Turbocharger off-line testing device and testing method based on natural gas system

Abstract

This invention relates to a turbocharger off-line testing device and method based on a natural gas system. Utilizing the flexible connection between the natural gas system and the turbocharger, and without requiring machining or damage to the turbocharger, the device controls the exhaust valve, vent valve, and natural gas system to simulate the turbocharger's operating conditions under various operating states. This enables off-line testing of turbochargers produced in small batches, reducing testing costs and shortening delivery time.

Description

Technical Field

[0001] This invention relates to the field of turbocharger testing technology, and more specifically, to a turbocharger offline testing device and testing method based on a natural gas system. Background Technology

[0002] End-of-line (EOL) testing is a common inspection process in industrial manufacturing. It is the final comprehensive performance and quality test of a product after it has gone through the entire manufacturing process. As a complex product with a design speed of up to 200,000 rpm and a high degree of mechanical and electronic integration, automotive turbochargers have extremely high requirements for quality and reliability. Therefore, in actual mass production, 100% EOL testing will be carried out on products for high-end customers.

[0003] Existing EOL equipment used for mass production is a highly automated, short-cycle-time specialized device with high investment costs and long delivery times. It is difficult to be available in a timely manner in the early stages of new product development, and it is difficult to meet customers' requirements for EOL testing of small batches of samples in the early stages. Therefore, there is no method for rapid EOL testing of small batches of samples. Summary of the Invention

[0004] The problem addressed by this invention is how to provide a test device and method for turbochargers based on natural gas systems that can meet the requirements for offline testing of small batches of samples.

[0005] To address the aforementioned problems, this invention provides a turbocharger and a natural gas system supplying fuel to the turbocharger, and also includes a controller. The turbocharger is equipped with a vibration sensor for collecting vibration noise. The turbocharger includes a turbine and a compressor. The natural gas system is connected to the inlet end of the turbine via a pipeline. The outlet end of the turbine and the inlet and outlet ends of the compressor are respectively connected to pipelines via connectors. A vent valve is connected to the compressor, and an exhaust valve is connected to the turbine. The exhaust valve, the vent valve, and the natural gas system are all electrically connected to the controller. Pressure sensors, flow sensors, and temperature sensors are respectively installed on the natural gas system, the outlet end of the turbine, the inlet end of the compressor, and the outlet end of the compressor.

[0006] The advantages of this testing device are: by utilizing the flexible installation and connection between the natural gas system and the turbocharger, it can simulate the working state of the turbocharger under various operating conditions by controlling the exhaust valve, vent valve and natural gas system through the connection controller without processing or damaging the turbocharger. This enables the off-line testing of turbochargers produced in small batches, reducing testing costs and shortening delivery time.

[0007] Preferably, the device also includes a vibration noise collector for collecting vibration noise and a microphone for collecting noise decibels, wherein the vibration noise collector is connected to a vibration sensor and the microphone is connected to the vibration noise collector.

[0008] A test method based on the aforementioned turbocharger offline test device for a natural gas system includes the following steps:

[0009] Step 1, Preparation Stage: The natural gas system is not supplied with gas, the turbocharger is stationary, and the controller sends electrical control execution signals to the exhaust valve and the vent valve respectively to make them work for a preset time before power is cut off; according to the preset acquisition frequency, the parameters of the pressure sensor, flow sensor, temperature sensor, vibration sensor, vibration-causing acquisition device and microphone on each pipeline are continuously acquired; at the same time, the voltage parameters of the vent valve and the least significant bit parameters of the exhaust valve are acquired at the preset acquisition frequency.

[0010] Step 2, Acceleration Phase: The natural gas system starts supplying gas, and the turbine accelerates to the preset speed and continues to operate for a preset time period; parameters from the pressure sensor, flow sensor, temperature sensor, vibration sensor, vibration-induced data acquisition device, and microphone on each pipeline are continuously collected according to the preset acquisition frequency;

[0011] Step 3, High-speed operation phase of the exhaust valve: The controller provides a preset operating voltage to the exhaust valve, controls the exhaust valve to open and release pressure. After the turbocharger decelerates to the preset speed, the operating voltage of the exhaust valve is disconnected, the exhaust valve closes, and the turbocharger returns to the preset speed of the acceleration phase; Parameters from pressure sensors, flow sensors, temperature sensors, vibration sensors, vibration-induced data acquisition devices, and microphones on each pipeline are continuously collected according to the preset acquisition frequency;

