GB2551785A - Apparatus for testing turbochargers - Google Patents

Abstract

Apparatus 1 for testing turbochargers includes a balance test module 2 for measuring rotational imbalance of a turbocharger core assembly 3, a flow setting module 4 for measuring and calibrating airflow through a variable geometry turbocharger 5 and a control unit 6 for controlling the apparatus and storing measurement data. The control unit is configured to receive a first measurement data set from the balance test module and a second measurement data set from the flow setting module and to store the data sets on a memory of the control unit. Also provided is a method of repairing or reconditioning a turbocharger comprising: disassembling a variable geometry turbocharger on the work surface of an integrated balance test and flow setting apparatus, testing rotational imbalance of the turbocharger core assembly using the balance test module of the apparatus, grinding material from the core assembly if a rotational imbalance is found, reassembling the turbocharger with the tested core assembly, measuring airflow through the reassembled turbocharger using a flow setting module of the apparatus whilst operating the actuator of the turbocharger and calibrating the turbocharger based on the measured airflow.

Description

(54) Title of the Invention: Apparatus for testing turbochargers Abstract Title: Testing and reconditioning a turbocharger (57) Apparatus 1 for testing turbochargers includes a balance test module 2 for measuring rotational imbalance of a turbocharger core assembly 3, a flow setting module 4 for measuring and calibrating airflow through a variable geometry turbocharger 5 and a control unit 6 for controlling the apparatus and storing measurement data. The control unit is configured to receive a first measurement data set from the balance test module and a second measurement data set from the flow setting module and to store the data sets on a memory of the control unit. Also provided is a method of repairing or reconditioning a turbocharger comprising: disassembling a variable geometry turbocharger on the work surface of an integrated balance test and flow setting apparatus, testing rotational imbalance of the turbocharger core assembly using the balance test module of the apparatus, grinding material from the core assembly if a rotational imbalance is found, reassembling the turbocharger with the tested core assembly, measuring airflow through the reassembled turbocharger using a flow setting module of the apparatus whilst operating the actuator of the turbocharger and calibrating the turbocharger based on the measured airflow.

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APPARTUS FOR TESTING TURBOCHARGERS

This invention relates generally to apparatus for testing turbochargers. More specifically, although not exclusively, this invention relates to testing apparatus for repaired or reconditioned turbochargers.

Turbochargers increase the efficiency and power output of internal combustion engines by forcing additional air into the combustion chamber. This is achieved using a turbine, which is driven by exhaust gas from the engine. However, optimum turbine characteristics vary with engine speed. This has led to the development of variable geometry turbochargers, which allow the effective aspect ratio to be altered as engine conditions change in order to optimise performance.

The advent of variable geometry turbochargers within the automotive industry has had a major impact on vehicle performance and driveability. The push for more compact and efficient engines has led to a drastic increase in the use of such turbochargers. Over time, wear, damage or failure of turbocharger components, such as bearings or features of the turbine, can reduce its efficiency drastically. Replacement of the entire turbocharger, or even the core assembly of a variable geometry turbocharger, is a costly exercise.

It is therefore desirable to repair or recondition worn or damaged turbocharger components to restore its operating efficiency. However, the equipment required to strip, recondition, rebalance, reassemble and test such turbochargers is diverse and can be expensive.

There is therefore a need for testing apparatus that simplifies the repair, reconditioning and testing of turbochargers. It is a first non-exclusive aim of the invention to provide such an apparatus. It is a more general non-exclusive object of the invention to provide an apparatus which overcomes or at least mitigates one or more issues associated with known testing apparatus.

Accordingly, a first aspect of the invention provides an apparatus for testing turbochargers, the apparatus comprising a balance test module, e.g. for measuring rotational imbalance of a turbocharger core assembly, and a flow testing and/or setting module, e.g. for measuring and/or calibrating airflow through a variable geometry turbocharger.

Thus, the invention provides an integrated apparatus that enables repaired or reconditioned turbochargers to be tested and calibrated using a single apparatus.

