperature Conflicts • Problems that occur due to low temperatures from the test stand: • The temperature of the ambient air that is used to drive the turbo on the test stand lacks the thermal energy seen in the engine’s exhaust gasses • The initial temperature of the turbine inlet are so low that the drop in temperature could produce ice build up on the turbine 19 JT

  24. Solutions for Test Stand • Current Solution : • Recirculation lines fed directly into a turbo using the built-in oiling system as a heater. • Potential Future Equipment: • Combustor - Would imitate the high thermal energy of the engine’s exhaust gasses by providing high temperature air to the turbine. • Compressor and Dryer combination – Would eliminate the possibility of icing when using compressor to spin turbo to design speeds 20 JT

  25. Air Flow Measurement Methods Velocity Measuring Probe at Various Locations Ideal Situation 21 Frank and Angela

  26. Probe Types EPI Series 8200 MPNH Diameter 0.5 inches 0.2 inches Temperature Limits -40° to 392°F -4° to 158°F Cost ~$1,000 $784 22 Frank and Angela

  27. Test Stand Pressure • Shop Air – Insufficient • Calculations from engine pressure data • Results of Preliminary Runs • What is needed? • Larger line for more flow • Higher pressure at inlet • Constant/Steady flow 24 Tom

  28. Recirculation Line • Part of Network for the Wind Tunnel • High pressure 1” line • Compressor capable of 300 psi • Operable by use of ball valve in test room • Flow regulator built in to line ~140 psi 24 Tom

  29. Custom Adapter Pieces • Air Line Adapter • Created to directly connect to turbo and base mount • Tapped to connect to recirculation line • Base Mount • Designed to attach to test rig’s surface • Mounting holes matching Line Adapter • and turbocharger 27 Charlie

  30. Test Stand Setup The test stand base Simple setup of adapter and custom base mount Leads to the current setup 28 Charlie

  31. Piping Network • Piping chosen based on Pressure and Temperature conditions: • PVC inlet pipe where air flow is ambient temperature • Steel pipe for exhaust and boost lines 28 Charlie

  32. Test Stand Instrumentation • Mounted light sensor measures RPM of turbo • Proximity Sensors measuring displacement of shaft • Pressure and Boost Gages • Thermocouples 29 Charlie

  33. Test Stand Oiling System • The set up can produce pressures of • over 25 psi • The system has an integrated heater for which we can vary the oil temp up to 150F • A flange was added to adapt from the HX-30/35 oiling system to the ½ inch NPT 31 Carter

  34. Testing Results • Reached up to • Boost reading • Pressure reading • Temperature reading • Regulator restriction **Replace picture with graphs or whatever bests fits…. If you need more room you can carry it over 32 AC

  35. ADRE Results • Vibrations data • Adre results • Compare engine adre with test stand • adre **Replace picture with graphs or whatever bests fits…. If you need more room you can carry it over 32 AC

  36. Future Processes Issues still Present • No use of combustor or pre-intake heating system • Unable to reach goal speeds of 135000 rpm • Have not yet mimicked exact engine conditions (pulsations from exhaust, etc.) 33 AC

  37. Resolutions for Issues Purchasing necessary equipment to reach goal speeds: • Buy a combustor to increase enthalpy • energy • Purchase more precise measuring • devices to measure and mimick • the characteristics of the engine 34 Jason

  38. Final Goals • Performing bearing testing similar to • on-engine tests • Spin turbo to design speed • Provide a safe testing environment Questions? 35 Jason

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