TEST BENCHES FOR TURBOCHARGERS - Kratzer Automation

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
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