[0012] Step 4, High-speed operation stage of the vent valve: The controller provides a preset working voltage to the vent valve, controls the vent valve to open, the compressor vent valve opens, after the pressure at the inlet and outlet of the compressor reaches the preset pressure value, the power supply to the vent valve is disconnected, so that the vent valve is closed, and the parameters of the pressure sensor, flow sensor, temperature sensor, vibration sensor, vibration-induced data acquisition device and microphone on each pipeline are continuously collected according to the preset acquisition frequency.

[0013] Step 5, Deceleration Phase: Gradually reduce the gas supply flow of the natural gas system, the pressure at the turbine inlet decreases, and the speed of the turbocharger decreases to zero. Parameters from pressure sensors, flow sensors, temperature sensors, vibration sensors, vibration-induced data acquisition devices, and microphones on each pipeline are continuously collected according to the preset acquisition frequency.

[0014] Step 6: Summarize the data of the turbocharger at each stage to form a chart. By comparing the chart data of different turbochargers at the same stage, quickly find the turbocharger with abnormal data.

[0015] The beneficial effects of this testing method are: by conducting offline tests on batch turbochargers at various stages to obtain test results for each stage, and by using big data to compare and analyze the corresponding sensor parameters at each stage, it is possible to quickly find abnormal parameters with obvious differences and quickly screen out abnormal turbochargers from the batch of turbochargers.

[0016] Preferably, in step 2, the turbine accelerates to a preset speed of 140,000 l / min; in step 3, the turbocharger decelerates to a preset speed of 7,000 l / min; in step 4, the controller provides a preset operating voltage of 12V to the vent valve, the pressure at the compressor's inlet increases from -60 hpa to a preset pressure value of -10 hpa, and the pressure at the compressor's outlet decreases from 680 hpa to a preset pressure value of 150 hpa.

[0017] Preferably, step 6 regarding the turbocharger for quickly finding abnormal data specifically includes:

[0018] Step 601: Obtain the parameters of a qualified turbocharger at each stage under the same conditions as reference data, and determine the upper limit t and lower limit t´ of the reference data;

[0019] Step 602: Continuously collect measurement data of batch turbochargers at the corresponding stages, and summarize the measurement data of all stages into a chart;

[0020] Step 603: If any of the measured data exceeds the upper limit t or falls below the lower limit t´, the corresponding turbocharger is a defective product. If the continuously measured data are all within the range of the upper limit t and the lower limit t´, the corresponding turbocharger is a qualified product. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of a specific embodiment 1 of the present invention;

[0022] Figure 2 This is a chart of various test parameters collected during the preparation stage in a specific embodiment 2 of the present invention;

[0023] Figure 3 This is a chart showing the test parameters for the lowest effective position of the exhaust valve of a batch turbocharger in a specific embodiment 2 of the present invention;

[0024] Figure 4 A turbine speed chart for a batch turbocharger in specific embodiment 2 of the invention;

[0025] Figure 5 A chart showing the pressure test parameters at the compressor inlet of a batch turbocharger in embodiment 2 of the invention;

[0026] Figure 6 A chart showing the pressure test parameters at the compressor outlet of a batch turbocharger in specific embodiment 2 of the invention;

[0027] Figure 7 This is a chart showing the pressure test parameters at the turbine inlet of a batch turbocharger in a specific embodiment 2 of the present invention;

[0028] Figure 8 A chart showing the pressure test parameters at the turbine outlet of a batch turbocharger in Embodiment 2 of the invention;

[0029] Figure 9 In a specific embodiment of the invention, a microphone is used to collect charts of test parameters for the sound pressure level of batch turbocharger noise.