The apparatus may comprise a control means, which may be operatively connected to at least one or each of the balance and flow setting modules. The apparatus may comprise memory means, which may be operatively connected to the control means. The control means may be configured to receive, in use, data or a data set, e.g. a first measurement data set, from the balance test module. Additionally or alternatively, the control means may be configured to receive data or a data set, e.g. a second measurement data set, from the flow setting module. The control means may be configured to store the data set(s) on the memory means.

The control means may be configured to associate the first and second data sets. The control means may be configured to store the associated data sets on the memory means.

The apparatus may comprise an input means, e.g. for inputting identification information relating to a turbocharger to be tested and/or for selecting one or more commands or programs to be run or used by the apparatus or one of the modules thereof. The control means may be configured to associate the first and/or second data sets with the identification information. The control means may be configured to store the associated identification information and data set(s) on the memory means.

The apparatus may comprise an air supply means, which may be operatively connected to the control means and/or fluidly connected to at least one or each of the balance and flow test modules. The air supply means may be operable to selectively provide air flow to one or each of the balance and flow test modules. The air supply means may comprise a connection means or connector, for example a quick release connection means or connector. The air supply means may be configured to connect to or with a source of compressed air, e.g. the compressed air supply of a factory in which the apparatus is to be installed or a standalone or integrated compressor. The air supply means may comprise a T-split or manifold, e.g. for supplying air to each of the modules. The air supply means or control means may comprise one or more valves, e.g. process valves for controlling the flow of air to at least one or each of the modules.

The apparatus or air supply means may comprise an airflow measurement device, which may be operatively connected to the control means. The airflow measurement device may be for, e.g. suitable or configured for, measuring the flow of air from the air supply means to the flow setting module. The airflow measurement device may be for, e.g. suitable or configured for, measuring leak-down or pressure decay, e.g. from a closed reservoir. The second measurement data set may comprise measured airflow data. The airflow measurement device may form part of the flow setting module, e.g. the flow setting module may comprise the airflow measurement device. Additionally or alternatively, the or a further airflow measurement device may be for measuring the flow of air through the air supply means or from the air supply means to both of the modules or from the air supply means to the balancing module. The or at least one or each of the airflow measurement devices may comprise a flowmeter.

The apparatus or flow setting module may comprise a feedback connector for operatively connecting to the actuator of a variable geometry turbocharger to be tested. The feedback connector may be operatively connected to the control means. The feedback connector may be configured to receive, in use, position data from an actuator and/or to transmit, in use, position data to the control means. The feedback connector may comprise a receptacle, socket, plug, fitting or any suitable electrical connector. Additionally or alternatively, the apparatus or flow setting module may comprise an actuator position measurement device, which may be operatively connected to the control means and/or which may be for measuring the position of the actuator. The second measurement data set may comprise measured actuator position data.

The apparatus or flow setting module may comprise pneumatic supply connector, e.g. for supplying pneumatic control signals to operate a pneumatic actuator of a turbocharger to be tested. The pneumatic supply connector may comprise a receptacle, socket, plug, fitting or any suitable pneumatic connector. The apparatus or flow setting module may comprise an electrical supply connector or driver with such a connector, e.g. for supplying electrical control signals to operate an electromechanical actuator of a turbocharger to be tested. The electrical supply connector may comprise a receptacle, socket, plug, fitting or any suitable electrical connector.

The balance test module may comprise a motion measurement device, e.g. for measuring vibration, such as oscillatory vibration, of a turbocharger core assembly during rotation. The motion measurement device may comprise an accelerometer or any other suitable motion measurement means. The or a further motion measurement device may comprise a rotation speed sensor. The rotation speed sensor may be for, e.g. configured for, measuring rotation of an impeller or a turbine of the turbocharger. The rotation speed sensor may be mounted to a carriage and/or within a shroud. The carriage may be movable from a deployed or testing position to a retracted or stowed position. The first data set comprising measured motion data, which may comprise vibrational or rotational motion data. The balance test module may comprise a base, which may be fixed to a frame or may be a base frame, and/or a support housing, e.g. for mounting a rotational core assembly thereon. The base may comprise a mounting flange, which may comprise one or more holes that may receive one or more fasteners for mounting the support housing thereto. The support housing may comprise a volute, for example through which air may be fed from the or an air supply means, e.g. to drive the core assembly. The support housing may be mounted to the base by resilient means, e.g. so as to afford a degree of movement of the support housing. The resilient means may comprise a resilient element or member, which may be formed of a resilient material, such as an elastomeric material, e.g. natural or synthetic rubber, or any other suitable material.

