A method and apparatus for predicting the life of a diesel engine supercharger rotating member

Abstract

This disclosure relates to the field of locomotive diesel engine equipment technology, and in particular to a method and apparatus for predicting the lifespan of rotating components of a diesel engine turbocharger. The method includes: obtaining a first remaining service life of the turbocharger rotating component calculated based on the turbine inlet temperature using a first formula; obtaining a second remaining service life of the turbocharger rotating component calculated based on the turbocharger speed using a second formula; obtaining a third remaining service life of the turbocharger rotating component calculated based on the turbocharger oil inlet pressure using a third formula; and obtaining the remaining service life of the turbocharger rotating component using a fourth formula. This method for predicting the lifespan of rotating components of a diesel engine turbocharger enables real-time prediction of the service life of the turbocharger rotating parts, allowing for timely maintenance and repair of the turbocharger, reducing the failure rate and impact of turbocharger rotating components, thereby improving the safety of the diesel engine and reducing operating costs.

Description

Technical Field

[0001] This disclosure relates to the field of locomotive diesel engine equipment technology, and in particular to a method and apparatus for predicting the lifespan of rotating components in a diesel engine turbocharger. Background Technology

[0002] Locomotive diesel engine turbochargers are divided into two types: radial flow and axial flow. Both types of turbochargers contain rotating components, which, as the core components, directly affect the turbocharger's performance and service life. The turbocharger is installed on the end pipe of the diesel engine's exhaust system. It utilizes the energy of the exhaust gases from the combustion in the diesel engine cylinders to drive the rotating components inside the turbocharger, compressing air for combustion in the cylinders. The diesel engine turbocharger, especially the internal rotating components, operates in a very harsh environment. During operation, it is subjected to the impact of high-temperature, high-pressure airflow, and simultaneously, due to its own high-speed rotation, it also experiences high-frequency vibration and centrifugal creep. During locomotive diesel engine operation, due to changes in track and environmental conditions, traction conditions frequently change, and the turbocharger's rotating components are subjected to fatigue creep caused by alternating temperature, rotational speed, and vibration.

[0003] The operating conditions and service life under these conditions are specified in the design, material selection, heat treatment, and manufacturing of turbocharger rotating components. In actual use, the maintenance methods for locomotive diesel engine turbocharger rotating components are either post-failure repair (e.g., damage from foreign objects, high-temperature burns from fuel cut-off) or replacement according to the locomotive's normal maintenance schedule (i.e., a certain amount of operating time or mileage). The actual operating conditions of the rotating components are not monitored or controlled, nor is their actual operating time accurately recorded. Therefore, it is impossible to accurately and effectively ensure the reliability of the turbocharger rotating components, nor to assess their service life in real time.

[0004] Failures in turbocharger rotating components can cause problems such as turbocharger swirl, oil leaks, and fuel leaks, directly affecting diesel engine performance and posing significant safety hazards. At best, this can lead to reduced engine power or shutdown; at worst, it can cause a fire. Because turbocharger rotating components are precision parts within the turbocharger and are affected by external operating conditions and their own weight, there are currently no effective means to monitor their operational status. Their reliability cannot be guaranteed, and potential malfunctions cannot be detected and addressed in advance. The current planned maintenance approach, based on routine inspections, is somewhat inaccurate and fails to accurately reflect the operational status of the turbocharger rotating components, resulting in significant bottlenecks in precise diesel engine maintenance, cost control, and reliable operation.

[0005] Therefore, existing technologies need to be improved. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the purpose of this invention is to provide a method and apparatus for predicting the life of rotating components of a diesel engine turbocharger. This method enables the prediction of the life of rotating components of the turbocharger, reduces the failure rate and impact of failures of the rotating components of the turbocharger, thereby improving the availability and maintenance cost of the diesel engine.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0008] According to one aspect of the present invention, a method for predicting the life of rotating components in a diesel engine turbocharger is provided, comprising:

[0009] The first remaining service life of the turbocharger rotating components is obtained based on the turbocharger turbine inlet temperature according to the first formula. The first formula includes: ty1=t-t1-tx1 and tx1=(t / n1)m1;

[0010] The second remaining service life of the turbocharger rotating parts is obtained based on the second formula calculated according to the turbocharger speed. The second formula includes: ty2=t-t2-tx2 and tx2=(t / n2)m2;

[0011] The third remaining service life of the turbocharger rotating parts is obtained based on the third formula, calculated according to the turbocharger oil inlet pressure. The third formula includes: ty3=t-t3-tx3 and tx3=(t / n3)m3;

[0012] Based on the first remaining service life, the second remaining service life, and the third remaining service life, and according to the fourth formula, the remaining service life of the turbocharger rotating components is obtained. The fourth formula includes:

[0013]

[0014] in:

[0015] ty1 is the first remaining service life, t is the theoretical service life of the turbocharger rotating parts under normal conditions, t1 is the service time of the turbocharger rotating parts under normal turbocharger turbine inlet temperature conditions, tx1 is the equivalent service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, n1 is the theoretical service life of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, and m1 is the service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions.