[0030] Figure 10 The specific embodiment of the invention is shown in Figure 2, which uses a microphone to collect batch turbocharger noise decibel test parameter charts.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1. Turbocharger; 1.1. Turbine; 1.2. Compressor; 2. Natural gas system; 3. Controller; 4. Vibration sensor; 5. Vent valve; 6. Exhaust valve; 7. Pressure sensor; 8. Flow sensor; 9. Temperature sensor; 10. Vibration and noise collector; 11. Microphone; 12. Connector. Detailed Implementation

[0033] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Specific Implementation Example 1:

[0035] like Figure 1The diagram shows a turbocharger 1 offline testing device based on a natural gas system 2, comprising a turbocharger 1 and a natural gas system 2 supplying fuel to the turbocharger 1, and a controller 3. The turbocharger 1 is equipped with a vibration sensor 4 for collecting vibration and noise. The turbocharger 1 includes a turbine 1.1 and a compressor 1.2. The natural gas system 2 is connected to the inlet of the turbine 1.1 via a pipeline. The outlet of the turbine 1.1 and the inlet and outlet of the compressor 1.2 are respectively connected to pipelines via connectors 12. A vent valve is connected to the compressor 1.2. 5. An exhaust valve 6 is connected to the turbine 1.1. The exhaust valve 6, the vent valve 5, and the natural gas system 2 are all electrically connected to the controller 3. A pressure sensor 7, a flow sensor 8, and a temperature sensor 9 are respectively installed on the pipes of the natural gas system 2, the outlet end of the turbine 1.1, the inlet end of the compressor 1.2, and the outlet end of the compressor 1.2. The system also includes a vibration noise collector 10 for collecting vibration noise and a microphone 11 for collecting noise decibels. The vibration noise collector 10 is connected to the vibration sensor 4, and the microphone 11 is connected to the vibration noise collector 10. Specific Implementation Example 2:

[0037] A test method for a turbocharger 1 based on a natural gas system 2 offline test device as described in Specific Embodiment 1 includes the following steps:

[0038] Step 1, Preparation Stage: Natural gas system 2 is not supplied with gas, turbocharger 1 is stationary, controller 3 sends electrical control execution signals to exhaust valve 6 and vent valve 5 respectively, causing them to operate for a preset time before power is cut off. Specifically, controller 3 first sends an electrical control execution signal to vent valve 5, which lasts for 2 seconds and then disconnects; then controller 3 sends an electrical control execution signal to exhaust valve 6, which lasts for 1.5 seconds and then disconnects. Parameters from pressure sensor 7, flow sensor 8, temperature sensor 9, vibration sensor 4, vibration-induced data acquisition device, and microphone 11 on each pipeline are continuously collected according to a preset acquisition frequency, such as... Figure 2 As shown, the voltage parameters of the vent valve 5 and the least significant bit parameters of the exhaust valve 6 are simultaneously collected at a preset sampling frequency, such as... Figure 2 As shown, first, an electrical control execution signal is given to the vent valve 5, and the voltage of the vent valve 5 rises to 1V, and drops to 0V after being disconnected; while an electrical control execution signal is given to the exhaust valve 6, and the least significant bit of the execution signal changes from 30000LSB to 500LSB, and returns to 3000LSB after the signal is disconnected. At this time, the exhaust valve 6 of the turbine 1.1 is closed.

[0039] Step 2, Acceleration Phase: Natural gas system 2 starts supplying gas, turbine 1.1 accelerates to a preset speed and continues to operate for a preset time period. In this specific embodiment, turbine 1.1 accelerates to 140,000 l / min and continues to operate for 30 seconds. Parameters from pressure sensor 7, flow sensor 8, temperature sensor 9, vibration sensor 4, vibration collector, and microphone 11 on each pipeline are continuously collected according to a preset collection frequency.

[0040] Step 3, High-speed operation phase of exhaust valve 6: Controller 3 provides a preset operating voltage to exhaust valve 6, controlling exhaust valve 6 to open. Exhaust valve 6 of turbine 1.1 opens to release pressure. After turbocharger 1 decelerates to the preset speed, the operating voltage of exhaust valve 6 is disconnected, exhaust valve 6 closes, and turbocharger 1 returns to the preset speed of the acceleration phase. In this specific embodiment, turbocharger 1 decelerates to 7000 l / min, and after running for 1 second, the operating voltage is disconnected, and turbocharger 1 returns to 140000 l / min. Parameters from pressure sensor 7, flow sensor 8, temperature sensor 9, vibration sensor 4, vibration collector, and microphone 11 on each pipeline are continuously collected according to the preset acquisition frequency.

