Acoustic Identification of Turbocharger Impeller Mistuning—A New Tool for Low Emission Engine Development

Abstract

At present, exhaust gas turbochargers not only form the basis for the economical operation of petrol, diesel or gas engines of all power categories, but also have an irreplaceable role on reducing their emissions. In order to reduce emissions from internal combustion engines, various systems are being developed, all of which have a turbocharger as an important component. Demands on turbocharger system durability and reliability keep growing, which requires the application of increasingly advanced computational and experimental methods at the development beginning of these systems. The design of turbochargers starts with a mathematical description of their rotationally cyclic impellers. However, mistuning, i.e., a slight individual blade property deviation from the intended design parameters, leads to a disturbance of the rotational cyclic symmetry. This article deals with the effects of manufacturing-related deviations on the structural dynamic behaviour of real turbine rotors. As opposed to methods exploiting expensive scanning vibrometers for experimental modal analysis or time-consuming accurate measurement of the geometry of individual blades using 3D optical scanners. A suitable microphone and a finite element rotor wheel model are the basis of this new method. After comparing the described acoustic approach with the laser vibrometer procedure, the results seemed to be practically identical. In comparison with the laser technique the unquestionable added value of this new method is the fact that it brings a significant reduction in the financial requirements for laboratory equipment. Another important benefit is that the measuring process of bladed wheel mistuning is significantly less time-consuming.At present, exhaust gas turbochargers not only form the basis for the economical operation of petrol, diesel or gas engines of all power categories, but also have an irreplaceable role on reducing their emissions. In order to reduce emissions from internal combustion engines, various systems are being developed, all of which have a turbocharger as an important component. Demands on turbocharger system durability and reliability keep growing, which requires the application of increasingly advanced computational and experimental methods at the development beginning of these systems. The design of turbochargers starts with a mathematical description of their rotationally cyclic impellers. However, mistuning, i.e., a slight individual blade property deviation from the intended design parameters, leads to a disturbance of the rotational cyclic symmetry. This article deals with the effects of manufacturing-related deviations on the structural dynamic behaviour of real turbine rotors. As opposed to methods exploiting expensive scanning vibrometers for experimental modal analysis or time-consuming accurate measurement of the geometry of individual blades using 3D optical scanners. A suitable microphone and a finite element rotor wheel model are the basis of this new method. After comparing the described acoustic approach with the laser vibrometer procedure, the results seemed to be practically identical. In comparison with the laser technique the unquestionable added value of this new method is the fact that it brings a significant reduction in the financial requirements for laboratory equipment. Another important benefit is that the measuring process of bladed wheel mistuning is significantly less time-consuming.