[0016] ty2 is the second remaining service life, t2 is the service time of the turbocharger rotating parts under normal turbocharger speed, tx2 is the equivalent service time of the turbocharger rotating parts under high turbocharger speed, n2 is the theoretical service life of the turbocharger rotating parts under high turbocharger speed, and m2 is the service time of the turbocharger rotating parts under high turbocharger speed.

[0017] ty3 represents the third remaining service life, t3 represents the service life of the turbocharger rotating parts under normal turbocharger oil inlet pressure, tx3 represents the equivalent service life of the turbocharger rotating parts under low turbocharger oil inlet pressure, n3 represents the theoretical service life of the turbocharger rotating parts under low turbocharger oil inlet pressure, and m3 represents the service life of the turbocharger rotating parts under low turbocharger oil inlet pressure.

[0018] ty represents the remaining service life of the turbocharger's rotating components, w1 represents the weighting factor for the influence of the turbocharger turbine inlet temperature on its service life, w2 represents the weighting factor for the influence of the turbocharger speed on its service life, and w3 represents the weighting factor for the influence of the turbocharger oil inlet pressure on its service life.

[0019] In one embodiment of the present invention,

[0020] The conditions for determining a normal state include: the turbocharger turbine inlet temperature T is less than T1, the turbocharger speed N is less than N1, and the turbocharger oil inlet pressure P is greater than P1.

[0021] The conditions for determining the normal turbocharger turbine inlet temperature state include: the turbocharger turbine inlet temperature T is less than T1;

[0022] The conditions for determining the state of the turbocharger turbine inlet temperature include: the turbocharger turbine inlet temperature T is greater than T1 and less than T2;

[0023] The conditions for determining the normal turbocharger speed state include: the turbocharger speed N is less than N1;

[0024] The conditions for determining the high turbocharger speed state include: the turbocharger speed N is greater than N1 and less than N2;

[0025] The conditions for determining the normal turbocharger oil inlet pressure state include: the turbocharger oil inlet pressure P is greater than P1;

[0026] The conditions for determining the low turbocharger oil inlet pressure include: the turbocharger oil inlet pressure P is less than P1 and greater than P2;

[0027] Wherein, T1 is the normal threshold for turbocharger turbine inlet temperature, N1 is the normal threshold for turbocharger speed, P1 is the normal threshold for turbocharger oil inlet pressure, T2 is the high threshold for turbocharger turbine inlet temperature, N2 is the high threshold for turbocharger speed, and P2 is the low threshold for turbocharger oil inlet pressure, and T1 < T2, N1 < N2, and P1 > P2.

[0028] In one embodiment of the present invention, the theoretical service life t of the turbocharger rotating component under normal conditions is obtained by a first experimental method, the first experimental method including:

[0029] With the turbocharger turbine inlet temperature T lower than T1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger speed N is cyclically varied within the range of 0 to N1. The time from the start of the first test to the failure of the turbocharger rotating parts is obtained as the theoretical service life t of the turbocharger rotating parts under normal conditions.

[0030] In one embodiment of the present invention, the theoretical service life n1 of the turbocharger rotating components under high turbocharger turbine inlet temperature is obtained by a second experimental method, the second experimental method including:

[0031] With the turbocharger speed N lower than N1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger turbine inlet temperature T is cyclically varied within the range of T1 to T2. The time from the start of the second test to the failure of the turbocharger rotating parts is obtained, which is taken as the theoretical service life n1 of the turbocharger rotating parts under high turbine inlet temperature conditions.

[0032] In one embodiment of the present invention, the theoretical service life n2 of the turbocharger rotating component under high turbocharger speed is obtained by a third experimental method, the third experimental method including:

[0033] With the turbocharger turbine inlet temperature T lower than T1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger speed N is cyclically varied within the range of N1 to N2. The time from the start of the third test to the failure of the turbocharger rotating parts is obtained, which is taken as the theoretical service life n2 of the turbocharger rotating parts under high turbocharger speed conditions.

