Bearing health monitor

• US 20070079613A1
• Filed: 10/11/2005
• Published: 04/12/2007
• Est. Priority Date: 10/11/2005
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Greentree, Christopher
• Granted Patent: US 7,631,498 B2
• Time in Patent Office: Days
• US Class Current: 60/602
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F01D 25/16 Arrangement of bearings; Supporting or mounting bearings in casings bearings per se F16C
• CPC Class Codes: F02B 39/16 Other safety measures for, or other control of, pumps
• CPC Class Codes: F05D 2220/40 in turbochargers
• CPC Class Codes: F05D 2270/301 Pressure
• CPC Class Codes: F05D 2270/304 Spool rotational speed
• CPC Class Codes: F05D 2270/42 passive or reactive, e.g. using large wind vanes
• CPC Class Codes: F16C 2360/24 Turbochargers

Abstract

A turbocharger monitor including a sensor adapted and positioned with respect to a turbocharger housing to sense passing compressor blades, generating both rotor rotation information and rotor displacement information. A controller is configured to receive the generated information from the blade sensor, and to establish rotor rotation speed and an indicator of bearing condition.

Claims

1. A turbocharger monitor, for use with a turbocharger having a rotor and a housing, the rotor being configured to rotate on a bearing about an axis of rotation with respect to the housing, comprising:

a sensor adapted and positioned with respect to the housing so as to sense rotor movement information, rotor movement information including both rotor rotation information and rotor displacement information, wherein the rotor rotation information pertains to rotation about the axis of rotation, and the rotor displacement information pertaining to displacement from the axis of rotation; and

a controller configured to receive the rotor movement information from the blade sensor, and further configured to establish indicators of rotor rotation speed and bearing condition from the rotor movement information.

2. The turbocharger monitor of claim 1, wherein the controller is configured to make a comparison based on the sensed rotor displacement information and previously established baseline rotor displacement information to establish the indicator of bearing condition.

3. The turbocharger monitor of claim 2, wherein the controller is configured to measure and store the previously established baseline rotor displacement information at a time when the level of bearing wear was minimal.

4. The turbocharger monitor of claim 2, wherein the controller is configured such that the comparison is made using sensed rotor displacement information developed at substantially the rotor rotational speed at which the previously established baseline rotor displacement information was developed.

5. The turbocharger monitor of claim 2, wherein the controller is configured such that the comparison is made using sensed rotor displacement information developed at substantially the rotor rotational speed, temperature and oil pressure at which the previously established baseline rotor displacement information was developed.

6. The turbocharger monitor of claim 5, wherein the controller is configured to store baseline rotor displacement information for only one operating condition.

7. The turbocharger monitor of claim 1, wherein the controller is configured to send a signal when the indicator of bearing condition passes a bearing wear threshold.

8. The turbocharger monitor of claim 1, wherein the controller is further configured to light a warning light when the indicator of bearing condition passes a first bearing wear threshold, and to reduce the rate of rotor rotation when the indicator of bearing condition passes a second bearing wear threshold.

9. A turbocharger, comprising:

a turbine housing containing an exhaust-driven turbine;

a compressor housing containing a compressor wheel configured to be driven in rotation with respect to the compressor housing by the turbine, the compressor wheel including a plurality of compressor blades; and

the turbocharger monitor of claim 1, being configured to detect blade proximity information from the blades of the compressor wheel.

10. An internal combustion engine, comprising:

the turbocharger of claim 9;

a block defining a combustion chamber for combusting fuel;

an intake manifold adapted to received pressurized air from the turbocharger compressor to be mixed with fuel and combusted in the combustion chamber; and

an exhaust manifold adapted to drive the turbocharger turbine with combusted gases exhausted by the combustion chamber.

11. The internal combustion engine of claim 10, and further comprising an engine control unit adapted to serve as the controller, wherein the controller receives an unconditioned signal from the sensor.

