CN113266461B - Fault detection method, control device, turbocharger and engine system - Google Patents
Fault detection method, control device, turbocharger and engine system Download PDFInfo
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- CN113266461B CN113266461B CN202110638280.9A CN202110638280A CN113266461B CN 113266461 B CN113266461 B CN 113266461B CN 202110638280 A CN202110638280 A CN 202110638280A CN 113266461 B CN113266461 B CN 113266461B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B39/00—Component parts, details, or accessories relating to, driven charging or scavenging pumps, not provided for in groups F02B33/00 - F02B37/00
- F02B39/16—Other safety measures for, or other control of, pumps
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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Abstract
The invention provides a fault detection method, a control device, a turbocharger and an engine system, and belongs to the technical field of engine system control. The fault detection method comprises the following steps: acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor; and determining fault information of the turbocharger according to the air inlet pressure, the air outlet pressure and the air inlet flow. Therefore, in the design process of the turbocharger, the possible faults of the turbocharger are predicted, and the problem that fault boundary measurement is inconsistent due to manual judgment is avoided. On the premise of ensuring the accuracy of fault detection, the method improves the timeliness and comprehensiveness of fault detection, helps users to quickly locate problems, avoids performance reduction caused by faults when the turbocharger runs actually, and plays a role in protecting the turbocharger and an engine and even protecting personal safety.
Description
Technical Field
The invention relates to the technical field of engine system control, in particular to a fault detection method, a control device, a turbocharger and an engine system.
Background
The turbocharger is a core part of a supercharged engine, and usually works under the conditions of high temperature, high load and high rotating speed, the limit rotating speed is as high as more than 20 tens of thousands of revolutions, when the turbocharger fails, the abrasion or the damage of the turbocharger can be accelerated, the impeller shaft system of the turbocharger is damaged and fails, and chips and engine oil enter a cylinder to damage the whole engine under severe conditions.
In the related technology, whether the supercharger has a surge fault or not is judged by monitoring the temperature change at the air inlet of the air compressor, and because the temperature is easily influenced by the external environment and the temperature change has hysteresis, whether the supercharger has surge or not can not be accurately judged in partial scenes, so that the method can not completely cover all use areas of the whole vehicle and can not monitor other kinds of fault problems.
Disclosure of Invention
The invention aims to at least solve or improve the problem that whether the supercharger fails or not can not be accurately and comprehensively judged under partial scenes in the prior art or the related technology.
To this end, a first aspect of the invention provides a failure detection method of a turbocharger.
The second aspect of the invention also provides a control device.
A third aspect of the invention also provides a turbocharger.
The fourth aspect of the invention also provides an engine system.
The fifth aspect of the present invention also provides a readable storage medium.
In view of this, a first aspect of the present invention provides a method for detecting a failure of a turbocharger, including: acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor; and determining fault information of the turbocharger according to the air inlet pressure, the air outlet pressure and the air inlet flow.
The invention provides a fault detection method of a turbocharger, which considers that the fault problems of surging, overspeed, blockage and the like of the turbocharger are all related to air flowing in a compressor. Therefore, when the turbocharger is designed, the supercharging pressure ratio of air flowing through the air compressor is determined according to the air inlet pressure and the air outlet pressure of the air compressor so as to reflect the compression degree of the air compressor to the air, meanwhile, whether the turbocharger has a fault or not is judged according to the supercharging pressure ratio and the air inlet flow of the air compressor, and possible fault reasons are analyzed when the turbocharger has the fault. On one hand, when the turbocharger is designed in a calibration mode, possible faults of the turbocharger can be predicted, and the problem that fault boundary measurement is inconsistent due to manual judgment is solved. On the other hand, on the premise of ensuring the accuracy of fault detection, the timeliness and comprehensiveness of fault detection are improved, a user is helped to quickly locate problems, performance reduction caused by the fact that flow field parameters (such as pressure, flow, temperature, noise and the like) of the gas compressor exceed a fault boundary in the actual operation process of the turbocharger is avoided, and the effects of protecting the turbocharger and an engine and even protecting personal safety are achieved.
In addition, the turbocharger includes: the device comprises a turbine, a gas compressor, a gas inlet pipeline, a gas outlet pipeline and a detection device. The air compressor is connected with the turbine and can compress air under the driving of the turbine. The air inlet pipeline is connected between the air source and the compressor and used for transmitting air to the compressor. The air outlet pipeline is connected between the air compressor and the engine and used for transmitting compressed air to a cylinder of the engine so as to increase the combustion amount of fuel in the engine and the rotating speed of the engine and enhance the output power of the engine. Then, the exhaust gas generated by the operation of the engine drives the turbine to rotate under the inertia effect, and further, the compressor is continuously driven to perform gas compression.
Specifically, the fault information includes whether the turbocharger is faulty and the cause of the fault, including surge, overspeed, clogging, and the like. The turbocharger surge is an unstable flow phenomenon of a compressor for the turbocharger in a small flow area, namely, the compressor for the turbocharger flows in an axial direction, various flow field parameters of the compression system oscillate to a large extent after the surge occurs, the compressor is greatly damaged, and the safety and the reliability of an engine are influenced. When the negative pressure of the air inlet is too large and enters an area above the allowable altitude of the engine, the fuel injection quantity of a fuel injection system of the engine is too large, so that the exhaust temperature, the pressure and the like are too large, the turbocharger can overspeed, the abrasion or the damage of the turbocharger is accelerated, and the normal service life of the engine is directly shortened. The compressor is blocked, namely the rotating speed is unchanged, after the flow rate is increased to a certain value, the pressure ratio is sharply reduced, and the flow rate cannot be continuously increased. This may increase the resistance of the airflow in the intake system, deteriorating engine performance.
