TEST BENCHES FOR TURBOCHARGERS - Kratzer Automation

Hot gas generation from natural gas combustion
Stainless steel combustion chamber (without ceramic lining)
Available sizes
I II III IV V
Hot gas mass flow min
0,01 0,013 0,02 0,04 0,14
kg/s
max 0,25 0,32 0,50 1,00 1,40
Power range of
burner
Hot gas temperature
Hot gas pressure
Temperature distribution
over the
cross-section
Mass flow at compressor
Oil volume flow
Oil temperature
Oil pressure
Coolant volume
flow
Coolant temperature
min
5 8 10 20 60
kW
max 200 330 400 800 800
min
150 150 150 150 300
°C
max 1200 1200 1200 1200 750
min bar 1 1 1 1 1
max (abs) 6 6 6 6 6
°C ± 8 ± 10
min
0,01 0,013 0,02 0,04 0,14
kg/s
max 0,25 0,32 0,50 1,00 1,40
min
0,5 0,5 0,5 1,0 1,0
l/min
max 5,0 5,0 5,0 10,0 10,0
min
70
°C
max 150
min bar
1,5
max (abs)
7,0
min
1,5 1,5 1,5 3,0 3,0
l/min
max 15,0 15,0 15,0 30,0 30,0
min
70
°C
max 110
KRATZER AUTOMATION’s test benches —
internationally in demand
The flexible configuration, the advantages of hot gas technology
and the facilities for fully-automatic mapping have convinced numerous
suppliers and automotive manufacturers: there are already
around 60 KRATZER AUTOMATION turbocharger test benches installed
in Europe and Asia. The company is thus playing its part to
enable development departments to expedite the market readiness
of energy-efficient and environment-friendly drive technologies.
KRATZER AUTOMATION supplies innovative, turnkey software
solutions. Our customers include international companies
from the automotive, electronics and transport
industries. Our projects focus on efficient processes and an
optimal cost-benefit ratio. Worldwide we operate three divisions
with over 200 employees at your service.
In its “Test Systems” division, KRATZER AUTOMATION plans
and implements test benches for the automotive industry,
primarily for turbochargers, engines, gear chains and
other drive train components. In particular, the company
focuses on developing test systems for energy-saving and
environmentally-friendly drive concepts such as hybrid or
electric drives and fuel cell technology. The various types
of test bench are controlled by the PAtools software. User
interface and test procedures can be flexibly adapted as
needed and users benefit from uniform system technology.
The testXplorer software administers test data in the testing
environment and so ensures greater transparency and
efficient use of resources.
The scalable, modular manufacturing execution system intra-
FACTORY® offers greater transparency and more efficient
processes in electronics and equipment manufacturing, in
particular as regards product and process traceability, material
and setup management as well as the integration of
repair stations. intraFACTORY® covers all process steps from
incoming goods to finished products. To further enhance efficiency
in order processing and capacity utilization, KRATZER
AUTOMATION offers solutions for granular production planning
based on its advanced planning and scheduling tool
intraFACTORY® Scheduler. The portfolio of the Integrated
Manufacturing division is rounded off by software for the
control of complex automated devices and the integration of
machines in customer-specific software systems.
The Logistics Automation division at KRATZER AUTOMATION
delivers cadisTRANSPORT TMS, a transport management
system for optimizing the planning, execution and analysis
of all operative work processes for freight transport.
For 30 years, the combination of application expertise,
innovative software tools, many years of project experience,
international on-site support and our willingness to take on
full project responsibility as general contractor has made
KRATZER AUTOMATION an expert and reliable partner for
your projects.
You will find up-to-date company information at
www.kratzer-automation.com.
KRATZER AUTOMATION AG
Gutenbergstraße 5
85716 Unterschleissheim / Munich
Germany
Phone +49-89-32152-100
Fax +49-89-321 52-599
www.kratzer-automation.com
testsystems@kratzer-automation.com
TEST BENCHES FOR TURBOCHARGERS
TEST SYSTEMS FOR A MOBILE FUTURE
Turbocharger tests
KRATZER AUTOMATION‘s test benches lead the world in turbocharger development
• Complete system
Test benches and software from a single source
• Innovation
Precise testing of turbines and compressors at up to 1,000°C
• Efficiency
Optimized test procedures save time and money
• Sustainable
Environment-friendly because it burns almost pollution-free natural gas
powered by PAtools
Developing and optimising exhaust gas turbochargers calls for test benches that enable mass
flow, temperature and pressure conditions to be set up as required and precisely reproduced.
