Choose A Suitable Bearing

Turbocharger is one of the important technology in the future automotive development. Compared to the naturally aspirated engine which with equal power, the turbocharger always own smaller displacement and lower oil consumption. It has a positive significance on energy saving and emission reduction. When the energy worked, there is a part of the oil supply of turbocharger rotor bearing lubrication and it also could used for cooling.

The running energy stopped suddenly and the oil pressure decreased to zero. The high temperature of turbocharger parts pass to the middle and the heat of bearing shell can not be took away quickly. At the same time, turbocharger rotor is still rotating in high speed with the effect of inertia. So it is easy to make the oil too hot and even damage the bearing if the energy stopped suddenly in heat state.

Turbocharger is composed by fixed nozzle ring, rotating impeller and turbine shell. Some small turbochargers are without nozzle ring because it could reduce the volume and weight, and even make its structure simple. This is called non turbine shell. Turbine impeller and the compressor working wheels shares one rotating shaft, the rotor is just composed by these three parts. With the high speed of the rotor, we muse check its dynamic balance and choose a suitable bearing type to ensure the turbocharger work successfully.

Solve Common Problems In Bearing House

Wear is the most common problem to bearing house. The traditional method to solve this problem is processing by welding machine to repair. Surfacing will make parts surface reach to high temperature and even make the part deformation or cracks. Nowadays we adopt polymer composite materials to repair it on site. There is not any limited to repair the thickness. Repairing in site can save a lot of downtime to manufacture and even create huge production.

The repairing process is very simple. At first, you should do some surface treatment. It means that you should remove grease and moisture from bearing house surface. Then reconcile repairing materials. Secondly, painting the material on the repair parts of the bearing house evenly and filled it strongly. After the material has been cured, you can heat its surface properly and accelerated material curing.

Generally speaking, bearing house wear can be repaired about three hours or even more, but it must be less than six hours. This operation usually easy to learn and don’t need any special equipment and professional training. While on site repairing has reduce the equipment repairing time and transportation cost.

Changing Judgment For Turbocharger Spare Parts

Whether the turbocharger spar parts need change or not is rely on many factors, such as ablation, wear and deformation. In daily life, you had better check turbocharger spar parts carefully.

Sealing ring will produce wear if the turbocharger working with dry friction intermittently. After disassemble, the sealing ring is difficult to recovery and its sealing will be decreased. At this time, you must replace it with a new one. The inner and outer ring of floating bearing are all in the oil film. At the same time, there is little wear. If you find the oil become dirty, oil film scratched or the bearing deformation, you should change floating bearing as soon as possible.

Generally speaking, thrust bearing plate will be without any wear if the oil is enough. But it is easy to plug oil hole if the oil become dirty. Then you may replace it according to the real situation. After the turbine shaft working for a period of time, the shaft surface will be in high temperature and its color will be changed too. As long as there is no obvious scratches and grooves of the shaft neck, you can continue to use. Inner hole wall of floating bearing will not wear due to enough oil supply. You could not change new one if there is no obvious scratch.

Take Good Maintain To Thrust Bearings

Generally speaking, thrust bearing is used on the parts which under axial load side and in high speed, such as crane hook, vertical pump, Hoisting jack and speed reducer. Bearing ring, seat and roller are separate and could assembly and disassembly respectively.

Pump which used just now usually should change the grease after working 100 hours. Then you can change it about 500 hours once. Thrust ball bearing which use grease had better change the grease 1500 hours once, filling oil quantity should be moderate. The thrust ball bearing will be heating because without appropriate amount of grease. In general, the gas volume had better in half or even more.

Container for lubricating oil and lubricating grease should be clean and also in good daily sealing. Dust, debris and other sundries can not exist. So that it will not damage trust ball bearing. Motor thrust ball bearings often use sodium base grease. This nature of the lubricating grease can be resistant to high temperature. But it can dissolve in water. So don’t this lubricating grease in trust ball bearing.