The apparatus or flow setting module or balance test module may comprise a work surface, e.g. for disassembling and/or reassembling a turbocharger thereon. The apparatus or flow setting module or balance test module may comprise a fixture assembly, e.g. for selectively holding an assembled turbocharger or a turbine or core assembly. At least part of the fixture assembly may be mounted, secured or fixed to the work surface. At least part of the fixture assembly may be removably mounted, secured or fixed to the work surface.

The fixture assembly may comprise a base, which may be secured to the work surface and/or which may comprise a locating feature. The fixture assembly may comprise a cradle, which may comprise a locating feature. The locating feature of the cradle may cooperate with the locating feature of the base, e.g. to locate and/or inhibit movement of the cradle relative to the base.

The cradle may comprise a pair of spaced support elements, at least one or each of which may have a cradle surface, e.g. for receiving and supporting respective portions of an assembled turbocharger. The space between the support elements may be adjustable, for example by an adjustment means. The space between the support elements may be step-wise adjustable, e.g. by a step-wise adjustment means such as a rack and latch mechanism or any other step-wise adjustment means. The space between the support elements may be continuously adjustable, e.g. by a continuous adjustment means such as a connecting element along which one or each support element may be movable, slidable and/or to which one or each support element may be releasably secured.

The cradle may comprise a connecting member, e.g. connecting or for connecting the support elements together. At least one of the support elements may be adjustably or releasably connected or secured to the connecting member, e.g. to enable adjustment of its position relative to another of the support elements. At least one of the support elements may be adjustably or releasably connected or secured to the connecting member by a releasable connection, which may be provided by a thumbscrew or setscrew that releasably engages the connecting member or a recess therein. The connecting member may comprise a rod, which may be received by each support element and/or secured relative thereto by a set screw or thumbscrew.

The fixture assembly may comprise a holding block, e.g. for receiving a turbine or core assembly. The holding block may comprise a locating feature, which may or may also cooperate with the locating feature of the base, e.g. to locate and/or inhibit movement of the holding block relative to the base.

The cooperating locating features may comprise a key and a keyway, one of which may include a stop, e.g. for inhibiting relative movement between the cradle or holding block and the base.

The apparatus may comprise a grinder, e.g. for removing material from a turbine or core assembly of a turbocharger. The grinder may be pneumatically operated and/or fluidly connected to the air supply means and/or operatively connected to the control means. The control means may be configured to operate the air supply means to selectively provide air flow to the grinder.

The memory means may comprise a memory, for example one or more memory devices. The control means may comprise a control system, which may comprise the memory means and/or one or more processors or controllers. The memory devices, processors or controllers may be operatively, physically or wirelessly connected or may be separate and/or perform one or more functions independently or separately. The input means may comprise an input or input device, such as a keyboard, keypad, switch(es), button(s) or any other suitable input or input device. The input means may comprise a touchscreen display or a mobile device, e.g. a mobile telecommunications device such as a smartphone. The input means may be operatively connected, e.g. hard wired or wirelessly connected, to the control means.

Another aspect of the invention provides a method of repairing or reconditioning a turbocharger, e.g. using the apparatus described above. The method may comprise disassembling a variable geometry turbocharger, for example on the work surface of an integrated balance test and flow setting apparatus, e.g. an apparatus as described above. The method may comprise testing a core assembly using a balance test module of the apparatus, for example by measuring the rotational imbalance thereof.