[0034] In one embodiment of the present invention, the theoretical service life of the turbocharger rotating components under low turbocharger oil inlet pressure is obtained by a fourth test method, the fourth test method including:

[0035] With the turbocharger turbine inlet temperature T below T1 and the turbocharger speed below N1, the turbocharger oil inlet pressure is cyclically varied within the range of P1 to P2. The time from the start of the fourth test until the turbocharger rotating component fails is obtained as the theoretical service life n3 of the turbocharger rotating component under low turbocharger oil inlet pressure conditions.

[0036] In one embodiment of the present invention,

[0037] The weighted coefficient for the effect of turbocharger turbine inlet temperature on service life is: w1=n1 / (n1+n2+n3).

[0038] The weighted coefficient for the effect of turbocharger speed on service life is: w2=n2 / (n1+n2+n3).

[0039] The weighted coefficient for the effect of turbocharger oil inlet pressure on service life: w3=n3 / (n1+n2+n3).

[0040] According to another aspect of the present invention, an apparatus for predicting the lifespan of a rotating component of a diesel engine turbocharger is provided, comprising: a data acquisition unit and a data analysis and processing unit. The data acquisition unit is used to acquire operating data of the turbocharger and transmit the acquired operating data to the data analysis and processing unit. The data analysis and processing unit uses the above-described method based on the operating data to calculate the remaining lifespan of the rotating component of the turbocharger. The operating data includes: turbocharger turbine inlet temperature T, turbocharger speed N, and turbocharger oil inlet pressure P.

[0041] In one embodiment of the present invention, the data acquisition unit includes a turbine inlet temperature sensor, a turbocharger speed sensor, and a turbocharger oil inlet pressure sensor, for acquiring the turbocharger turbine inlet temperature T, turbocharger speed N, and turbocharger oil inlet pressure P, respectively.

[0042] In one embodiment of the present invention, the device further includes a display unit connected to the data analysis and processing unit for displaying the remaining service life of the turbocharger rotating component calculated by the data analysis and processing unit.

[0043] The beneficial effects of this invention are:

[0044] By monitoring the operating status of the turbocharger, the service life of the turbocharger's rotating components can be predicted in real time, enabling timely maintenance and repair of the turbocharger, reducing the failure rate and impact of turbocharger rotating components, thereby improving the safety of the diesel engine and reducing operating costs. Attached Figure Description

[0045] Figure 1 A topology diagram of the diesel engine turbocharger rotating component life prediction method provided by the present invention is shown;

[0046] Figure 2 A schematic diagram of the diesel engine turbocharger rotating component life prediction device provided by the present invention is shown. Detailed Implementation

[0047] It should be understood that the embodiments of the invention shown in the exemplary embodiments are merely illustrative. Although only a few embodiments have been described in detail in this invention, those skilled in the art will readily recognize that various modifications are possible without substantially departing from the teachings of the invention. Accordingly, all such modifications should be included within the scope of the invention. Other substitutions, modifications, variations, and deletions can be made to the design, operating conditions, and parameters of the following exemplary embodiments without departing from the spirit of the invention.

[0048] like Figure 1As shown, the present invention provides a method for predicting the life of rotating components of a diesel engine turbocharger, comprising: obtaining the first remaining life of the turbocharger rotating components calculated based on the turbocharger turbine inlet temperature according to a first formula, wherein the first formula includes: ty1=t-t1-tx1 and tx1=(t / n1)m1;

[0049] The second remaining service life of the turbocharger rotating parts is obtained based on the second formula calculated according to the turbocharger speed. The second formula includes: ty2=t-t2-tx2 and tx2=(t / n2)m2;

[0050] The third remaining service life of the turbocharger rotating parts is obtained based on the third formula, calculated according to the turbocharger oil inlet pressure. The third formula includes: ty3=t-t3-tx3 and tx3=(t / n3)m3;

[0051] Based on the first remaining service life, the second remaining service life, and the third remaining service life, and according to the fourth formula, the remaining service life of the turbocharger rotating component is obtained. The fourth formula includes:

[0052]

[0053] Where: ty1 is the first remaining service life, t is the theoretical service life of the turbocharger rotating parts under normal conditions, t1 is the service time of the turbocharger rotating parts under normal turbocharger turbine inlet temperature conditions, tx1 is the equivalent service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, n1 is the theoretical service life of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, and m1 is the service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions; ty2 is the second remaining service life, t2 is the service time of the turbocharger rotating parts under normal turbocharger speed conditions, tx2 is the equivalent service time of the turbocharger rotating parts under high turbocharger speed conditions, and n2 is the theoretical service life of the turbocharger rotating parts under high turbocharger speed conditions. m2 represents the service life of the turbocharger rotating parts under high turbocharger speed conditions; ty3 represents the third remaining service life; t3 represents the service life of the turbocharger rotating parts under normal turbocharger oil inlet pressure conditions; tx3 represents the equivalent service life of the turbocharger rotating parts under low turbocharger oil inlet pressure conditions; n3 represents the theoretical service life of the turbocharger rotating parts under low turbocharger oil inlet pressure conditions; m3 represents the service life of the turbocharger rotating parts under low turbocharger oil inlet pressure conditions; ty represents the remaining service life of the turbocharger rotating parts; w1 represents the weighting coefficient of the influence of turbocharger turbine inlet temperature on service life; w2 represents the weighting coefficient of the influence of turbocharger speed on service life; and w3 represents the weighting coefficient of the influence of turbocharger oil inlet pressure on service life.