According to the above-mentioned turbocharger failure detection method provided by the present invention, the following additional features may be provided:
in any of the above technical solutions, further determining fault information of the turbocharger according to the intake pressure, the outlet pressure, and the intake flow rate includes: calculating the ratio of air pressure to air inlet pressure; if the air inflow is in the preset flow range, determining a preset pressure ratio range corresponding to the air inflow; if the ratio is in the preset pressure ratio range, determining that the turbocharger has no fault; and if the air inflow exceeds the preset flow range or the ratio exceeds the preset pressure ratio range, determining the fault of the turbocharger and analyzing the fault reason.
In the technical scheme, division operation is performed on the outlet pressure and the inlet pressure to obtain the ratio of the outlet pressure to the inlet pressure, namely the supercharging pressure ratio. And comparing the air inflow with a preset flow range, and determining a preset pressure ratio range corresponding to the air inflow according to the corresponding relation between the preset air inflow and the preset pressure ratio range under the condition that the air inflow is in the preset flow range, wherein the preset pressure ratio range is used for representing the pressure ratio boundary of the normal work of the gas compressor. Whether the turbocharger breaks down or not is judged by comparing the ratio of the air outlet pressure to the air inlet pressure and the preset pressure ratio range, so that fault detection is realized by combining the air inlet flow and the supercharging pressure ratio, and the fault problem under different flow scenes can be judged, so that the fault diagnosis reliability of the turbocharger is remarkably improved, corresponding protection measures can be conveniently and timely adopted to avoid damage to equipment or reduce the damage degree of the equipment, the maintenance cost is reduced, and the running reliability of an engine system is ensured.
Specifically, on the basis that the intake flow is in the preset flow range, it is detected that the ratio (supercharging pressure ratio) of the outlet pressure to the intake pressure is in the preset pressure ratio range, that is, the ratio is greater than or equal to the lower limit value of the preset pressure ratio range and is less than or equal to the upper limit value of the preset pressure ratio range, it is determined that the compressor is working normally, and it is determined that the turbocharger is not in fault. When the air inlet flow exceeds a preset flow range or the ratio of the air outlet pressure to the air inlet pressure (supercharging pressure ratio) exceeds a preset pressure ratio range, namely the ratio is smaller than the lower limit value of the preset pressure ratio range and larger than the upper limit value of the preset pressure ratio range, the flow field parameters of the air compressor do not accord with the minimum standard when the air compressor works normally, the turbocharger is determined to have faults, detailed fault reasons are analyzed, so that a user can be helped to quickly locate the problems, the faults are timely eliminated by adopting corresponding protection measures, and the maintenance efficiency is improved.
In any of the above technical solutions, further, the preset flow range includes a first flow range, a second flow range, and a third flow range; analyzing the fault cause, including: if the air inflow exceeds the preset flow range, determining that the turbocharger has a flow metering fault; if the intake air flow is in the first flow range and the ratio is larger than the upper limit value of the preset pressure ratio range corresponding to the intake air flow, determining that the turbocharger has surge fault; if the intake air flow is in the second flow range and the ratio is larger than the upper limit value of the preset pressure ratio range corresponding to the intake air flow, determining that the turbocharger has overspeed fault; and if the intake flow is in the third flow range and the ratio is smaller than the lower limit value of the preset pressure ratio range corresponding to the intake flow, determining that the turbocharger has a blockage fault.
In the technical scheme, the preset flow range comprises a first flow range, a second flow range and a third flow range, the first flow range corresponds to a possible flow range of the turbocharger when a surge fault occurs, the second flow range corresponds to a possible flow range of the turbocharger when an overspeed fault occurs, and the third flow range corresponds to a possible flow range of the turbocharger when a blockage fault occurs.
When the intake air flow exceeds the preset flow range, it indicates that the intake air flow exceeds the flow range covered by the compressor during operation, and at this time, it may be that the device for detecting the flow in the turbocharger is out of order.
And if the ratio is larger than the upper limit value of the preset pressure ratio range, the supercharging pressure ratio is larger, the outlet pressure is far larger than the inlet pressure, and the fault reason is determined to be surging.
And under the condition that the intake flow is in the upper limit value of the second flow range, the intake flow meets the flow condition with overspeed fault, the ratio is further compared with a preset pressure ratio range corresponding to the intake flow, and if the ratio is larger than the upper limit value of the preset pressure ratio range, the supercharging pressure ratio is larger, and the fault reason is determined to be overspeed.
And under the condition that the intake flow is in the upper limit value of the third flow range, the intake flow meets the flow condition with the blockage fault, the ratio is further compared with a preset pressure ratio range corresponding to the intake flow, if the ratio is smaller than the lower limit value of the preset pressure ratio range, the supercharging pressure ratio is smaller, the compressor does not compress the air entering the compressor to the extent of meeting the requirement, the supercharging efficiency is low, and the fault reason is determined to be blockage.
Through the scheme, the possible problem range can be determined by utilizing the real-time air inlet flow of the air compressor, and the fault problem can be accurately positioned by combining the ratio of the air outlet pressure to the air inlet pressure. The fault diagnosis reliability of the turbocharger is remarkably improved, corresponding protection measures can be conveniently and timely adopted to avoid damage to equipment or reduce the damage degree of the equipment, the maintenance cost is reduced, and the running reliability of an engine system is guaranteed.