The method may comprise grinding material from the core assembly, e.g. if a rotational imbalance is found. The method may comprise reassembling the turbocharger with the tested core assembly, e.g. on the work surface. The method may comprise measuring airflow through the reassembled turbocharger using a flow setting module of the apparatus, e.g. whilst operating the actuator of the turbocharger.

The method may comprise calibrating the turbocharger based on the measured airflow. The method may comprise capturing and, optionally associating, measurement data from the balance test and/or from the flow setting test. The method may comprise storing, e.g. on a memory means of the apparatus or a control means thereof, the captured and/or associated measurement data.

For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the apparatus may comprise any one or more features of the method relevant thereto and/or the method may comprise any one or more features or steps relevant to one or more features of the apparatus.

A further aspect of the invention provides a computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement one or more steps of the aforementioned method. A yet further aspect of the invention provides the computer program element embodied on a computer readable medium. A yet further aspect of the invention provides a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the aforementioned method. A yet further aspect of the invention provides a control means or control system or controller comprising the aforementioned computer program element or computer readable medium.

For purposes of this disclosure, and notwithstanding the above, it is to be understood that any controller(s), control units and/or control modules described herein may each comprise a control unit or computational device having one or more electronic processors. The controller may comprise a single control unit or electronic controller or alternatively different functions of the control of the system or apparatus may be embodied in, or hosted in, different control units or controllers or control modules. As used herein, the terms “control unit” and “controller” will be understood to include both a single control unit or controller and a plurality of control units or controllers collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause said controller(s) or control unit(s) or control module(s) to implement the control techniques described herein (including the method(s) described herein). The set of instructions may be embedded in one or more electronic processors, or alternatively, may be provided as software to be executed by one or more electronic processor(s). For example, a first controller may be implemented in software run on one or more electronic processors, and one or more other controllers may also be implemented in software run on one or more electronic processors, optionally the same one or more processors as the first controller. It will be appreciated, however, that other arrangements are also useful, and therefore, the present invention is not intended to be limited to any particular arrangement. In any event, the set of instructions described herein may be embedded in a computer-readable storage medium (e.g., a non-transitory storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors/computational device, including, without limitation: a magnetic storage medium (e.g., floppy diskette); optical storage medium (e.g., CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM);

erasable programmable memory (e.g., EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information/instructions.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms “may”, “and/or”, “e.g.”, “for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is a perspective view of an apparatus for testing turbochargers according to an embodiment of the invention from the left showing the work surface;

Figure 2 is a perspective view of the apparatus of Figure 1 from a different position in which the balance test module is more clearly shown;

Figure 3 is a similar view to that of Figure 2 with the doors of the control unit closed and with an enlarged view of the balance test module;

Figure 4 is a similar view to that of Figures 2 and 3 with one turbocharger core assembly mounted in the balance test module and a further turbocharger in a disassembled condition on the work surface;

Figure 5 is a similar view to that of Figures 2 to 4 with one turbocharger core assembly mounted in the balance test module and a further, assembled turbocharger being tested using the flow setting module;

Figure 6 is a perspective view of the cradle on which the assembled turbocharger of Figure 5 is mounted; and

Figure 7 is an exploded perspective view of the cradle of Figure 6.

Referring now to Figures 1 to 5, there is shown an apparatus 1 fortesting turbochargers. The apparatus 1 includes a balance test module 2 for measuring rotational imbalance of a turbocharger core assembly 3, a flow setting module 4 for measuring and calibrating airflow through a variable geometry turbocharger 5 and a control unit 6 for controlling features of the apparatus 1 and storing measurement data. The apparatus 1 also includes a fixture assembly 7 for selectively holding an assembled turbocharger 5 or a core assembly 3, a grinder 8 and a storage cabinet 9.