Alloy Material Requirements For Journal Bearings

There are some requirements for journal bearings. Firstly, journal bearings should own enough fatigue resistance. The alloy material will have tiny cracks under alternating load if it has exceed fatigue strength, and even depth development until form alloy layer and  peeling. Secondly, journal bearings need enough wear performance. It includes seizure resistance, compliance, embedded possession and other performance. So journal bearings could be adapt to the negative effects, such as frequent cold starts, short oil, dirty oil or poor performance. Thirdly, Journal bearings had better own good corrosion resistance. Even the journal bearings works in the bad oil, its performance still be stable. Certainly, journal bearings must have enough bond strength in order to ensure that it will not drag shell under dual role.

At present, there are two methods to analysis and calculation nonlinear journal bearings. One adopt numerical methods to solve Reynolds equation directly. Another is analytic method. The former one has high precision, but the calculation speed is slow. The latter one is more easier.

Journal bearing is widely used in precision rotating machinery. Do nonlinear analysis to the radial journal bearing rotor system, and explore the the instability mechanism. It can not only offer theoretical basis to rotating machinery optimization design, mechanical control, fault monitoring and diagnosis, but also has important realistic significance.

Nozzle Ring In Turbocharger

Recent years, he automobile industry has been booming in China and it also has been new pillar to national economy. China has become largest auto market in the world in the year of 2010. With the greatly improved of car ownership, the difficult problem of environmental pollution brought by cars has become placed in front of people.

Some countries have put forward the automobile exhaust emission standards. Certainly China is not exception. The invention and application of turbocharger technology are not only decrease fuel consumption and improve the power of the engine, but also reduce the harmful gas in automobile exhaust components. So Countries of the world, especially the developed countries put a lot of manpower in turbocharger technology and manufacturing. Variable nozzle turbocharger technology is a new technology and has been widely used. It has broad future development.

Nozzle ring vane is the key component for variable nozzle turbocharger. At precent, there is nothing special processing equipment since this technique has just appeared. Now the main process of nozzle blade machining is casting or forging blank. Then machining and optical finishing. Generally speaking, people adopt the method of grinding wheel by hand in China. This is not efficient. However there are many technical personnels studying on the new method in order to improving efficiency.

Key Part To Turbocharger

The key part of turbocharger bearing which is named of lubrication type. It is also called full floating bearing. This bearing is in high working speed and with bad working environment. So ensure lubrication is very important.

Low oil pressure can lead suppling slowly and turbocharger will be in failure. It will not make such failures occur if the energy started normally. Oil supply will be slow when the energy stated at first time after changing the oil. At the same time, the bearing will be lack of oil lubricated. At this condition, you should idle running for about three minutes after starting. Certainly you could not improve the running quickly. While you also could not stop the energy suddenly on the highway or uphill. You must make the energy running for about one minute in order to prevent shorten oil to the turbocharger bearing. So drivers must obey the rule of manufacturers instructions. At the same time, you should be careful to oil quality.

In fact turbocharger is an air compressor. It increase the air intake quantity by compressed air. Sports cars which take part in the competition are usually equipped with turbocharger on the engine. That can make the car burst out more power. Energy is rely on the fuel combustion in the cylinder to generate power.

The entered fuel is limited by amount of air which sucked into the cylinder. You can only increase the output power from compressing more air if the energy has been in the best statue. And even improve combustion performance ability. Turbocharger is an only mechanical device that increase the output power under the same work efficiency.

Exhaust turbocharger Spare Parts

Exhaust turbocharger can improve the power of the engin by the energy of exhaust. Turbocharger can increase the power and torque without increasing engine output. The maximum power output of engine with turbocharger could be increased 40 percent and even more. At the same time, it also can improve the fuel economy and reduce exhaust emissions.

Exhaust turbocharger spare parts are mainly about centrifugal compressor, radial turbine and intermediates.