[0054] The above-mentioned technical solution of the present invention enables real-time prediction of the service life of the turbocharger rotating components, so as to enable timely maintenance and repair of the turbocharger, reduce the failure rate and impact of the turbocharger rotating components, thereby improving the safety of the diesel engine and reducing the operation and maintenance costs.

[0055] In the above method,

[0056] The conditions for determining a normal state include: the turbocharger turbine inlet temperature T is less than T1, the turbocharger speed N is less than N1, and the turbocharger oil inlet pressure P is greater than P1.

[0057] The conditions for determining the normal turbocharger turbine inlet temperature state include: the turbocharger turbine inlet temperature T is less than T1;

[0058] The conditions for determining the state of the turbocharger turbine inlet temperature include: the turbocharger turbine inlet temperature T is greater than T1 and less than T2;

[0059] The conditions for determining the normal turbocharger speed state include: the turbocharger speed N is less than N1;

[0060] The conditions for determining the high turbocharger speed state include: the turbocharger speed N is greater than N1 and less than N2;

[0061] The conditions for determining the normal turbocharger oil inlet pressure state include: the turbocharger oil inlet pressure P is greater than P1;

[0062] The conditions for determining the low turbocharger oil inlet pressure include: the turbocharger oil inlet pressure P is less than P1 and greater than P2;

[0063] Wherein, T1 is the normal threshold for turbocharger turbine inlet temperature, N1 is the normal threshold for turbocharger speed, P1 is the normal threshold for turbocharger oil inlet pressure, T2 is the high threshold for turbocharger turbine inlet temperature, N2 is the high threshold for turbocharger speed, and P2 is the low threshold for turbocharger oil inlet pressure, and T1 < T2, N1 < N2, and P1 > P2.

[0064] In the above method, the theoretical service life t of the turbocharger rotating component under normal conditions is obtained through the first test method, which includes:

[0065] With the turbocharger turbine inlet temperature T lower than T1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger speed N is cyclically varied within the range of 0 to N1. The time from the start of the first test to the failure of the turbocharger rotating parts is obtained as the theoretical service life t of the turbocharger rotating parts under normal conditions.

[0066] In the above method, the theoretical service life n1 of the turbocharger rotating components under high turbocharger turbine inlet temperature is obtained through a second experimental method, which includes:

[0067] With the turbocharger speed N lower than N1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger turbine inlet temperature T is cyclically varied within the range of T1 to T2. The time from the start of the second test to the failure of the turbocharger rotating parts is obtained, which is taken as the theoretical service life n1 of the turbocharger rotating parts under high turbine inlet temperature conditions.

[0068] In the above method, the theoretical service life n2 of the turbocharger rotating parts under high turbocharger speed is obtained through a third test method. The third test method includes:

[0069] With the turbocharger turbine inlet temperature T lower than T1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger speed N is cyclically varied within the range of N1 to N2. The time from the start of the third test to the failure of the turbocharger rotating parts is obtained, which is taken as the theoretical service life n2 of the turbocharger rotating parts under high turbocharger speed conditions.

[0070] In the above method, the theoretical service life of the turbocharger rotating parts under low turbocharger oil inlet pressure is obtained through the fourth test method. The fourth test method includes:

[0071] With the turbocharger turbine inlet temperature T below T1 and the turbocharger speed below N1, the turbocharger oil inlet pressure is cyclically varied within the range of P1 to P2. The time from the start of the fourth test until the turbocharger rotating component fails is obtained as the theoretical service life n3 of the turbocharger rotating component under low turbocharger oil inlet pressure conditions.

[0072] In the above method,

[0073] The weighted coefficient for the effect of turbocharger turbine inlet temperature on service life is: w1=n1 / (n1+n2+n3).

[0074] The weighted coefficient for the effect of turbocharger speed on service life is: w2=n2 / (n1+n2+n3).

[0075] The weighted coefficient for the effect of turbocharger oil inlet pressure on service life: w3=n3 / (n1+n2+n3).