As seen most clearly in Figure 3, the balance test module 2 includes an enclosure 20 accessible by a door 21 having a window 21a. Within the enclosure 20, the balance test module 2 includes an exhaust silencer 22 in the form of a rectangular conduit mounted to an inner wall of the enclosure 20 with a circular inlet at one end and feeding through to an exhaust port at the rear of the machine. Also within the enclosure 20 is a support housing 23, which includes a pair of quick release clamps 23a (only one of which is shown) for releasably mounting a core assembly 3 thereon. The support housing 23 also defines an internal volute through which air is fed from an air supply pipe 23b via a nozzle assembly 25 to drive the core assembly 3. The support housing 23 is secured to the nozzle assembly 25 and feeds exhaust air into the inlet of the exhaust silencer 22.

The nozzle assembly 25 also includes a motion measurement device 25a for measuring oscillatory vibration of a turbocharger core assembly during rotation. The motion measurement device 25a is mounted to the nozzle assembly 25 by elastomeric members (O-rings in this embodiment). The motion measurement device 25a may include an accelerometer or any other suitable measurement means and is connected to the control unit 6 via a cable 25b. The balance test module 2 also includes a rotation speed sensor 26a mounted on a carriage 26 opposite the support housing 23 configured to cover the exposed impeller of the core assembly 3. The carriage 26 is adjustable to accommodate core assemblies of different sizes.

The balance test module 2 may also incorporate one or more features disclosed in EP2775282, the contents of which are incorporated herein by reference.

In this embodiment, the flow setting module 4 includes a work surface 40 for disassembling and reassembling turbochargers 5. However, it will be appreciated that the flow setting module 4 may be provided with a separate platform or may even be integrated in (e.g. as a separate compartment of) the enclosure 20 of the balance test module 3. As illustrated in Figures 4 and 5, the turbocharger 5 includes a core assembly 3, a turbine housing 50, a compressor housing 51 and an actuator 52 for altering the flow characteristics of the turbocharger 5. Although the actuator 52 shown in the drawings is pneumatically driven, the apparatus 1 is also able to accommodate actuators that are electromechanically driven.

The flow setting module 4 includes an airflow supply port 41 to which an air supply hose 42 is fluidly connected (see Figure 5) and a retractable exhaust tube 43 to connect to the turbine housing 50 of a turbocharger 5 under test for managing the exhausted air and to reduce noise (not shown connected in Figure 5). The free end of the air supply hose 42 includes a magnetic element 42a to facilitate its connection to a turbocharger 5. Upstream the supply port 41 and in the control unit 6 is a flowmeter 44 for measuring the flow of air supplied thereto. The flow setting module 4 also includes a pneumatic supply port 45, an electrical feedback connection 46, an electrical driver 47 and a calibration device 48. When a turbocharger 5 under test includes a pneumatic actuator 52, the pneumatic supply port 45 is used to operate the actuator 52. When the turbocharger 5 under test includes an electromechanical actuator 52, the electrical driver 47 is used to operate the actuator 52. The electrical feedback connection 46 is configured to connect with and receive electrical feedback from the actuator 52 indicative of its position. The air supply hose 42 may be connected to the calibration device 48 for calibrating the flowmeter 44.

The control unit 6 includes control circuitry 60 and a touchscreen display 61, which together incorporate control and memory means for controlling features of each of the modules 2, 4 and for receiving and storing measurement data therefrom. The control unit 6 includes flow testing programs for a variety of different designs of turbocharger 5 stored in the memory means. The control circuitry 60 is mounted to side doors 60a of the unit 6, while the touchscreen display 61 is mounted to the enclosure 20. The touchscreen display 61 provides both an input means for inputting information and/or commands for controlling the apparatus 1 and a display means for displaying information and data. The touchscreen display 61 may also be in the form of a panel PC, in which case the test programs, set points, and measurement evaluation and display would all be provided by the panel PC 61. In such a case, it is envisaged that the data acquisition, which would involve capturing analogue and/or digital signals from various devices, may be incorporated in the control circuitry 60 or in its own dedicated housing, preferably mounted within the control unit 6. The control unit 6 is configured to receive via the touchscreen display 61 identification information relating to a turbocharger to be tested. The control unit 6 is also configured to receive measurement data from the motion measurement device 25a and from the rotation speed sensor 26a of the balance test module 2, which can be referred to collectively as a first measurement data set. The control unit 6 is also configured to receive measurement data from the flowmeter 44 and from the electrical feedback connection 46, which can be referred to collectively as a second measurement data set.