Centrifugal compressor is composed of intake population, compressor impeller, the compressor, compressor back cover and other parts. The compressor inlet is connected with the air filter through the hose, runoff turbocharger are mostly use the axial air intake type and the air resistance is small. Inlet is generally made by aluminum alloy casting. It can reduce the air resistance. Certainly the inlet surface must be machined. The annular space formed by the gap between the compressor and compressor back cove is known as compressor diffuser. Compressor impeller is consist of blades, wheel hub, wheel disc and wheel cover. Compressor impeller made by aluminum alloy casting and use  nut  fixed on the rotor shaft. The volute collect the air from diffuser pipe and lead air to the compressor outlet.

The turbine is a device that change exhaust energy into mechanical energy. Radial turbine are made from the vortex shell, turbine and the airway. Gas turbine blade and disk are cast into integration by precision method. The shape of the blade generally use a parabolic or general two times curve. Turbine work under the impact of  high temperature,high speed and corrosive gas. So its material must be in high strength, high temperature resistance and corrosion resistance.

How To Use Turbocharger Safely

1.Ensure the connecting clamps between turbocharger, pipes and other connecting bolt are not loosen and eliminate the leakage phenomenon. Check whether the return pipe and inlet pipe are not bending, flattening, oil spills. Joints connecting bolts could be no loose. While turbocharger housing is not overheating color and there is no crack.

2.Piping from the air filter to the turbocharger compressor inlet must be intact.

3.Check the oil quality and twisting the oil by hand. Then observed whether there is any mechanical impurity and viscosity changes and check the amount of oil.

4.Turn the crankshaft several times and do pre lubrication before starting.  Idle for about three to five minutes after starting until the water temperature and oil temperature are all normal. Then speed loading.

5.Diesel engine can not running at idle condition for a long time. Monitor turbocharger condition in operation, you should excluded the problem if the turbocharger noise or vibration is abnormal.

6.Control the intake air temperature strictly while pay attention to the out air temperature. Certainly you also should note the exhaust color. When the power of the diesel engine suddenly dropped and also with the exhaust pipe of black smoke, you should stop to checking immediately.

7.Diesel engine reduce the throttle gradually and idle for three to five minutes before stop.

Common Faults Of Turbocharger

Generally, turbocharger has four kinds of faults. They are oil leakage, compressor surge, excessive noise and overheated.

The reason of leakage are various. Such as the oil is not clean, the solid particle polluted seriously, poor quality or low grade oil, oil supply shortage or low oil pressure, the oil inlet pressure is too high, the air filter is clogged and others. If you have met this problem, you should check your engine speed. If the engine idling time is too long, you should improve the speed. If the import hydraulic booster is too high or too low, you should check the oil level. Add or replace the  eligible oil if it is necessary. If the oil pressure display normal, you should check the oil return channel turbocharger is smooth. Clean air filter, then dredge and clean diesel engine crankcase ventilation device.

The reason of excessive noise is also various. The leak noise because of the connection or the seal is not good. If there is foreign body entered, it may cause damage to the turbine or compress or impeller blade. Movement change of gas will make the supercharger vibration strongly. If you have met this problem, you should check the air filter without obstruction, whether foreign body have entered to the compressor inlet pipe or compressor casing, exhaust system of diesel engine. Diesel engine intake or exhaust pipe is loose and clean up or fastening.

The Development Of Turbocharger

The turbocharger will have a greater torque to meet the driving pleasure. There has been turbocharger with variable boost since in 1989 in order to meet the demand of different engine speeds. The turbocharger reduce the throat and improve the booster at low engine speeds. When the engine is running at full steam and turbocharger throat increased, that will ensure the pressure does not exceed the demand. Throat can control by vacuum tube. Its advantage is improve acceleration performance at the low speed. Now turbocharger have become fewer components,smaller volume, higher speed and air compression ratio has reached 2-2.5:1 for gasoline engine and 4-6:1 for diesel engine.
At present, the turbocharger has accounted for 50%. It is still in growth in Asia and America. Modern turbocharger also changed the views of the diesel engine, turbocharger has become the mainstream direction of improving dynamic performance. The turbocharger also plays an important role in the car in twenty-first Century with the development of new high temperature material, new balance technology and trace oil bearing system and the new use of electronic control. But with the development of technology, there has been factory combine the turbocharged with supercharged to cars which is in mass production.

