增压器结构原理

1、1无锡霍尔塞特工程有限公司增压器培训教材TURBOCHARGER TRAINING WUXI HOLSET LTD王新建 -2联系电话： 5732274-888传真： 联系人： 王新建 / 潘建华无锡霍尔塞特工程有限公司增压器培训教材TURBOCHARGER TRAINING WUXI HOLSET LTD3无锡霍尔塞特公司介绍INTRODUCTION发动机为什么要增压 WHY TURBOCHARGE增压器部件和增压器工作原理TURBOCHARGER COMPONENTS AND HOW A TURBOCHARGER WORKS为什么要动平衡WHY BALANCE增压器的性能及匹配 - （可选

2、）无锡霍尔塞特工程有限公司增压器培训教材TURBOCHARGER TRAINING WUXI HOLSET LTD4VCD （25）无锡霍尔塞特工程有限公司增压器培训教材TURBOCHARGER TRAINING WUXI HOLSET LTD5失效分析 （可选）FAILURE DIAGNOSIS放气阀WASTEGATES增压器安装/检查/使用注意事项DOS & DONTS日常检查routine maintenance增压器常见故障及排除方法FAULT SHOOTING结束QUESTIONS / WRAP UP无锡霍尔塞特工程有限公司增压器培训教材TURBOCHARGER TRAINING W

3、UXI HOLSET LTD6无锡霍尔塞特工程有限公司介绍WUXI HOLSET ENGINEERING CO., LTD.7成立于1996年2月1日 Established on February 1st 1996.无锡动力机厂（45%）与霍尔塞特工程有限公司（55%）的合资企业A joint venture between Wuxi Power (45%) and Holset Engineering (55%).注册资金10,000,000美元, 总投资14,000,000美元Registered capital of USD 10 Million and total investmen

4、t of USD 14 Million. 拥有国内40%的涡轮增压市场，是国内最大的涡轮增压器制造商之一 Enjoy 40% of the Chinese turbocharging market, is one of the largest turbocharger manufacturer in China.遍布全国的售后销售和维修网络Nationwide Aftermarket Sales and service network无锡霍尔塞特简介 Intro to Wuxi Holset8建厂53年的国营企业A state owned company with 53 years of hi

5、story主要生产柴油发动机，发电机组并拥有铸造分厂 Manufacture mainly diesel engine, gen-set and own a foundry division八十年代初期从Holset引进了H1系列增压器技术H1 series turbocharger technical license agreement reached with Holset in early 1980s.合资前的增压器分厂是国内最早并且最大的增压器制造商The largest domestic turbocharger manufacturer with longest history b

6、efore Joint Venture无锡动力机厂 Wuxi Power9集团总部位于英国，制造工厂遍及世界不同地区，英国，北美，南美，印度及中国 Headquartered in UK with manufacturing facilities in UK, North-America,South-America, China and India.增压器技术处于世界领先地位, 是世界上最大的中型和重型涡轮增压器制造商之一 World leader in turbocharging technology, is one of the largest MR to HD turbocharger

7、manufacturer.全球最大的200马力以上柴油发动机制造商-康明斯公司的全资子公司Wholly-owned by Cummins Inc.,the worlds largest producer of diesel engines above 200 horsepower. 霍尔塞特公司 Holset Engineering10建立世界水准的制造设施To establish world class manufacturing facility确保在中国中重市场的领先地位To maintain market leadership in China in Middle Range and

8、Heavy Duty market.发展成为霍尔塞特亚洲战略中心To become focal point for Holset Asia Strategy无锡霍尔塞特的前景 Wuxi Holset Vision 11型号 新型号 HC5 HX80HC3 HX60H2D HX55H2C HX50H1D HX40H1E HX35H1C HX30 HX25产品系列 Product Range 12康明斯 Cummins沃尔沃 Volvo依维柯 Iveco斯堪尼亚 Scania雷诺 RVI小松 KomatsuMAN MAN等 ETC霍尔塞特主要客户 Holset Major Customers13D

9、FM柴发厂 DFM Engine PlantFAW锡柴,大柴 FAW Wuxi and Dalian Diesel玉柴机器 Yuchai 东风康明斯 DCEC重庆康明斯 CCEC其他主机厂 Other Domestic OEMs出口到南韩大宇Export to Daewoo in Korea无锡霍尔塞特主要客户 Wuxi Holset Major Customers14在前五年内设备投资达到了六千五百万人民币, 其中大多为进口设备65 M RMB were invested on new machines in the first five years of JV, most of which

10、 are imported.先进的试验台位及质量检测设备Advanced test cells and quality inspection equipment目前年生产能力已超过15万台Current annual capacity is over 150,000.2001及2002年将是第二个投资高峰年，2003年的年生产能力将达到近25万台。 This year and next year are the second high investment years, the annual capacity will reach 250,000 by 2003. 固定资产投资 Capital