[0076] In addition, such as Figure 2 As shown, the present invention provides a device for predicting the lifespan of rotating components of a diesel engine turbocharger, comprising: a data acquisition unit and a data analysis and processing unit. The data acquisition unit is used to collect the operating data of the turbocharger and transmit the collected operating data to the data analysis and processing unit. The data analysis and processing unit uses the above-mentioned method to calculate the remaining lifespan of the turbocharger rotating components based on the operating data. The operating data includes: turbocharger turbine inlet temperature T, turbocharger speed N, and turbocharger oil inlet pressure P.

[0077] In the above-mentioned device, the data acquisition unit includes a turbine inlet temperature sensor, a turbocharger speed sensor, and a turbocharger oil inlet pressure sensor, which are used to collect the turbocharger turbine inlet temperature T, turbocharger speed N, and turbocharger oil inlet pressure P, respectively.

[0078] The device also includes a display unit connected to the data analysis and processing unit to display the remaining service life of the turbocharger rotating component calculated by the data analysis and processing unit.

[0079] Example:

[0080] Figure 1 The diagram shows a topology for a method to predict the lifespan of rotating components in a diesel engine turbocharger. To implement the prediction method shown in the topology diagram, a design is as follows... Figure 2 The prediction device shown adopts a 32-bit high-speed single-chip microcomputer system (hereinafter referred to as "system device"). The system device integrates a 24V regulated power conversion module, a data acquisition unit, a data analysis and processing unit, a data storage unit, a data transmission unit, and a data display unit. The system hardware realizes parameter early warning, power reduction and shutdown protection functions, data acquisition and processing functions, data storage functions, remaining service life assessment functions, and data transmission functions through software programs.

[0081] The system is powered by an external 110V DC power supply. The system has a power supply interface and integrates a 24V regulated power conversion module, which converts the voltage to power all integrated modules of the system.

[0082] The turbine inlet temperature sensor and the turbocharger oil inlet pressure sensor typically output 4–20mA current signals or 0–5V voltage signals. These sensors are active and require external power or are powered internally by the system. The turbocharger speed sensor is a magnetoelectric sensor; its output signal is typically a potential signal. It directly converts the mechanical energy of the measured object into an electrical signal output and is a passive sensor, requiring no external power. The integrated data acquisition unit of the system needs to power the active sensors and simultaneously convert the sensor output electrical signals into analog signals for transmission to the data analysis and processing unit. The data acquisition unit generally uses electronic chips or integrated circuit boards with strong filtering and anti-interference capabilities.

[0083] The system integrates a data analysis and processing unit, which can use a customized integrated circuit board according to the design functional requirements. This unit is responsible for analyzing and processing the data from the data acquisition unit, and includes system software. The software incorporates a two-level threshold analysis and processing mechanism. The first level sets the normal thresholds for turbocharger turbine inlet temperature (T1), turbocharger speed (N1), and turbocharger oil inlet pressure (P1). The second level sets the high thresholds for turbocharger turbine inlet temperature (T2), turbocharger speed (N2), and turbocharger oil inlet pressure (P2). When these three indicators are below T1, below N1, and above P1, the turbocharger is in a normal state. When these three indicators are between T1 and T2, N1 and N2, and P1 and P2, the turbocharger is in a high-load operating state. When these three indicators are above T2, above N2, and below P2, the turbocharger is in a prohibited operating state, at which point the diesel engine control system executes a shutdown command. T2, N2, and P2 are the maximum permissible operating parameters of the turbocharger; T1 and N1 are 85% to 90% of the maximum permissible operating parameters; and P1 is 110% to 115% of the maximum permissible operating parameters.

[0084] The system software of the data analysis and processing unit is designed with analysis and statistical functions for the collected data, including the statistical analysis of the normal working state time t1, t2, t3, and the high-load working state time m1, m2, m3.

[0085] The system software of the data analysis and processing unit is designed with a function to predict the remaining service life of the turbocharger rotating components. The specific algorithm is as follows:

[0086] a) ty1=t-t1-tx1

[0087] tx1 = (t / n1)m1

[0088] In the formula, t is the theoretical service life (time) of the turbocharger rotating parts under normal conditions, n1 is the theoretical service life (time) of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, t1 is the service time of the turbocharger rotating parts under normal turbocharger turbine inlet temperature conditions, m1 is the service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, tx1 is the equivalent service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, and ty1 is the first remaining service life (time) of the turbocharger rotating parts calculated based on the turbocharger turbine inlet temperature.