The control unit 6 includes an external panel 62 beside the door 21 of the enclosure 20 of the balance test module 2. The panel 62 includes various control features including a lever 63 for controlling the flow of air delivered to the nozzle assembly 25 for driving the core assembly 3. Within the control unit 6 is housed an oil supply pump 64 for supplying lubricating oil to the core assembly 3, an air filter 65 and the flowmeter 44 of the flow setting module 4. The control unit 6 also includes an air supply means 66 in the form of a quick release connector for connection with the compressed air supply of a factory (not shown) within which the machine is to be installed. The air supply means 66 splits to feed each of two circuits via individual process valves (not shown), a first circuit that supplies the balance test module 2 and a second circuit that supplies the flow setting module 4.

The first circuit is controlled by a process valve (not shown) and supplies the nozzle assembly 25 via the lever 63, an accessory air supply via a filter/regulator (not shown) and a control circuit for the grinder 8. The second circuit is controlled by another process valve 44a, which is situated after a filter/regulator (not shown) and air filter 65, through a pressure control valve 44b and through the flowmeter 44. The control unit 6 also includes secondary solenoids, regulators and controls after the air filter 65 for pressure/vacuum supply to the pneumatic supply port 45. It is also envisaged that the air supply may include or be provided by a compressor, which may be separate from or built into the unit 6. A USB port 67 on the uppermost side door 60a of control unit 6 enables data stored on the memory means of the control unit 6 to be exported and downloaded for further offline analysis. A control unit door 68 at the front of the control unit 6 allows access to these components.

The fixture assembly 7 includes a base 70 secured to the work surface 40, a holding block 71 for receiving the core assembly 3 and a cradle 72 for receiving and supporting a io turbocharger 5 thereon. The base 70 is substantially square in plan with opposed vertical walls 70a each having a respective inwardly extending lip 70b to define an inverted Tshaped slot or keyway 70c. Each lip 70b includes a projecting portion at one end of the base 70 to provide a pair of opposed stops 70d. The upper side of the holding block 71 includes a recess 71a shaped to receive a core assembly 3 therein. The lower side of the holding block 71 includes a pair of outwardly projecting flanges such that the crosssectional profile of the holding block 71 corresponds to and cooperates with the slot or keyway 70c of the base 70. The holding block 71 is slidably receivable within the slot or keyway 70c of the base 70 to the point at which it engages the stops 70d, which inhibit movement of a core assembly 3 received within the holding block 71. Thus, the shape of the slot or keyway 70c and complimentary shape of the holding block 71 (or key) provides respective locating features to locate the holding block 71 relative to the base 70.

The cradle 72 includes a pair of spaced support elements 73 interconnected by a connecting member 74. Each support element 73 is in the form of a substantially rectangular plate with V-shaped cutout, offset toward a front of the support element 73, which define an upper cradle surface 75. The lower portion of each support element 73 includes an undercut 76 at each of its sides to provide a complementary shape (or key) corresponding to and cooperating with the slot or keyway 70c of the base 70. Each support element 73 also includes a hole 77 through its thickness adjacent its lower rear corner and a threaded hole (not shown) extending from its rear surface into the through hole 77. The connecting member 74 is a rod in this embodiment that is received in the through hole 77 of each of the support elements 73 and secured therein by a respective thumbscrew 78. It is also envisaged that the thumbscrew 78 may be replaced by any other suitable fastening means, such as a set screw. Thus, the spacing between the support elements 73 may be adjusted by loosening one or both of the thumbscrews 78, sliding it along the connecting member 74 and re-tightening the thumbscrew(s) 78.

