Research Papers: Gas Turbines: Controls, Diagnostics, and Instrumentation

Turbocharger Synchronous Vibration Control on High Speed Balancer: Test and Prediction

[+] Author and Article Information
Kostandin Gjika

Honeywell Turbo Technologies,
Zone Industrielle Inova 3000,
2 rue de l'Avenir,
Thaon-les-Vosges 88155, France
e-mail: kostandin.gjika@honeywell.com

Pradeep Mahadevan

Honeywell Technology Solutions Lab,
151/1, Doraisanipalya,
Bannerghatta Road,
Bangalore 560076, India,
e-mail: pradeep.mahadevan@honeywell.com

Antoine Costeux

Honeywell Turbo Technologies,
Zone Industrielle Inova 3000,
2 rue de l'Avenir,
Thaon-les-Vosges 88155, France
e-mail: antoine.costeux@honeywell.com

1Corresponding author.

Contributed by the Controls, Diagnostics and Instrumentation Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received January 10, 2014; final manuscript received January 15, 2014; published online February 18, 2014. Editor: David Wisler.

J. Eng. Gas Turbines Power 136(7), 071603 (Feb 18, 2014) (8 pages) Paper No: GTP-14-1018; doi: 10.1115/1.4026600 History: Received January 10, 2014; Revised January 15, 2014

Current trends for advanced automotive engines focusing on downsizing, better fuel efficiency, and lower emissions have led to several changes in turbocharger bearing systems design, and technology. Automotive turbochargers are running faster under high engine vibration level. Vibration control is becoming a real critical issue and turbocharger manufacturers are focusing more and more on new and improved balancing technology. This paper deals with turbocharger synchronous vibration control on high speed balancers. In a first step the synchronous rotordynamics behavior is identified. The developed fluid bearing code predicts bearing rotational speed (in case of fully floating design), operating inner and outer bearing film clearances and bearing force coefficients. A rotordynamics code uses this input to predict the synchronous lateral dynamic response of the rotor-bearing system by converging with bearing eccentricity ratio. The rotor-bearing system model is validated by shaft motion test data on high speed balancer (HSB). It shows that only one of the peaks seen on the synchronous G level plot collected in a high speed balancer can be explained by rotordynamics physics. A step-by-step structural dynamics model and analysis validated by experimental frequency response functions provides robust explanations for the other G level peaks. The synchronous vibration response of the system “turbocharger-HSB fixture” is predicted by integrating the predicted rotordynamics rotational bearing loads on the structural dynamics model. Numerous test data show very good correlation with the prediction, which validates the developed analytical model. The “rotordynamics—structural dynamics model” allows deep understanding of turbocharger synchronous vibration control, as well as optimization of the high speed balancer tooling.

Copyright © 2014 by ASME
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Fig. 1

Fully floating hydrodynamic rotor-bearing system

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Fig. 2

Semifloating hydrodynamic rotor-bearing system

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Fig. 3

Ball bearing rotor-bearing system

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Fig. 4

Radial and axial pressure distribution on hydrodynamic bearing

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Fig. 5

High speed balancer

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Fig. 6

CHRA unbalance master

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Fig. 7

Cross section of test CHRA

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Fig. 8

Structural model of test turbocharger for rotordynamics analysis

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Fig. 9

First two measured and predicted free-free natural frequencies and associated mode shapes of turbocharger rotating group: (a) first bending mode shape and (b) second bending mode shape

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Fig. 10

Measured CHRA master unbalance response and HSB synchronous G level response

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Fig. 11

Finite element model of the assembly “CHRA nonrotating structure-HSB fixture”

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Fig. 12

Excitation/response points on the assembly “CHRA nonrotating structure-HSB fixture”

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Fig. 13

Frequency response functions of the assembly “CHRA non rotating structure-HSB fixture”. Prediction and test data.

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Fig. 14

“CHRA nonrotating structure-HSB fixture” mode shape associated with a natural frequency of 2450 Hz

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Fig. 15

HSB synchronous G level plot under single plane unbalance. Test/prediction on four CHRA masters with different bearing clearances: (a) ODminIDmin; (b) ODmaxIDmin; (c) ODmaxIDmax; (d) ODminIDmax.

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Fig. 16

HSB synchronous G level plot under multiplane unbalance. Test/prediction on four CHRA masters with different bearing clearances: (a) ODminIDmin; (b) ODmaxIDmin; (c) ODmaxIDmax; (d) ODminIDmax.




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