In any of the above technical solutions, further, the method for detecting a failure of a turbocharger further includes: acquiring equipment information of a turbocharger; determining a preset flow range and a preset pressure ratio range according to the equipment information; the device information includes: the size of the turbocharger piping and the turbine size.
In the technical scheme, the flow field parameters of the compressor can be different when different turbochargers run. Before the fault is detected, the equipment information of the turbocharger is firstly acquired, and the appropriate preset flow range and preset pressure ratio range are selected through the equipment information, so that the preset flow range and the preset pressure ratio range can be matched with the turbocharger, and the accuracy of fault detection can be further ensured.
The equipment information comprises the pipeline size and the turbine type of the turbocharger, and the turbine type directly determines the maximum value and the minimum value of the booster pressure ratio of the compressor. The size of the conduit affects the intake air flow, e.g., the diameter of the intake conduit, which determines the allowable intake air flow rate of the compressor, which in turn affects the intake air flow rate. Therefore, different turbochargers can be distinguished through the equipment information of the turbochargers, so that the optimal preset flow range and the optimal preset pressure ratio range are matched.
It should be noted that the preset pressure ratio range obtained according to the device information includes one or more sets of pressure ratio ranges, where each set of pressure ratio range in the plurality of sets of pressure ratio ranges corresponds to a different intake air flow rate.
In any of the above technical solutions, further, the method for detecting a failure of a turbocharger further includes: and outputting prompt information according to the fault information.
According to the technical scheme, after the turbocharger is determined to have a fault, prompt information is sent to a user according to the fault information, so that the fault condition of the turbocharger is prompted to the user by the aid of the prompt information. The problem of quick positioning by a user is solved, the performance reduction of the turbocharger caused by long-time failure is avoided, and the effects of protecting the turbocharger and an engine and even protecting personal safety are achieved.
The prompt information may include flow field parameters such as inlet and outlet pressures of the compressor and inlet flow during fault, fault reasons, equipment information of the turbocharger, and the like.
In any of the above technical solutions, further, the method for detecting a failure of a turbocharger further includes: and setting an operation parameter range which can be executed by an engine connected with the turbocharger according to the fault information.
In the technical scheme, under the condition that the turbocharger is determined to have a fault, an operation parameter range which can be adopted by an engine connected with the turbocharger is set according to fault information, namely an upper limit value and a lower limit value of operation parameters related to the operation of the engine are set, so that the operation parameters during the operation of the engine are limited through the operation parameter range, and the flow field parameters of the turbocharger in practical application can be in a preset pressure ratio range and a preset flow range. Therefore, on the basis of maintaining the operation of the engine system, the possibility of failure danger of the turbocharger is reduced, the compressor and the engine are conveniently combined and matched, and the reliability of the engine system is improved.
According to a second aspect of the present invention, there is also provided a control apparatus comprising: a memory storing a program or instructions; and the processor is connected with the memory and realizes the fault detection method of the turbocharger in the first aspect when the processor executes the program or the instructions. Therefore, the control device has all the advantages of the method for detecting the fault of the turbocharger provided by the first aspect, and redundant description is omitted for avoiding redundancy.
According to a third aspect of the present invention, there is also provided a turbocharger comprising: a compressor; the air inlet of the air inlet pipeline is connected with an air source, and the air outlet of the air inlet pipeline is connected with the air compressor; the air inlet of the air outlet pipeline is connected with the air compressor, and the air outlet of the air outlet pipeline is connected with the engine; the detection device is arranged on the air inlet pipeline and the air outlet pipeline and is used for acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor; the control device is connected with the detection device, and the control device is used for determining the fault information of the turbocharger according to the inlet pressure, the outlet pressure and the inlet flow.
In the technical scheme, the turbocharger comprises a gas compressor, a gas inlet pipeline, a gas outlet pipeline, a detection device and a control device. The compressor is used for compressing air. The air inlet pipeline is connected between an air source and the air compressor, the air outlet pipeline is connected between the air compressor and the engine, air enters the air compressor of the turbocharger through the air inlet pipeline of the turbocharger, the air compressor compresses the air under the driving of the turbine, and the compressed air is transmitted to the engine through the air outlet pipeline of the turbocharger. The control device can determine the fault information of the turbocharger according to the air inlet pressure, the air outlet pressure and the air inlet flow collected by the detection device. Therefore, the control device is utilized to realize automatic identification of possible faults in the design process of the turbocharger, and the problem of inconsistent fault boundary measurement caused by manual judgment is avoided. And the fault detection is carried out by comprehensively considering the air inlet pressure, the air outlet pressure and the air inlet flow, on the premise of ensuring the accuracy of the fault detection, the timeliness and the comprehensiveness of the fault detection are improved, the problem of rapid positioning of a user is helped, the performance reduction of the turbocharger caused by long-time faults is avoided, and the effects of protecting the turbocharger and an engine and even protecting the personal safety are achieved.
Further, the detection device includes a pressure sensor and a flow sensor. And the pressure sensors are arranged on the air inlet pipeline and the air outlet pipeline and are used for acquiring the air inlet pressure and the air outlet pressure of the air compressor. The flow sensor is arranged on the air inlet pipeline and used for collecting the air inlet flow of the air compressor.
According to a fourth aspect of the present invention, there is also provided an engine system comprising: an engine; a supercharger; in a third aspect, a turbocharger is provided that is coupled to an engine. Therefore, the engine system has all the advantages of the turbocharger provided by the third aspect, and redundant description is omitted for avoiding repetition.
It is worth mentioning that the control device in the turbocharger can also be used to control the engine to optimize the structure of the engine system.