[0089] b) ty2 = t - t2 - tx2

[0090] tx2 = (t / n2)m2

[0091] In the formula, t is the theoretical service life (time) of the turbocharger rotating parts under normal conditions, n2 is the theoretical service life (time) of the turbocharger rotating parts under high turbocharger speed conditions, t2 is the service time of the turbocharger rotating parts under normal turbocharger speed conditions, m2 is the service time of the turbocharger rotating parts under high turbocharger speed conditions, tx2 is the equivalent service time of the turbocharger rotating parts under high turbocharger speed conditions, and ty2 is the second remaining service life (time) of the turbocharger rotating parts calculated based on the turbocharger speed.

[0092] c) ty3 = t - t3 - tx3

[0093] tx3 = (t / n3) m3

[0094] In the formula, t is the theoretical service life (time) of the turbocharger rotating parts under normal conditions, n3 is the theoretical service life (time) of the turbocharger rotating parts under low turbocharger oil inlet pressure, t3 is the service time of the turbocharger rotating parts under normal turbocharger oil inlet pressure, m3 is the service time of the turbocharger rotating parts under low turbocharger oil inlet pressure, tx3 is the equivalent service time of the turbocharger rotating parts under low turbocharger oil inlet pressure, and ty3 is the third remaining service life (time) of the turbocharger rotating parts calculated based on the turbocharger oil inlet pressure.

[0095] d)

[0096]

[0097] In the formula, ty1 is the first remaining service life (time), ty2 is the second remaining service life (time), ty3 is the third remaining service life (time), ty is the remaining service life (time) of the turbocharger rotating parts, w1 is the weighting coefficient of the influence of turbine inlet temperature on service life, w2 is the weighting coefficient of the influence of turbocharger speed on service life, and w3 is the weighting coefficient of the influence of turbocharger oil inlet pressure on service life.

[0098] The theoretical service life (time) t, n1, n2, n3 of the turbocharger under various states, stored in the data analysis and processing unit system software, as well as the weighting coefficients w1, w2, w3 affecting the service life of the turbocharger's rotating parts, can all be determined through turbocharger reliability growth tests (RGT), as follows:

[0099] 1) The theoretical service life (time) t of the turbocharger under normal conditions was obtained using the first test method:

[0100] Specific implementation process: Multiple turbocharger samples of different models are selected for testing. Turbocharger speed is usually used as the basic variable for load alternation. The turbocharger speed N is in the range of 0 to N1. Every 10 minutes of operation, the turbocharger speed N increases by 2000 rpm. After N gradually increases from 0 to N1, the next identical cycle begins. During the test, the turbocharger turbine inlet temperature T is strictly controlled to be lower than T1 and the turbocharger oil inlet pressure P is higher than P1 until the rotating parts of the turbocharger fail. The test time of multiple turbochargers is counted, and the average value is taken as the theoretical service life (time) t of the turbocharger under normal conditions.

[0101] 2) The theoretical service life (time) n1 of the turbocharger rotating components under high turbocharger turbine inlet temperature conditions was obtained using the second experimental method:

[0102] Specific implementation process: Select multiple turbocharger samples for testing. The turbocharger turbine inlet temperature T is within the range of T1 to T2. Every 10 minutes of operation, the turbocharger turbine inlet temperature T increases by 5°C. After T gradually increases from T1 to T2, the next identical cycle begins. During the test, the turbocharger speed N is strictly controlled to be lower than T1 and the turbocharger oil inlet pressure P is higher than P1 until the rotating parts of the turbocharger fail. The test time of multiple turbochargers is counted, and the average value is taken as the theoretical service life (time) n1 of the rotating parts of the turbocharger under high turbine inlet temperature conditions.

[0103] 3) The theoretical service life (time) n2 of the turbocharger rotating components at high turbocharger speed was obtained using the third test method:

[0104] Specific implementation process: Select multiple turbocharger samples for testing. The turbocharger speed N is within the range of N1 to N2. Every 10 minutes of operation, the turbocharger speed N increases by 2000 rpm. After N gradually increases from N1 to N2, the next identical cycle begins. During the test, the turbocharger turbine inlet temperature T is strictly controlled to be lower than T1 and the turbocharger oil inlet pressure P is higher than P1 until the rotating parts of the turbocharger fail. The test time of multiple turbochargers is counted, and the average value is taken as the theoretical service life (time) n2 of the rotating parts of the turbocharger under high turbocharger speed conditions.

[0105] 4) The theoretical service life (time) n1 of the turbocharger rotating parts under low turbocharger oil inlet pressure was obtained using the fourth test method:

[0106] Specific implementation process: Select multiple turbocharger samples for testing. The turbocharger oil inlet pressure P is within the range of P1 to P2. Every 10 minutes of operation, the turbocharger oil inlet pressure P decreases by 10 kPa. After P gradually decreases from P1 to P2, the next identical cycle begins. During the test, the turbocharger turbine inlet temperature T is strictly controlled to be lower than T1 and the turbocharger speed N is lower than N1 until the rotating parts of the turbocharger fail. The test time of multiple turbochargers is counted, and the average value is taken as the theoretical service life (time) n3 of the turbocharger rotating parts under the low turbocharger oil inlet pressure state.