[0041] Step 4, High-speed operation stage of vent valve 5: Controller 3 provides a preset operating voltage to vent valve 5, controlling vent valve 5 to open. Vent valve 5 of compressor 1.2 opens. After the pressure at the inlet and outlet of compressor 1.2 reaches the preset pressure value, the power supply to vent valve 5 is disconnected, causing vent valve 5 to close. In this specific embodiment, controller 3 provides a preset operating voltage of 12V to vent valve 5. After running for 4 seconds, the pressure at the inlet of compressor 1.2 increases from -60hpa to the preset pressure value of -10hpa, and the pressure at the outlet of compressor 1.2 decreases from 680hpa to the preset pressure value of 150hpa. Parameters from pressure sensor 7, flow sensor 8, temperature sensor 9, vibration sensor 4, vibration sensor, and microphone 11 on each pipeline are continuously collected according to the preset acquisition frequency.

[0042] Step 5, Deceleration Phase: Gradually reduce the gas supply flow of natural gas system 2. After running for 30 seconds, the pressure at the intake end of turbine 1.1 decreases, and the speed of turbocharger 1 decreases to zero. Parameters from pressure sensor 7, flow sensor 8, temperature sensor 9, vibration sensor 4, vibration-induced data acquisition device, and microphone 11 on each pipeline are continuously collected according to the preset acquisition frequency.

[0043] Step 6: Summarize the data from turbocharger 1 at each stage to form a chart. By comparing the chart data of different turbochargers 1 at the same stage, quickly identify turbochargers 1 with abnormal data. Specifically:

[0044] Step 601: Obtain the parameters of the turbocharger 1 under the same conditions at each stage as reference data, and determine the upper limit t and lower limit t´ of the reference data;

[0045] Step 602: Continuously collect measurement data of the batch turbochargers 1 at the corresponding stages, and summarize the measurement data of all stages into a chart; in this specific embodiment, the continuously collected measurement data of the batch turbochargers 1 includes, for example: Figure 3 The diagram shown illustrates the least effective position of exhaust valve 6; as follows: Figure 4 The turbine speed chart shown in Figure 1.1; as follows: Figure 5 The chart shown is a graph of the pressure data at the inlet of compressor 1.2; as shown. Figure 6 The chart shown is a graph of the pressure data at the outlet of compressor 1.2; as shown. Figure 7 The chart shown is a graph generated from the pressure data at the inlet of turbine 1.1; as shown. Figure 8 The chart shown is a graph generated from the pressure data at the outlet of turbine 1.1; as shown. Figure 9 The graph showing the noise sound pressure level collected by microphone 11 and as shown in the figure Figure 10 The graph shows the noise levels in decibels collected by microphone 11.

[0046] Step 603: If any of the measured data exceeds the upper limit t or falls below the lower limit t´, the corresponding turbocharger 1 is a defective product. If the continuously measured data are all within the range of the upper limit t and the lower limit t´, the corresponding turbocharger 1 is a qualified product.

[0047] While the disclosure is as stated above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of this disclosure, and all such changes and modifications will fall within the protection scope of this invention.