According to a fifth aspect of the present invention, there is provided a readable storage medium having stored thereon a program or instructions which, when executed by a processor, performs the method of fault detection of a turbocharger proposed by the first aspect. Therefore, the readable storage medium has all the advantages of the method for detecting a fault of a turbocharger provided in the first aspect, and redundant description is omitted to avoid redundancy.
Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 shows one of the flow diagrams of a method of fault detection for a turbocharger in accordance with an embodiment of the present invention;
FIG. 2 illustrates a second schematic flow chart of a turbocharger fault detection method in accordance with an embodiment of the present invention;
FIG. 3 shows a third schematic flow chart of a turbocharger fault detection method in accordance with an embodiment of the present invention;
FIG. 4 shows a fourth flowchart of a turbocharger fault detection method according to an embodiment of the present invention;
FIG. 5 shows a fifth flowchart of a turbocharger fault detection method according to an embodiment of the present invention;
FIG. 6 shows a sixth flowchart of a turbocharger fault detection method according to an embodiment of the present invention;
FIG. 7 is a block diagram showing a control apparatus according to an embodiment of the present invention;
FIG. 8 is a schematic block diagram of an engine system according to an embodiment of the present invention;
figure 9 shows a compressor performance curve diagram of an embodiment of the present invention.
Wherein, the correspondence between the reference numbers and the names of the components in fig. 8 is:
800 turbocharger, 810 compressor, 822 inlet pipeline, 824 outlet pipeline, 832 pressure sensor, 834 flow sensor, 840 control device, 850 alarm prompting device and 900 engine.
Detailed Description
In order that the above objects, features and advantages of the present invention can be more clearly understood, a more particular description of the invention will be rendered by reference to the appended drawings. It should be noted that the embodiments and features of the embodiments of the present application may be combined with each other without conflict.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, however, the present invention may be practiced in other ways than those specifically described herein, and therefore the scope of the present invention is not limited by the specific embodiments disclosed below.
A method of detecting a failure of a turbocharger, a control apparatus, a turbocharger, and an engine system according to some embodiments of the present invention are described below with reference to fig. 1 to 9.
Example 1:
as shown in fig. 1, according to an embodiment of a first aspect of the present invention, there is provided a failure detection method of a turbocharger, including:
102, acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor;
and step 104, determining fault information of the turbocharger according to the air inlet pressure, the air outlet pressure and the air inlet flow.
In this embodiment, it is considered that the problems of failure of the turbocharger, such as surge, overspeed, clogging, etc., are all related to the air circulating in the compressor. Therefore, the supercharging pressure ratio of the air flowing through the air compressor is determined according to the air inlet pressure and the air outlet pressure of the air compressor so as to reflect the degree of compression of the air by the air compressor, and whether the turbocharger has a fault or not is judged by combining the supercharging pressure ratio and the air inlet flow of the air compressor, and possible fault reasons are analyzed during the fault. On one hand, when the turbocharger is designed in a calibration mode, possible faults of the turbocharger are predicted, and the problem that fault boundary measurement is inconsistent due to manual judgment is solved. On the other hand, on the premise of ensuring the accuracy of fault detection, the timeliness and comprehensiveness of fault detection are improved, a user is helped to quickly locate problems, the performance reduction of the turbocharger caused by long-time faults is avoided, and the effects of protecting the turbocharger and the engine and even protecting personal safety are achieved.
Further, the intake pressure and the intake flow may be the intake pressure and the intake flow detected at the intake pipeline of the compressor, or the intake pressure and the intake flow detected at the intake port of the compressor.
In addition, the turbocharger includes: the device comprises a turbine, a gas compressor, a gas inlet pipeline, a gas outlet pipeline and a detection device. The compressor is connected with the turbine and can compress air under the driving of the turbine. The air inlet pipeline is connected between the air source and the compressor and used for transmitting air to the compressor. The air outlet pipeline is connected between the air compressor and the engine and used for transmitting compressed air to a cylinder of the engine so as to increase the combustion amount of fuel in the engine and the rotating speed of the engine and enhance the output power of the engine. Then, the exhaust gas generated by the operation of the engine drives the turbine to rotate under the inertia effect, and further, the compressor is continuously driven to perform gas compression.
Specifically, the fault information includes whether the turbocharger is faulty and the cause of the fault, including surge, overspeed, clogging, and the like. The turbocharger surge is an unstable flow phenomenon of a compressor for the turbocharger in a small flow area, namely, the compressor for the turbocharger flows unstably along the axial direction in a compression system, and various flow field parameters (such as pressure, flow, temperature, noise and the like) of the compression system generate large-amplitude oscillation after the surge occurs, so that the compressor is greatly damaged, and the safety and the reliability of an engine are influenced. When the negative pressure of the air inlet is too large and enters an area above the allowable altitude of the engine, the fuel injection quantity of a fuel injection system of the engine is too large, so that the exhaust temperature, the pressure and the like are too large, the turbocharger can overspeed, the abrasion or the damage of the turbocharger is accelerated, and the normal service life of the engine is directly shortened. The phenomenon that the pressure ratio is sharply reduced and the flow rate cannot be continuously increased after the compressor is blocked, namely the rotating speed is unchanged and the flow rate is increased to a certain value. This increases the resistance of the airflow at the time of turbocharger intake, deteriorating engine performance.
Example 2:
as shown in fig. 2, according to an embodiment of the present invention, there is provided a failure detection method of a turbocharger, including:
step 202, acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor;
in step 214, turbocharger failure is determined and the cause of the failure is analyzed.