[0107] 5) Method for determining the weighting coefficients w1, w2, and w3 for the service life of the turbocharger rotating components:

[0108] w1 = n1 / (n1 + n2 + n3);

[0109] w2 = n2 / (n1 + n2 + n3);

[0110] w3 = n3 / (n1 + n2 + n3).

[0111] The system unit integrates a data storage unit to store the processed data from the data analysis and processing unit, typically using a standard portable hard drive. The recorded data includes the times t1, t2, and t3 during normal operation of the turbocharger, the times m1, m2, and m3 during high-load operation, and the remaining service life ty of the turbocharger.

[0112] The system device integrates a debugging interface module, typically a USB interface module. This is used for system device software installation, monitoring, and debugging, and also for downloading recorded data.

[0113] The system integrates a data transmission unit to enable external communication for processed data, and can utilize an integrated Ethernet gateway for data communication. Data from the data analysis and processing unit is sent to a data display unit, which is integrated into the system's casing for real-time viewing.

[0114] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. Any modifications or equivalent substitutions made to the present invention without departing from the spirit and scope thereof should be covered within the protection scope of the claims of the present invention.

Claims

1. A method for predicting the lifespan of rotating components in a diesel engine turbocharger, characterized in that, include: The first remaining service life of the turbocharger rotating components is obtained based on the turbocharger turbine inlet temperature according to the first formula, which includes: ty1=t-t1-tx1 and tx1=(t / n1)m1; The second remaining service life of the turbocharger rotating parts is obtained based on the second formula calculated according to the turbocharger speed. The second formula includes: ty2=t-t2-tx2 and tx2=(t / n2)m2; The third remaining service life of the turbocharger rotating parts is obtained based on the third formula, calculated according to the turbocharger oil inlet pressure. The third formula includes: ty3=t-t3-tx3 and tx3=(t / n3)m3; Based on the first remaining service life, the second remaining service life, and the third remaining service life, and according to the fourth formula, the remaining service life of the turbocharger rotating component is obtained, wherein the fourth formula includes: in: ty1 is the first remaining service life, t is the theoretical service life of the turbocharger rotating parts under normal conditions, t1 is the service time of the turbocharger rotating parts under normal turbocharger turbine inlet temperature conditions, tx1 is the equivalent service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, n1 is the theoretical service life of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions, and m1 is the service time of the turbocharger rotating parts under high turbocharger turbine inlet temperature conditions. ty2 is the second remaining service life, t2 is the service time of the turbocharger rotating parts under normal turbocharger speed, tx2 is the equivalent service time of the turbocharger rotating parts under high turbocharger speed, n2 is the theoretical service life of the turbocharger rotating parts under high turbocharger speed, and m2 is the service time of the turbocharger rotating parts under high turbocharger speed. ty3 represents the third remaining service life, t3 represents the service life of the turbocharger rotating parts under normal turbocharger oil inlet pressure, tx3 represents the equivalent service life of the turbocharger rotating parts under low turbocharger oil inlet pressure, n3 represents the theoretical service life of the turbocharger rotating parts under low turbocharger oil inlet pressure, and m3 represents the service life of the turbocharger rotating parts under low turbocharger oil inlet pressure. ty represents the remaining service life of the turbocharger rotating parts, w1 represents the weighting coefficient of the turbocharger turbine inlet temperature on the service life, w2 represents the weighting coefficient of the turbocharger speed on the service life, and w3 represents the weighting coefficient of the turbocharger oil inlet pressure on the service life. The conditions for determining the normal state include: the turbocharger turbine inlet temperature T is less than T1, the turbocharger speed N is less than N1, and the turbocharger oil inlet pressure P is greater than P1. The conditions for determining the normal turbocharger turbine inlet temperature state include: the turbocharger turbine inlet temperature T is less than T1; The conditions for determining the state of the turbocharger turbine inlet temperature include: the turbocharger turbine inlet temperature T is greater than T1 and less than T2; The conditions for determining the normal turbocharger speed state include: the turbocharger speed N is less than N1; The conditions for determining the high booster speed state include: the booster speed N is greater than N1 and less than N2; The conditions for determining the normal turbocharger oil inlet pressure state include: the turbocharger oil inlet pressure P is greater than P1; The conditions for determining the low turbocharger oil inlet pressure include: the turbocharger oil inlet pressure P is less than P1 and greater than P2. Wherein, T1 is the normal threshold of turbocharger turbine inlet temperature, N1 is the normal threshold of turbocharger speed, P1 is the normal threshold of turbocharger oil inlet pressure, T2 is the high threshold of turbocharger turbine inlet temperature, N2 is the high threshold of turbocharger speed, and P2 is the low threshold of turbocharger oil inlet pressure, and T1 < T2, N1 < N2, P1 > P2. The weighted coefficient for the effect of turbocharger turbine inlet temperature on service life is: w1=n1 / (n1+n2+n3). The weighted coefficient for the effect of turbocharger speed on service life is: w2=n2 / (n1+n2+n3). The weighted coefficient for the effect of turbocharger oil inlet pressure on service life: w3=n3 / (n1+n2+n3).

