TURBOCHARGER PERFORMANCE QUALIFICATION METHOD AND APPARATUS

• US 20080011070A1
• Filed: 06/30/2006
• Published: 01/17/2008
• Est. Priority Date: 06/30/2006
• Status: Active Grant

• Current Assignee: International Engine Intellectual Property Company, LLC (Volkswagen AG)
• Original Assignee: International Engine Intellectual Property Company, LLC (Volkswagen AG)
• Inventors: Wood, Terry G.
• Granted Patent: US 7,380,445 B2
• Time in Patent Office: Days
• US Class Current: 73/118.1
• CPC Class Codes: F04D 27/001 Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
• CPC Class Codes: G01M 15/14 Testing gas-turbine engines or jet-propulsion engines

Abstract

A method for qualifying turbocharger performance includes the step of operating a turbocharger at a single test condition (402). A set of data may be acquired from a set of operating parameters of the turbocharger (404) operating at the test condition. The set of data acquired may be compared to a set of operating ranges (406) that are deemed acceptable, and a determination may be made as to whether the set of data falls within the acceptable operating ranges (408). Performance of the turbocharger may then be qualified (412, 414) based on an outcome of the determination (410).

Claims

1. A method for qualifying turbocharger performance, comprising the steps of:

operating a turbocharger at a test condition;

acquiring a set of data from a set of operating parameters of the turbocharger at the test condition;

comparing the set of data to a set of acceptable operating ranges;

determining whether the set of data falls within the acceptable operating ranges;

qualifying the turbocharger based on an outcome of the determination.

2. The method for qualifying turbocharger performance of claim 1, further comprising the steps of:

operating the turbocharger at an additional test condition;

acquiring an additional set of data from the set of operating parameters of the turbocharger at the additional test condition;

comparing the additional set of data to the set of acceptable operating ranges;

determining whether the additional set of data falls within the acceptable operating ranges;

qualifying the turbocharger based on the determination for the set of data and the determination for the additional set of data;

wherein the test condition is equivalent to a low engine speed range of operation, and the additional test condition is equivalent to a high engine speed range of operation.

3. The method of qualifying turbocharger performance of claim 1, wherein the determination step further includes the steps of:

plotting the set of data on a graph;

defining a rectangular area on the graph to represent the acceptable operating ranges; and

determining whether data points on the graph fall within the rectangular area on the graph.

4. The method of qualifying turbocharger performance of claim 1, wherein the steps of comparing, determining, and qualifying are accomplished in an electronic controller.

5. The method of qualifying turbocharger performance of claim 1, wherein the set of data is selected from the set of operating parameters that includes at least one of:

a turbine inlet gas temperature, a turbine inlet gas pressure, a turbine inlet gas enthalpy, a turbine inlet gas flow rate, a compressor inlet air temperature, a compressor inlet air pressure, a compressor inlet air enthalpy, a compressor inlet air flow rate, an engine fueling rate, an engine speed, a VNT duty cycle, a turbine shaft speed, a fluid pump work input, and a heater energy input.

6. The method of qualifying turbocharger performance of claim 1, further comprising the step of sending at least one of a pass notification, a fail notification, or a retest notification.

7. The method of qualifying turbocharger performance of claim 1, wherein the step of operating the turbocharger at the test condition is accomplished by operating the turbocharger on an internal combustion engine.

8. The method of qualifying turbocharger performance of claim 1, wherein the step of operating the turbocharger at the test condition is accomplished by operating the turbocharger on a test fixture.

9. A method of testing turbochargers, comprising the steps of:

operating a turbocharger at a test condition as part of an engine system;

monitoring a set of inputs to the system that includes a fuel consumption rate of the engine system;

monitoring a set of outputs from the system that includes a compressor outlet pressure of the turbocharger;

comparing the set of outputs to a set of respective acceptable ranges;

finding a performance of the turbocharger acceptable at times when the set of outputs is within the set of respective acceptable ranges.

10. The method of claim 9, further comprising the step of plotting a set of points representing the set of inputs and the set of outputs on a graph, wherein the graph includes a horizontal axis that represents one of the set of inputs, wherein the graph includes at least one vertical axis that represents at least one of the set of outputs, wherein the test condition is represented by at least one point on the graph, wherein at least one of the set of acceptable ranges is represented by an area on the graph, and wherein the finding of acceptable turbocharger performance occurs when the at least one point is within the area on the graph.

11. The method of claim 9, wherein the set of inputs includes measurable parameters and derivative parameters of operation of the engine system, wherein measurable values are selected from the group comprising turbine inlet gas temperature, turbine inlet gas pressure, turbine inlet gas flow rate, compressor inlet air temperature, compressor inlet air pressure, compressor inlet air flow rate, engine fueling rate, engine speed, VNT duty cycle, and turbine shaft speed, and wherein derivative parameters are selected from the group comprising turbine inlet gas enthalpy and compressor inlet air enthalpy.

12. A test station for qualifying turbocharger performance, comprising:

a test fixture having a turbocharger mounting apparatus attached thereon;

an electronic controller associated therewith;

a plurality of sensors that are disposed to measure operating parameters of the test station and are operably connected to the test station;

a fluid pump arranged and constructed to fluidly connect to a turbocharger at times when the turbocharger is connected to the test fixture with the mounting apparatus, such that a fluid pump outlet is connected to a turbine inlet passage.

13. The test station of claim 12, further comprising a flow meter device fluidly connected to a compressor inlet passage, wherein the compressor inlet passage is arranged to connect to an inlet of a compressor of the turbocharger.

14. The test station of claim 12, further comprising at least one of:

a first pressure sensor arranged to measure an air pressure in the turbine inlet passage;

a second pressure sensor arranged to measure an air pressure in a turbine outlet passage;

a third pressure sensor arranged to measure an air pressure in the compressor inlet passage; and

a fourth pressure sensor that is arranged to measure an air pressure in a compressor outlet passage;

wherein at least one of the first pressure sensor, the second pressure sensor, the third pressure sensor and the fourth pressure sensor is connected to the electronic controller.

15. The test station of claim 12, further comprising a heater disposed in the turbine inlet passage between the fluid pump and the turbocharger.

16. The test station of claim 12, further comprising an orifice disposed in the compressor outlet passage.

17. The test station of claim 12, further comprising a display operably associated with the electronic controller.

18. The test station of claim 12, further comprising a turbocharger, wherein the turbocharger includes a turbine having a turbine inlet and a turbine outlet, a compressor having a compressor inlet and a compressor outlet, wherein the turbine inlet is fluidly connected to the turbine inlet passage, wherein the compressor inlet is fluidly connected with the compressor inlet passage, and wherein the compressor outlet is fluidly connected to the compressor outlet passage.