In this example, η is usedk＝Pk/P0And dividing the outlet pressure and the inlet pressure to obtain a ratio of the outlet pressure to the inlet pressure, namely a supercharging pressure ratio. Wherein eta iskIndicating the boost pressure ratio, PkIndicating the pressure of the exhaust gas, P0Representing the intake air pressure. And comparing the air inflow with a preset flow range, and determining a preset pressure ratio range corresponding to the air inflow according to the corresponding relation between the preset air inflow and the preset pressure ratio range under the condition that the air inflow is in the preset flow range, wherein the preset pressure ratio range is used for representing the pressure ratio boundary of the normal work of the compressor. Whether the turbocharger breaks down or not is judged by comparing the ratio of the air outlet pressure to the air inlet pressure and the preset pressure ratio range, so that the fault detection is realized by combining the air inlet flow and the supercharging pressure ratio, the fault problem under different flow scenes can be judged, the fault diagnosis reliability of the turbocharger is obviously improved, corresponding protective measures can be conveniently and timely adopted to avoid damage to equipment or reduce the damage degree of the equipment, the maintenance cost is reduced, and the reliability of the operation of an engine system is ensured.
Specifically, on the basis that the intake flow is in the preset flow range, it is detected that the ratio (supercharging pressure ratio) of the outlet pressure to the intake pressure is in the preset pressure ratio range, that is, the ratio is greater than or equal to the lower limit value of the preset pressure ratio range and is less than or equal to the upper limit value of the preset pressure ratio range, it is determined that the compressor is working normally, and it is determined that the turbocharger is not in fault. When the air inlet flow exceeds a preset flow range or the ratio of the air outlet pressure to the air inlet pressure (supercharging pressure ratio) exceeds a preset pressure ratio range, namely the ratio is smaller than the lower limit value of the preset pressure ratio range and larger than the upper limit value of the preset pressure ratio range, the flow field parameters of the air compressor do not accord with the minimum standard when the air compressor works normally, the turbocharger is determined to have faults, detailed fault reasons are analyzed, so that a user can be helped to quickly locate the problems, the faults are timely eliminated by adopting corresponding protection measures, and the maintenance efficiency is improved.
In particular, to ensure reliable operation of the turbocharger on the engine system, turbocharger and engine are providedBefore matching, a performance curve of the turbocharger compressor is measured through tests. Fig. 9 is a schematic diagram showing a performance curve of a turbocharger compressor under a certain normal operation condition, wherein a surge line, a maximum rotation speed line and a blockage line are included in the diagram and respectively used for representing the relation between the minimum normal operation flow and the pressure ratio of the compressor, for example, a curve formed by a series of points formed by intersecting a 55% equivalent ratio circle and the maximum flow is a blockage line. The ordinate of the surge line, the maximum rotation speed line and the blockage line forms a preset flow range, and the ordinate forms a preset pressure ratio range. If the air inlet flow and the ratio of the air compressor are in an area formed by the enclosed surge line, the highest rotating speed line and the blocking line, the turbocharger is not in fault, and if the air inlet flow and the ratio of the air compressor are outside the area formed by the enclosed surge line, the highest rotating speed line and the blocking line, namely the left area of the surge line, the upper area of the highest rotating speed line and the right area and the lower area of the blocking line, the turbocharger is in fault. For example, as shown in FIG. 9, the intake air flow rate is 0.3m3Min, the upper limit value of the corresponding preset pressure ratio range is 3.4 (the ordinate of the surge line corresponding to 0.3), and the upper limit value is 1.0; the inlet flow rate was 0.5m3And/min, the upper limit value of the corresponding preset pressure ratio range is 4.7 (the ordinate of the maximum rotating speed line corresponding to 0.5), and the upper limit value is 1.7 (the ordinate of the blockage line corresponding to 0.5).
Example 3:
as shown in fig. 3, according to an embodiment of the present invention, there is provided a failure detection method of a turbocharger, including:
308, determining a preset pressure ratio range corresponding to the air inflow;
step 312, determining that the turbocharger has a flow metering fault;
and 322, if the intake air flow is in the third flow range and the ratio is smaller than the lower limit value of the preset pressure ratio range corresponding to the intake air flow, determining that the turbocharger has a blockage fault.
The preset flow range comprises a first flow range, a second flow range and a third flow range, the first flow range corresponds to a possible flow range of the turbocharger when a surge fault occurs, the second flow range corresponds to a possible flow range of the turbocharger when an overspeed fault occurs, and the third flow range corresponds to a possible flow range of the turbocharger when a blockage fault occurs.
In this embodiment, in the case where the intake air flow rate exceeds the preset flow rate range, it is described that the intake air flow rate exceeds the flow rate range covered when the compressor is operating, and it may be that the apparatus for detecting the flow rate in the turbocharger is malfunctioning.
And if the ratio is larger than the upper limit value of the preset pressure ratio range, the supercharging pressure ratio is larger, the outlet pressure is far larger than the inlet pressure, and the fault reason is determined to be surging.
And under the condition that the intake flow is in the upper limit value of the second flow range, the intake flow meets the flow condition with overspeed fault, the ratio is further compared with a preset pressure ratio range corresponding to the intake flow, and if the ratio is larger than the upper limit value of the preset pressure ratio range, the supercharging pressure ratio is larger, and the fault reason is determined to be overspeed.
And under the condition that the air inflow is located at the upper limit value of the third flow range, the air inflow meets the flow condition with the blockage fault, the ratio is further compared with a preset pressure ratio range corresponding to the air inflow, if the ratio is smaller than the lower limit value of the preset pressure ratio range, the supercharging pressure ratio is smaller, the air compressor does not compress the air entering the air compressor to the extent of meeting the requirement, and the fault reason is determined to be blockage.