This is particularly important for recording maps and analysing efficiency. Our turbocharger test
benches are a particularly efficient tool for this purpose.
A high-tech hot gas generator enables arbitrary operating points to be positioned within the
compressor map and turbine map. The burner power can be adjusted through an extremely wide
range, enabling whole production series of turbochargers to be inspected on a single test bench.
Special investigations with high pressure coupled with low temperature are also possible. The
test bench is regulated and controlled using PAtools.

TEST BENCHES FOR TURBOCHARGERS
Hot gas technology
This test bench is based on environmentally friendly natural gas
burner technology (see illustration). The hot exhaust gas for
testing the prototype is generated in a stainless steel combustion
chamber and is available at a temperature of between 150
and 1200°C and a pressure of from 0 to 8 bar. The mass flow
is adjustable from 0.01 to 1.4 kg/s depending on the type of
system (see the table on the reverse of this page).
Natural gas burner technology, especially with integrated combustion,
exhibits a very even temperature distribution on the
turbine input and a wide adjustment range. Using this burner
you can set up exactly reproducible conditions of mass flow,
temperature and pressure on the turbocharger and simulate
each required operating point. This means that an entire series
of turbochargers can be tested on the test bench without
having to make any changes to the set-up. Natural gas offers
additional advantages over liquid fuels: because natural gas is
supplied through a feed line there is no need for a fuel tank that
would have to be periodically refilled.
The test stand is constructed as a compact unit with integrated
conditioning for both lubricant and coolant.
Since natural gas burns with almost no pollutants – typical values
are less than 100 ppm NOx and CO – there is also no need
to install an exhaust gas cleaning system. In addition, the system
is largely maintenance-free: we recommend just one annual
inspection. The low price of natural gas compared to diesel
also contributes to the generally lower running costs.
General system components
• Hot gas generator to provide a wide range of
temperature, mass flow and pressure
• Back pressure unit to adjust the correct mass flow
of the TC compressor
• Oil conditioning unit to adjust a stable input pressure
and input temperature for the TC bearing
• Water conditioning unit to adjust a stable water
input temperature for water cooled bearing housings
Additional equipment
• Electrical heater to increase the operation field in lower
temperature regions
• Thermo shock unit single flow to run thermo shocks and
thermo cycles
• Thermo shock switching unit to run thermo shock tests
with two turbochargers in parallel
• Closed loop system to increase the operation field of the
turbine
• Exhaust gas back pressure unit to simulate the exhaust
gas system
• Soot contamination unit to simulate diesel application in
natural gas burner
• Low-pressure unit at the compressor intake to simulate
compressor air-intake systems
• Measuring pipes of various dimensions for measuring
performance characteristics
• Blow-by meter for measuring the leakage of gas from the
bearing housing
• Mobile oil conditioning unit for oil contamination test
Testing turbochargers
General tasks
• Measuring characteristic maps of turbine and compressor
in developing set up as well as in application set up
• Stability research of thermomechanical behaviour
• Endurance tests of all components, such as bearing
housing, turbine wheel, etc.
• Dynamic behaviour research of load capacities
Specific tasks
• Mapping compressor
• Mapping turbine
• Low temperature turbine map
• Thermo shock
• Temperature cycles
• Blow-by tests
• Low pressure test on compressor
• Speed cycles
• Low-cycle fatigue tests
• Start stop tests
• Waste gate tests
• Axial trust tests
• Shaft motion tests
+++ COMBUSTION ENGINES +++ GEAR BOxES +++ TURBO CHARGER +++ ExHAUST PIPES +++ BRAKE SySTEMS +++ dRIVE TRAIN +++ fUEL CELLS +++ CATALyTIC CONVERTER +++ ALTERNATIVE dRIVES +++ PUMPS +++ CHASSIS +++ HyBRId