Claims

1. A method for offline testing of a turbocharger based on a natural gas system, characterized in that, Includes the following steps: Step 1, Preparation stage: The natural gas system (2) is not supplied with gas, the turbocharger (1) is stationary, the controller (3) sends electrical control execution signals to the exhaust valve (6) and the vent valve (5) respectively to make them work for a preset time and then cut off the power; according to the preset acquisition frequency, the parameters of the pressure sensor (7), flow sensor (8), temperature sensor (9), vibration sensor (4), vibration-caused acquisition device and microphone (11) on each pipeline are continuously collected, and at the same time, the voltage parameters of the vent valve (5) and the least effective bit parameters of the exhaust valve (6) are collected at the preset acquisition frequency; Step 2, Acceleration phase: The natural gas system (2) starts to supply gas, and the turbine (1.1) accelerates to the preset speed and continues to run for a preset time period; according to the preset acquisition frequency, the parameters of the pressure sensor (7), flow sensor (8), temperature sensor (9), vibration sensor (4), vibration-induced acquisition device and microphone (11) on each pipeline are continuously collected; Step 3, High-speed operation stage of exhaust valve (6): The controller (3) provides a preset working voltage to the exhaust valve (6) to control the exhaust valve (6) to open and release pressure. After the turbocharger (1) decelerates to the preset speed, the working voltage of the exhaust valve (6) is disconnected, the exhaust valve (6) closes, and the turbocharger (1) returns to the preset speed of the acceleration stage. The parameters of the pressure sensor (7), flow sensor (8), temperature sensor (9), vibration sensor (4), vibration-induced acquisition device and microphone (11) on each pipeline are continuously collected according to the preset acquisition frequency. Step 4, High-speed operation stage of the vent valve (5): The controller (3) gives the vent valve (5) a preset working voltage, controls the vent valve (5) to open, the vent valve (5) of the compressor (1.2) opens, after the pressure at the inlet and outlet of the compressor (1.2) reaches the preset pressure value, the power supply of the vent valve (5) is disconnected, so that the vent valve (5) is closed, and the parameters of the pressure sensor (7), flow sensor (8), temperature sensor (9), vibration sensor (4), vibration-induced acquisition device and microphone (11) on each pipeline are continuously collected according to the preset acquisition frequency; Step 5, deceleration phase: Gradually reduce the gas supply flow of the natural gas system (2), the pressure at the inlet of the turbine (1.1) decreases, the speed of the turbocharger (1) is reduced to zero, and the parameters of the pressure sensor (7), flow sensor (8), temperature sensor (9), vibration sensor (4), vibration-induced collector and microphone (11) on each pipeline are continuously collected according to the preset collection frequency. Step 6: Summarize the data of turbocharger (1) at each stage to form a chart. By comparing the chart data of different turbochargers (1) at the same stage, quickly find the turbocharger (1) with abnormal data.

2. The method for offline testing of a turbocharger based on a natural gas system according to claim 1, characterized in that, In step 2, the turbine (1.1) accelerates to a preset speed of 140,000 l / min; in step 3, the turbocharger (1) decelerates to a preset speed of 7,000 l / min; in step 4, the controller (3) supplies the vent valve (5) with a preset operating voltage of 12V, the pressure at the inlet of the compressor (1.2) increases from -60 hpa to a preset pressure value of -10 hpa, and the pressure at the outlet of the compressor (1.2) decreases from 680 hpa to a preset pressure value of 150 hpa.

3. The method for offline testing of a turbocharger based on a natural gas system according to claim 1, characterized in that, The turbocharger (1) in step 6 for quickly finding abnormal data specifically includes: Step 601: Obtain a qualified turbocharger (1) Use the parameters of each stage under the same conditions as reference data, and determine the upper limit t and lower limit t´ of the reference data; Step 602: Continuously collect measurement data of batch turbochargers (1) at the corresponding stages, and summarize the measurement data of all stages into a chart; Step 603: If any of the measured data exceeds the upper limit t or is lower than the lower limit t´, the corresponding turbocharger (1) is a defective product. If the continuously measured data are all within the range of the upper limit t and the lower limit t´, the corresponding turbocharger (1) is a qualified product.

4. A testing apparatus based on the turbocharger offline testing method for a natural gas system according to any one of claims 1-3, comprising a turbocharger (1) and a natural gas system (2) supplying fuel gas to the turbocharger (1), characterized in that, It also includes a controller (3), and the turbocharger (1) is equipped with a vibration sensor (4) for collecting vibration noise. The turbocharger (1) includes a turbine (1.1) and a compressor (1.2). The natural gas system (2) is connected to the inlet end of the turbine (1.1) through a pipeline. The outlet end of the turbine (1.1) and the inlet and outlet ends of the compressor (1.2) are respectively connected to the pipeline through a connector (12). The compressor (1.2) is connected with a vent valve (5). The turbine (1.1) is connected with an exhaust valve (6). The exhaust valve (6), the vent valve (5) and the natural gas system (2) are all electrically connected to the controller (3). The natural gas system (2), the outlet end of the turbine (1.1), the inlet end of the compressor (1.2) and the outlet end of the compressor (1.2) are respectively equipped with a pressure sensor (7), a flow sensor (8) and a temperature sensor (9). It also includes a vibration noise collector (10) for collecting vibration noise and a microphone (11) for collecting noise decibels, wherein the vibration noise collector (10) is connected to the vibration sensor (4) and the microphone (11) is connected to the vibration noise collector (10).

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