Through the scheme, the possible problem range can be determined by utilizing the real-time air inlet flow of the air compressor, and the fault problem can be accurately positioned by combining the ratio of the air outlet pressure to the air inlet pressure. The fault diagnosis reliability of the turbocharger is remarkably improved, corresponding protection measures can be conveniently and timely adopted to avoid damage to equipment or reduce the damage degree of the equipment, the maintenance cost is reduced, and the running reliability of an engine system is guaranteed.
It should be noted that the first flow rate range, the second flow rate range, and the third flow rate range may have overlapping portions, and thus, when the turbocharger fails, there may be various failure problems. For example, as shown in fig. 9, there is a point of intersection (0.45, 4.8) between the surge line and the maximum rotation speed line when the detected intake air flow rate is 0.45m3At/min, the first flow range, the second flow range and the third flow range are simultaneously satisfied, i.e. there is a possibility of surging, overspeed and clogging at the intake flow rate, passing 0.45m3And determining that the corresponding preset pressure ratio range is 1.6-4.8 according to the inlet air flow per min, wherein when the supercharging pressure ratio is greater than 4.8, the turbocharger is indicated to generate surge and overspeed, and when the supercharging pressure ratio is less than 1.6, the turbocharger is indicated to generate blockage.
Example 4:
as shown in fig. 4, according to an embodiment of the present invention, there is provided a failure detection method of a turbocharger, including:
step 402, acquiring air inlet pressure, air outlet pressure and air inlet flow of an air compressor and equipment information of a turbocharger;
in step 416, turbocharger failure is determined and the cause of the failure is analyzed.
In this embodiment, the compressor flow field parameters may be different to account for different turbocharger operation. Before the fault is detected, the equipment information of the turbocharger is firstly acquired, and the appropriate preset flow range and preset pressure ratio range are selected through the equipment information, so that the preset flow range and the preset pressure ratio range can be matched with the turbocharger, and the accuracy of fault detection can be further ensured.
The equipment information comprises the pipeline size and the turbine type of the turbocharger, and the turbine type directly determines the maximum value and the minimum value of the booster pressure ratio of the compressor. The size of the line affects the intake flow, e.g. the diameter of the intake line, which determines the allowable intake flow rate of the compressor and thus the intake flow. Therefore, different turbochargers can be distinguished through the equipment information of the turbochargers, so that the optimal preset flow range and the optimal preset pressure ratio range are matched.
Currently, the device information may also include information about other turbochargers that are associated with flow field parameters.
It should be noted that the preset pressure ratio range obtained according to the device information includes one or more sets of pressure ratio ranges, where each set of pressure ratio range in the plurality of sets of pressure ratio ranges corresponds to a different intake air flow rate.
Example 5:
as shown in fig. 5, according to an embodiment of the present invention, there is provided a failure detection method of a turbocharger, including:
502, acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of an air compressor;
and step 506, outputting prompt information according to the fault information.
In the embodiment, after the turbocharger is determined to have the fault, prompt information is sent to a user according to the fault information, and the user is prompted for the fault condition of the turbocharger by using the prompt information. The problem of quick positioning by a user is solved, the performance reduction of the turbocharger caused by long-time failure is avoided, and the effects of protecting the turbocharger and an engine and even protecting personal safety are achieved.
Specifically, the prompt information can be transmitted to a management terminal connected with the engine system through a data wire harness, and can also be transmitted to a mobile terminal of a user through communication modes such as a data network, WIFI and Bluetooth, so that the user can conveniently carry out remote monitoring on the engine system.
The prompt information may include flow field parameters such as inlet and outlet pressures of the compressor and inlet flow during fault, fault reasons, equipment information of the turbocharger, and the like, and the output form of the prompt information includes one or a combination of light, voice, characters and images.
Example 6:
as shown in fig. 6, according to an embodiment of the present invention, there is provided a failure detection method of a turbocharger, including:
and 606, outputting prompt information according to the fault information, and setting an operation parameter range which can be executed by an engine connected with the turbocharger according to the fault information.
In this embodiment, when it is determined that the turbocharger has a fault, an operating parameter range that can be used by an engine connected to the turbocharger is set according to fault information, that is, an upper limit value and a lower limit value of a parameter related to engine operation are set, so as to limit the operating parameter during engine operation through the operating parameter range, so that a flow field parameter of the turbocharger in practical application can be within a preset pressure ratio range and a preset flow range. Therefore, on the basis of maintaining the operation of the engine system, the possibility of failure danger of the turbocharger is reduced, the compressor and the engine are conveniently combined and matched, and the reliability of the engine system is improved.
Specifically, for example, in the stage of research and development of a supercharger product, when the electronic control calibration and control strategy design of the engine are performed, the fuel flow of the engine is adjusted by adjusting an electronic control unit (control device) of the engine, so that the flow field parameters of the supercharger, such as the intake air flow, the pressure and the like, are in the range surrounded by the surge line, the maximum rotation speed line and the blocking line as shown in fig. 9, and the fuel flow of the flow field parameters on the surge line, the maximum rotation speed line and the blocking line is the limit value of the fuel flow range of the engine. Therefore, the purposes of no surge, no blockage and no overspeed of the supercharger in the design stage can be achieved, and the reliable operation of the supercharger IV in different altitudes and in extreme environments is ensured. For example, when the turbocharger has an overspeed fault, the target offset amount can be matched according to the difference between the boost pressure and the upper limit value of the preset pressure ratio range, and the allowable fuel flow range of the engine can be adjusted according to the target offset amount, so that the upper limit value of the fuel flow of the engine is reduced, and the turbine speed and the compressor speed are reduced.