One of the support elements 73 of the cradle 72 is slidably receivable within the slot or keyway 70c of the base 70 to the point at which it engages the stops 70d. An assembled turbocharger 5 is receivable by the cradle 72 such that a portion of each of the turbine housing 50 and the compressor housing 51 rests on the cradle surface 75 of a respective one of the support elements 73. The shape of the slot or keyway 70c and complimentary shape of the support element 73 (or key) provides respective locating features to locate the cradle 72 relative to the base 70. Thus, movement of a turbocharger 5 received by the cradle 72 is inhibited by engagement between the slot or keyway 70c, the support element 73 and the stops 70d.

The grinder 8 is a handheld device that includes a handle 80 and a grinder wheel 81 rotatably mounted to the handle 80 by a shaft 82. A foot pedal 83 at the base of the control unit 6 operates the grinder 8.

The storage cabinet 9 is under the work surface 40 and beside the control unit 6. The storage cabinet 9 has an open front through which a printer 90 and two storage bins 91 are accessible. The apparatus 1 also includes an upstand 49 extending vertically from the work surface 40 to which is mounted an elongate tray 49a for receiving the air supply hose 42 when it is not in use and four small storage bins 49b.

In use, a user enters via the touchscreen display 61 identification information relating to the turbocharger to be tested. The user then disassembles the identified turbocharger 5 on the work surface 40, mounts the core assembly 3 thereof to the support housing 23, magnetises the shaft of the core assembly 3, positions the carriage 26 over the exposed impeller of the core assembly 3 and closes the door 21 of the enclosure 20 (the positioning of the carriage 26 may be automated when the enclosure door 21 is closed). The lever 63 is then operated to introduce a flow of air into the support housing 23 via the air supply pipe 23b and nozzle assembly 25 to drive rotation of the core assembly 3 to the desired speed for balance test to be performed.

As the core assembly 3 rotates, the motion measurement device 25a measures any oscillatory vibration and the rotation speed sensor 26a measures the rotational speed of the core assembly 3. The first measurement data set, that is to say the measured motion and speed data, is captured by the control unit 6, associated with the identification information and stored in the memory means. If any imbalance is determined during the balance test, the grinder 8 is used to remove material from an appropriate portion of the core assembly 3 and the test is re-run until any imbalance is measured to be in tolerance.

The core assembly 3 is then removed from the balance test module 2 and reassembled into a complete turbocharger 5. One of the support elements 73 of the cradle 72 is inserted into the slot or keyway 70c of the base 70 to the point at which it engages the stops 70d and the assembled turbocharger 5 is placed on the cradle 72. The free end of the air supply hose 42 is then connected to the inlet of the turbine housing of the turbocharger 5 and is retained by the magnetic attraction between the magnetic element 42a and the turbine housing 50. In some cases, the turbine housing 50 material is not sufficiently magnetisable, in which case an intermediate mild steel flange (not shown) is affixed to the turbine housing 50, thereby allowing the magnetic element 42a to then affix to the intermediate flange (not shown) to create the inlet circuit.

The actuator 52 is then connected either to the pneumatic supply port 45 or to the electrical driver 47, depending on the type of actuator 52. The appropriate flow setting program is then selected via the touchscreen display 61 and the air flow and pneumatic or electrical control signals are provided to the turbocharger 5 to carry out the flow setting test.

As the test is conducted, the flowmeter 44 measures the rate of airflow provided to the turbocharger 5 and the position of the actuator 52 is relayed to the control unit 6 via the electrical feedback connection 46. The second measurement data set, that is to say the measured airflow and actuator position data, is captured by the control unit 6, associated with the identification information and stored in the memory means.

The test results of one or both tests can then be printed via the printer 90 and/or downloaded via the USB port 67 for later analysis.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims (21)

1. Apparatus for testing turbochargers, the apparatus comprising a balance test module for measuring rotational imbalance of a turbocharger core assembly, a flow

5 setting module for measuring and/or calibrating airflow through a variable geometry turbocharger, memory means and control means operatively connected to each of the balance test module, the flow setting module and the memory means, wherein the control means is configured to receive, in use, a first measurement data set from the balance test module and a second measurement data set from the flow setting io module and to store the data set(s) on the memory means.