Turbocharger Benefits

With the emission standards more and more strictly at present, auto manufacturers can satisfy the requirements of environmental protection and customer. It can ensure enough driving pleasure. Turbocharger is able to satisfy to reduce emissions and improve fuel economy. At the same time, it will not lose the fun of driving. Turbocharger can provide better fuel economy,because the pressure will provide more air to the combustion chamber. Combustion will be more thoroughly and emissions will be more clean. Certainly, it can  meet the air supply in high altitude area, make three element catalytic work into faster during the cold starting.
Nowadays, turbocharger has accounted for 50 percent in Europe. Certainly it is also increased in Asia and America. Modern turbocharger also changed the views of the diesel engine. The turbocharger has become the mainstream direction of improving dynamic performance. Turbocharger also has important effect on the car. Turbocharger can improve the power.  It can increase air density in the engine capacity that unchanged and make the engine multiple injection. So it improves the power of the engine, the power and torque can increase about 20 percent after installing the supercharger. Turbocharger can improve the engine emissions. It can reduce particles in engine exhaust and the discharge of harmful components. 

Maintenance Guide For Turbocharge

Firstly, you must use good oil. Turbocharge damaged with broken oil seal between turbocharge and  intake pipe. And it leads mass burning oil. From our research, the damaged oil seal is caused by not changed oil in time or use bad oil. Principal rotation axis of floating turbine can not lubrication and cooling normally. So it will damage the oil seal and cause leaks under high temperature. We suggest that turbocharge should choose good oil with high temperature resistant, good antioxidant.
Secondly keep the turbocharge clean. The gap between the shaft and the shaft sleeve is small. So it will make the turbocharge excessive wear if the oil or oil filter are not clean.
Thirdly, starting should be slow and idle for a while and then stall. Turbine belongs to a high speed moving parts, so it needs real time protection by lubricating oil. At the beginning of cold start, the temperature of oil is usually low and viscous. So the effect of  lubrication is not good. It needs several minutes to make the temperature to normal. If you forced it to work in full load condition of turbine in these several minutes, that will increased wear and shorten its service life.
Finally, regular inspection is very  critical. If you have found some abnormal  phenomenon when driving, you should take it to repair as soon as possible.

Working Principle Of Turbocharger

Turbocharger is a kind of which rely on exhaust gases generated by internal combustion engine to driven air compressor operation. Compared with the supercharger, the turbocharger functions are similar and they also can increase the air that enter to the an internal combustion engine or boiler. So it can improve the efficiency of the machine. In commonly, turbocharger is used in the engine of cars, and use of exhaust heat and flow to improve the engine power output.
Turbocharger is a mechanical device. Because of its working environment is often in high speed, high working temperature, turbocharger exhaust turbine end temperature is above 600 degrees. While the turbocharger speed is very high. So in order to ensure  the supercharger work normally, it is very important to use and maintain correctly.
The mainly effect of turbocharger is improve the air intake of the engine. Then it will improve the engine power and torque. After the engine fitted with a turbocharger, its maximum power has 40 percent higher than with no the supercharger. It is means that, the engine can output more bigger power. For example, 1.8T turbocharged engine power can meet the standard of 2.4L engine after booster. However, fuel consumption is not less than the1.8L engine. In another aspect, it improves the fuel economy and reduce exhaust emissions.
Turbocharge size also effects one car efficient. The smaller the turbo, the sooner it will work,where a larger turbocharger may need a few seconds to fully kick in. A-WIN can provide most kinds of turbocharger for aftermarket.