Example 7:
as shown in fig. 7, according to the embodiment of the second aspect of the present invention, a control device 840 is provided, which includes a processor 844, a memory 842 and a program or instructions stored on the memory 842 and executable on the processor 844, and when the program or instructions are executed by the processor 844, the steps of the method for detecting a failure of a turbocharger according to the embodiment of the first aspect are implemented. Therefore, the control device 840 has all the advantages of the turbocharger failure detection method according to the first embodiment.
Example 8:
as shown in fig. 8, according to the third aspect of the present invention, a turbocharger 800 is provided, which includes a compressor 810, an air inlet pipe 822, an air outlet pipe 824, a detecting device (832, 834) and a control device 840 according to the second aspect of the present invention.
In detail, an air inlet of the air inlet pipe 822 is connected to an air source, and an air outlet of the air inlet pipe 822 is connected to the compressor 810. An air inlet of the air outlet pipeline 824 is connected with the compressor 810, and an air outlet of the air outlet pipeline 824 is connected with the engine 900. The detection devices are arranged on the air inlet pipe 822 and the air outlet pipe 824 and are used for acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the compressor 810. The control device 840 is connected to the detection device.
In this embodiment, a compressor 810 is used to compress air. The air inlet pipe 822 is connected between an air source and the compressor 810, the air outlet pipe 824 is connected between the compressor 810 and the engine 900, air enters the compressor 810 of the turbocharger 800 through the air inlet pipe 822 of the turbocharger 800, the compressor 810 compresses the air under the driving of a turbine, and the compressed air is transmitted to the engine 900 through the air outlet pipe 824 of the turbocharger 800. The control device 840 can determine the failure information of the turbocharger 800 according to the intake pressure, the outlet pressure, and the intake flow rate collected by the detection device. Therefore, the control device 840 is used for predicting possible faults of the turbocharger 800 in the design process of the turbocharger 800, and the problem that fault boundary measurement is inconsistent due to manual judgment is avoided. And the fault detection is carried out by comprehensively considering the air inlet pressure, the air outlet pressure and the air inlet flow, on the premise of ensuring the fault detection accuracy, the timeliness and the comprehensiveness of the fault detection are improved, the problem of rapid positioning of a user is helped, the performance reduction caused by faults in the actual operation process of the turbocharger 800 is avoided, and the functions of protecting the turbocharger 800 and the engine 900 and even protecting the personal safety are achieved.
Further, the detection means includes a pressure sensor 832 and a flow sensor 834. And the pressure sensors 832 are arranged on the air inlet pipe 822 and the air outlet pipe 824 and are used for acquiring the air inlet pressure and the air outlet pressure of the compressor 810. A flow sensor 834 is disposed in the inlet pipe 822 for collecting the inlet flow of the compressor 810.
Example 9:
as shown in fig. 8, according to an embodiment of the fourth aspect of the present invention, there is provided an engine system including: an engine 900 and a turbocharger 800 according to the third aspect embodiment connected to the engine 900. The engine system thus provides all of the benefits of the turbocharger 800 proposed in the third aspect embodiment.
Specifically, air enters the compressor 810 of the turbocharger 800 through the air inlet pipe 822 of the turbocharger 800, the compressor 810 compresses the air under the driving of a turbine, and the compressed air is transmitted to the cylinder of the engine 900 through the air outlet pipe 824 of the turbocharger 800, so that the combustion amount of fuel in the engine 900 and the rotating speed of the engine 900 are increased, and the output power of the engine 900 is enhanced. Then, the exhaust gas generated by the operation of the engine 900 drives the turbine to rotate under the inertia effect, and further continues to drive the compressor 810 to compress the gas.
Example 10:
as shown in fig. 8, according to an embodiment of the present invention, there is provided an engine system, wherein the engine system includes: turbocharger 800, engine 900 and the necessary wiring harness.
Specifically, the turbocharger 800 includes a compressor 810, a pre-compression inlet conduit 822, a post-compression outlet conduit 824, a pressure sensor 832 (a pre-compression pressure sensor and a post-compression pressure sensor), a flow sensor 834, and an alarm prompting device 850. Air enters the inlet of the compressor 810 via the inlet bleed line 822, flows through the outlet of the compressor 810, and passes through the outlet bleed line 824 to the cylinders of the engine 900. A pre-pressure sensor and a flow sensor 834 are arranged at the inlet of the compressor 810, and a post-pressure sensor is arranged at the outlet of the compressor 810. The pre-compression pressure sensor, the flow sensor 834 and the post-compression pressure sensor are connected with an engine electronic control unit (control device 840), and the measured inlet and outlet pressures and inlet flow are transmitted to the engine electronic control unit. The alarm prompting device 850 is connected with an engine electronic control unit.
In the process of developing an engine system, the pressure ratio and the intake flow of the engine 900 under different working conditions in a standard atmospheric state are recorded to obtain data in a compressor characteristic diagram, the data in the compressor characteristic diagram are stored in an electronic control unit, as shown in fig. 9, the data include the intake flow and the pressure ratio corresponding to a surge line, a maximum rotating speed line and a blockage line, and coordinate values of the flow and the pressure ratio corresponding to the surge line, the maximum rotating speed line and the blockage line are set as threshold values required for judging faults.