2. Apparatus according to claim 1, wherein the control means is configured to associate the first and second data sets and to store the associated data sets on the memory means.

3. Apparatus according to any preceding claim comprising an input means for inputting identification information relating to a turbocharger to be tested, wherein the control means is configured to associate the first and/or second data sets with the identification information and to store the associated identification information and

20 data set(s) on the memory means.

4. Apparatus according to any preceding claim comprising an air supply means operatively connected to the control means and fluidly connected to each of the balance and flow test modules, the air supply means being operable to selectively

25 provide air flow to each of the balance and flow test modules.

5. Apparatus according to claim 4 comprising an airflow measurement device operatively connected to the control means for measuring the flow of air or pressure decay from the air supply means to the flow setting module, wherein the second

30 measurement data set comprises measured airflow data.

6. Apparatus according to claim 5, wherein the flow setting module comprises a feedback connector for operatively connecting to the actuator of a variable geometry turbocharger to be tested, the feedback connector being operatively connected to

35 the control means and being configured to receive, in use, position data from the actuator, the second measurement data set comprising measured actuator position data.

7. Apparatus according to any preceding claim, wherein the balance test module comprises a motion measurement device for measuring oscillatory vibration of a turbocharger core assembly during rotation, the first data set comprising measured motion data.

8. Apparatus according to any preceding claim comprising a work surface to which is mounted a fixture assembly for selectively holding an assembled turbocharger or a turbine or core assembly.

9. Apparatus according to claim 8, wherein the fixture assembly comprises a base secured to the work surface and a cradle with a locating feature which cooperates with a locating feature of the base to locate the cradle relative to the base.

10. Apparatus according to claim 9, wherein the cradle comprises a pair of spaced support elements each having a cradle surface for receiving and supporting respective portions of an assembled turbocharger.

11. Apparatus according to claim 10, wherein the space between the support elements is adjustable.

12. Apparatus according to claim 11, wherein the cradle comprises a connecting member to which at least one of the support elements is releasably secured.

13. Apparatus according to claim 12, wherein the connecting member comprises a rod received by each support element and secured relative thereto by a set screw or thumbscrew.

14. Apparatus according to any one of claims 8 to 13, wherein the fixture assembly comprises a holding block for receiving a turbine or core assembly, the holding block comprising a locating feature which also cooperates with the locating feature of the base to locate the holding block relative to the base.

15. Apparatus according to any one of claims 8 to 14, wherein the cooperating locating features comprise a key and a keyway, one of which includes a stop for inhibiting relative movement between the cradle or holding block and the base.

5

16. Apparatus according to any preceding claim comprising a grinder for removing material from a turbine or core assembly of a turbocharger.

17. Apparatus according to claim 16 when dependent upon claim 4, wherein the grinder is pneumatically operated, is fluidly connected to the air supply means and is io operatively connected to the control means, the control means being configured to operate the air supply means to selectively provide air flow to the grinder.

18. Apparatus according to any preceding claim, wherein the balance test module comprises a base and a support housing for mounting a rotational core assembly

15 thereon and comprising a volute through which air may be fed from the or an air supply means to drive the core assembly, the support housing being mounted to the base by resilient means so as to afford a degree of movement of the support housing.

20

19. Apparatus for testing turbochargers substantially as described herein and/or as shown in the accompanying drawings.

20. Method of repairing or reconditioning a turbocharger comprising disassembling a variable geometry turbocharger on the work surface of an integrated balance test

25 and flow setting apparatus, testing a core assembly using a balance test module of the apparatus by measuring the rotational imbalance thereof, grinding material from the core assembly if a rotational imbalance is found, reassembling the turbocharger with the tested core assembly, measuring airflow through the reassembled turbocharger using a flow setting module of the apparatus whilst operating the

30 actuator of the turbocharger and calibrating the turbocharger based on the measured airflow.

21. Method of repairing or reconditioning a turbocharger substantially as described herein.

Intellectual

Property

Office

Application No: GB1611386.2 Examiner: Mr Zac Stentiford