12. The internal combustion engine of claim 11, wherein the controller is further configured to light a warning light when the blade distance variation exceeds a first threshold, and when the blade distance variation exceeds a second threshold, to do at least one of:

restrict fuel flow to the combustion chamber, and reduce the speed of compressor wheel rotation.

13. The internal combustion engine of claim 10, and further comprising:

an engine control unit adapted to serve as the controller; and

an electric actuator configured to control operation of the turbocharger and digitally communicate with the engine control unit;

wherein the electric actuator is configured to receive the blade proximity information in an analog format from the sensor; and

wherein the electric actuator is configured to provide the blade proximity information to the engine control unit in a digital format.

14. A method for monitoring a turbocharger having a rotor and a housing, the rotor being configured to rotate on a bearing about an axis of rotation with respect to the housing, comprising:

sensing rotor movement information using a sensor, the rotor movement information including both rotor rotation information and rotor displacement information, wherein the rotor rotation information pertains to rotation about the axis of rotation, and the rotor displacement information pertains to displacement from the axis of rotation; and

establishing indicators of rotor rotation speed and bearing condition from the rotor movement information.

15. A turbocharger monitor for monitoring a turbocharger having a rotor and a housing, the rotor being configured to rotate on a bearing about an axis of rotation with respect to the housing, comprising:

a means for sensing rotor movement information using a single sensor, the rotor movement information including both rotor rotation information and rotor displacement information, wherein the rotor rotation information pertains to rotation about the axis of rotation, and the rotor displacement information pertains to displacement from the axis of rotation; and

a means for establishing indicators of rotor rotation speed and bearing condition from the rotor movement information.

16. A bearing wear monitor, for use with a rotatable turbocharger wheel having a plurality of blades, comprising:

a blade sensor located proximate the wheel, and configured to detect blade proximity information for blades passing the blade sensor, the blade proximity information being indicative of a blade distance between the blade sensor and blades passing the blade sensor; and

a controller configured to receive the blade proximity information from the blade sensor, and further configured to establish a blade distance variation from the blade proximity information.

17. The bearing wear monitor of claim 16, wherein:

the controller is configured to compare the variation in the blade distance with a previously established baseline variation to establish a level of bearing wear; and

the controller is configured to send a signal when the level of bearing wear has exceeded a wear limit.

18. The bearing wear monitor of claim 17, wherein the controller is configured to store an established variation in blade distance sensed at a time when the level of bearing wear is minimal to establish the baseline variation.

19. The bearing wear monitor of claim 18, wherein the controller is configured such that the variation in the blade distance is sensed at the rotational speed at which the established baseline variation in the blade distance was established.

20. The bearing wear monitor of claim 18, wherein the controller is configured such that the variation in the blade distance is sensed at the rotational speed, temperature and oil pressure at which the established baseline variation in the blade distance was established.

21. The bearing wear monitor of claim 17, wherein the controller is configured to store only one baseline variation.

22. The bearing wear monitor of claim 17, wherein the controller is further configured to process the blade distance information and produce a signal indicative of the rotational speed of the wheel.

23. The bearing wear monitor of claim 17, wherein the controller is further configured to light a warning light when the blade distance variation exceeds a first threshold, and to reduce the rate of wheel rotation when the blade distance variation exceeds a second threshold.

24. A method for monitoring the wear of a bearing of a turbocharger, wherein the turbocharger has a housing containing a wheel rotating with respect to the housing, the wheel including a plurality of blades, comprising:

detecting blade proximity information for the plurality of blades on the rotating wheel as they pass by a blade sensor, the blade proximity information being indicative of a blade distance between passing blades and the blade sensor; and

establishing a variation in the blade distance indicated by the blade proximity information.

25. A bearing wear monitor for monitoring the wear of a bearing of a turbocharger, wherein the turbocharger has a housing containing a wheel rotating with respect to the housing, the wheel including a plurality of blades, comprising:

a means for detecting blade proximity information for the plurality of blades on the rotating wheel as they pass by a blade sensor, the blade proximity information being indicative of a blade distance between passing blades and the blade sensor; and

a means for establishing a variation in the blade distance indicated by the blade proximity information.