In the actual use process of the engine system, data measured by the pre-compression pressure sensor, the flow sensor 834 and the post-compression pressure sensor are transmitted to the electronic control unit, and the pressure ratio and the flow parameter, namely the coordinate value, are calculated through the electronic control unit. And comparing and inserting the calculated pressure ratio and flow parameters with a threshold value stored in the electronic control unit. When the measured coordinate values are located in the left, upper, and right intervals of the threshold, it can be determined that the compressor 810 has suffered from the surge, overspeed, and blockage failure phenomena. At this time, the electronic control unit of the engine feeds back a fault signal to the alarm prompting device 850 to prompt a user of the engine 900 to perform work such as shutdown check and the like, so that the functions of protecting the supercharger, the engine 900 and even personal safety are achieved.
In this embodiment, further, by using an existing electronic control unit in the engine system for controlling the engine 900, the electronic control unit compares the pressure ratio and the flow rate parameter of the engine 900 under different working conditions with the characteristic data of the compressor 810 during normal operation in real time, determines whether the pressure ratio and the flow rate parameter exceed the area surrounded by the surge line, the highest usage rotation speed line and the blockage line, sends out a correct instruction, and gives an alarm when the turbocharger 800 has a working fault, thereby protecting the exhaust turbocharger 800 and the engine 900.
Example 11:
according to an embodiment of the fifth aspect of the present invention, a readable storage medium is proposed, on which a program or instructions are stored, which when executed by a processor performs the method of detecting a failure of a turbocharger proposed in the embodiment of the first aspect. Therefore, the readable storage medium has all the advantages of the method for detecting a fault of a turbocharger provided in the embodiment of the first aspect, and redundant description is omitted to avoid redundancy.
In the present invention, the term "plurality" means two or more unless explicitly defined otherwise. The terms "mounted," "connected," "fixed," and the like are to be construed broadly and include, for example, fixed connections, detachable connections, or integral connections; "coupled" may be direct or indirect through an intermediary. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the description herein, the description of the terms "one embodiment," "some embodiments," "specific embodiments," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. A failure detection method of a turbocharger, characterized in that the turbocharger includes a compressor, the failure detection method comprising:
acquiring the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor;
determining fault information of the turbocharger according to the inlet pressure, the outlet pressure and the inlet flow;
the determining fault information of the turbocharger according to the inlet pressure, the outlet pressure and the inlet flow comprises:
calculating the ratio of the outlet pressure to the inlet pressure;
if the air inflow is in a preset flow range, determining a preset pressure ratio range corresponding to the air inflow;
if the ratio is in the preset pressure ratio range, determining that the turbocharger has no fault;
if the intake air flow exceeds the preset flow range or the ratio exceeds the preset pressure ratio range, determining the fault of the turbocharger and analyzing the fault reason;
the preset flow range comprises a first flow range, a second flow range and a third flow range; the analyzing the fault cause comprises the following steps:
if the intake air flow exceeds the preset flow range, determining that the turbocharger has a flow metering fault;
if the intake air flow is in the first flow range and the ratio is larger than the upper limit value of the preset pressure ratio range corresponding to the intake air flow, determining that the turbocharger has a surge fault;
if the intake air flow is in the second flow range and the ratio is larger than the upper limit value of the preset pressure ratio range corresponding to the intake air flow, determining that the turbocharger has an overspeed fault;
if the intake air flow is in the third flow range and the ratio is smaller than the lower limit value of the preset pressure ratio range corresponding to the intake air flow, determining that the turbocharger has a blockage fault;
and setting an operation parameter range which can be executed by an engine connected with the turbocharger according to the fault information.
2. The method of detecting a turbocharger malfunction according to claim 1, characterized by further comprising:
acquiring equipment information of the turbocharger;
determining the preset flow range and the preset pressure ratio range according to the equipment information; the device information includes: the pipeline size and the turbine type of the turbocharger.
3. The method of detecting a turbocharger malfunction according to claim 1, characterized by further comprising:
and outputting prompt information according to the fault information.
4. A control device, comprising: a memory storing a program or instructions;
a processor coupled to the memory, the processor executing the program or the instructions
A failure detection method of implementing the turbocharger according to any one of claims 1 to 3.
5. A turbocharger, comprising: a compressor;
the air inlet of the air inlet pipeline is connected with an air source, and the air outlet of the air inlet pipeline is connected with the air compressor;
the air inlet of the air outlet pipeline is connected with the air compressor, and the air outlet of the air outlet pipeline is connected with the engine;
the detection device is arranged on the air inlet pipeline and the air outlet pipeline and is used for collecting the air inlet pressure, the air outlet pressure and the air inlet flow of the air compressor;
the control device of claim 4, connected to the detection device, the control device
And the fault information of the turbocharger is determined according to the inlet pressure, the outlet pressure and the inlet flow.
6. An engine system, comprising: an engine;
the turbocharger of claim 5, said turbocharger being connected with said engine.
7. A readable storage medium on which a program or instructions are stored, characterized in that the program or instructions, when executed by a processor, perform a method of fault detection of a turbocharger according to any one of claims 1 to 3.
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| CN115013175B (en) * | 2022-07-19 | 2023-06-16 | 湖南道依茨动力有限公司 | Method and system for detecting faults of turbocharger actuator |
| CN115263534A (en) * | 2022-08-01 | 2022-11-01 | 长城汽车股份有限公司 | Control method and control device for turbocharger, electronic device, and storage medium |
| CN117668470B (en) * | 2024-01-31 | 2024-04-12 | 天津市职业大学 | Intelligent detection method and system for air inlet and outlet faults of engine |
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