2. The method for predicting the lifespan of rotating components in a diesel engine turbocharger according to claim 1, characterized in that, The theoretical service life t of the turbocharger rotating component under normal conditions was obtained through a first test method, which included: With the turbocharger turbine inlet temperature T lower than T1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger speed N is cyclically varied within the range of 0 to N1. The time from the start of the first test to the failure of the turbocharger rotating parts is obtained as the theoretical service life t of the turbocharger rotating parts under normal conditions.

3. The method for predicting the lifespan of rotating components in a diesel engine turbocharger according to claim 1, characterized in that, The theoretical service life n1 of the turbocharger rotating components under high turbocharger turbine inlet temperature was obtained through a second experimental method, which included: With the turbocharger speed N lower than N1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger turbine inlet temperature T is cyclically varied within the range of T1 to T2. The time from the start of the second test to the failure of the turbocharger rotating parts is obtained, which is taken as the theoretical service life n1 of the turbocharger rotating parts under high turbine inlet temperature conditions.

4. The method for predicting the lifespan of rotating components in a diesel engine turbocharger according to claim 1, characterized in that, The theoretical service life n2 of the turbocharger rotating components under high turbocharger speed conditions was obtained through a third experimental method, which included: With the turbocharger turbine inlet temperature T lower than T1 and the turbocharger oil inlet pressure P higher than P1, the turbocharger speed N is cyclically varied within the range of N1 to N2. The time from the start of the third test to the failure of the turbocharger rotating parts is obtained, which is taken as the theoretical service life n2 of the turbocharger rotating parts under high turbocharger speed conditions.

5. The method for predicting the lifespan of rotating components in a diesel engine turbocharger according to claim 1, characterized in that, The theoretical service life of the turbocharger rotating components under low turbocharger oil inlet pressure was obtained through a fourth test method, which includes: When the turbocharger turbine inlet temperature T is lower than T1 and the turbocharger speed is lower than N1, the turbocharger oil inlet pressure is cyclically varied within the range of P1 to P2. The time from the start of the fourth test to the failure of the turbocharger rotating parts is obtained, which is the theoretical service life n3 of the turbocharger rotating parts under the low turbocharger oil inlet pressure condition.

6. A device for predicting the lifespan of rotating components in a diesel engine turbocharger, characterized in that, include: The system includes a data acquisition unit and a data analysis and processing unit. The data acquisition unit collects the operating data of the turbocharger and transmits the collected operating data to the data analysis and processing unit. The data analysis and processing unit has internal system software, which includes a two-level threshold analysis and processing mechanism, a data analysis and statistical function, and a function to predict the remaining service life of the turbocharger rotating components. The first level includes the normal threshold values ​​T1 for turbocharger turbine inlet temperature, N1 for turbocharger speed, and P1 for turbocharger oil inlet pressure. The second level includes the high threshold values ​​T2 for turbocharger turbine inlet temperature, N2 for turbocharger speed, and P2 for turbocharger oil inlet pressure. The data analysis and processing unit calculates the remaining service life of the turbocharger rotating components based on the operating data using the method described in any one of claims 1-5. The operating data includes: turbocharger turbine inlet temperature T, turbocharger speed N, and turbocharger oil inlet pressure P.

7. The apparatus for predicting the lifespan of rotating components of a diesel engine turbocharger according to claim 6, characterized in that, The data acquisition unit includes a turbine inlet temperature sensor, a turbocharger speed sensor, and a turbocharger oil inlet pressure sensor, which are used to collect the turbocharger turbine inlet temperature T, turbocharger speed T, and turbocharger oil inlet pressure P, respectively.

8. The apparatus for predicting the lifespan of rotating components of a diesel engine turbocharger according to claim 6, characterized in that, The device further includes a display unit connected to the data analysis and processing unit to display the remaining service life of the turbocharger rotating component calculated by the data analysis and processing unit.

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