11、 Investment 15特 能力发展核心件战略：涡轮部件/压气机叶轮/中间壳/装配重点投资 集中优势，保障发展，规避风险。1996.2S/WB/HC/WT/HC/CD/FNUTSS/CO/SJ/SC/B.161998.12S/WB/HC/WC/CT/HD/FNUTSJ/SC/B.112000.6S/WB/HC/WASS.C/CD/FJ/BC/B.92001-2005S/WB/HC/WASS.4公司人员规模稳定、培训有效性提高；有限的投资，最佳的效果；非核心零件的专业化规模化。161999 年9月通过了英国劳氏船级社的ISO9001审核ISO9001 accreditation by LRQ

12、A in September 19992000年4月通过了英国劳氏船级社的QS9000 质量体系认证, 计划通过ISO14001认证QS900 accreditation by LRQA in April 2000,has a plan to pass ISO14001 audit通过了一汽/东风等公司的质量体系审核 Passed FAW and DFM quality system audit所有供应商都已通过ISO9000质量体系认证 All suppliers have passed ISO9000 audit将引进6管理方法Will introduce 6 activity in th

13、e near future质量控制 Quality Control 17质量控制全方位质量管理供应商内部客户采用预防性质量控制方式（FAIL SAFE）PQC（产品质量委员会）持续改进，满足/超过客户不断提高的要求18质量控制-客户质量用户服务体系售前服务售后服务BIS/AIS-CAR系统PQC（产品质量委员会）定期审查产品质量，满足用户的需要连续不断的改进CACI19质量控制-工厂内部质量策划控制计划降风险活动操作人员与专职检验人员相结合统计技术SPC内部质量整改-CAR20供应商质量提高程序SQIP供应商质量体系完善供应商PPAP能力供应商质量问题监控-CAR定期工作回顾SQI工程师/入厂

14、检验员质量控制-供应商21与康明斯有关企业合作Work with Cummins licensees and Joint Ventures东风，一汽和玉柴是我公司的A类客户DFM，FAW and Yuchai are our Category A customers争取更多的售后市场业务To win more aftermarket business创造产品出口机会Develop export capability and opportunity企业成立至今销售以每年40%的幅度增长, 预计仍将保持快速增长态势Sales growth of 40% per year since JV esta

15、blishment, high growth will continue in future several years.市场与销售增长 Sales and Marketing Growth22采用康明斯生产管理(CPS)，营销管理(CMS)方法 Using Cummins Production and Marketing System1998年底CPE已达到I级水平, 目前达II级水平CPE achieved Level 1 by end 1998 and now at Level 2CMS 方法从1999年起实施，初级阶段将注重客户小组工作方式CMS introduced since 19

16、99, focus on account team building at the early stage. CPS/CMS管理方法 CPS and CMS Introduction 23康明斯市场系统 Cummins Marketing System了解顾客的所有业务需求, 而不仅仅是产品需求Understanding customers total business needs, not just product needs给我们的顾客全方位的服务 - 价值包 Provide a total service to our customers - Value Package 24多次获得东风

17、公司优秀供应商称号Excellent Supplier awards from DFM for consecutive years获一汽无锡柴油机厂质量优胜和最佳质量奖Quality Excellence and Best Quality award from FAW Wuxi Diesel获一汽大连柴油机厂A类供应商称号Category A supplier award from Dalian Diesel连续两年获HOLSET年度优秀奖Holset 1999 and 2000 Quality Award were given to Wuxi Holset 客户认可 Recognition

18、Received25客户是我们企业最重要的客人。A Customer is the most important visitor on our premises.他并不依靠我们，我们却依靠着他。He is not dependent on us. We are dependent on him.他并没有打断我们的工作，他正是我们工作的目的。He is not an interruption to our work. He is the purpose of it他不是我们业务的局外人，他是我们业务工作的一部分。He is not an outsider to our business.He i

19、s part of it.我们并没有通过给他们服务而给他们施恩。正相反，他在施惠于我们。We are not doing him a favor by serving him. He is doing us a favor by giving us an opportunity to do so. Mahatma. Gandhi穆罕默德. 甘地关心客户 Customer Care26英国Huddersfield- Turbochargers- Holset Service-美国Charleston- Turbochargers美国Memphis - Holset Service巴西- Hols

20、et Service中国- Turbochargers- Holset Service印度- Turbochargers- Holset Service荷兰- Holset Service介绍-世界范围内的合资企业27马力 Horse Power per Turbo增压器型号Turbocharger Model Name产品功率范围 Product Range Holset/MHI Range HX Range HY Range28典型应用 Typical Applications29为什么要增压 Why Turbocharge为什么要增压 ?30提高发动机的功率Increase engine

21、 power为什么要增压 Why Turbocharge为什么增压WHY TURBOCHARGER?高原功率补偿 Altitude Compensation中冷 Aftercooling保护环境Environment protection31提高发动机的功率为什么要增压 Why Turbocharge提高发动机功率的办法有Engine Power increased by增加发动机体积Increasing Engine Size增加额外的燃油 Adding Extra Fuel增压Turbocharging32增加额外燃油Adding extra fuel+O2=POWER为什么增压-提高发动

22、机功率 Why Turbocharge: develop Engine Power较多的空气消耗= 较大的功率More Air MASS (+ fuel) = More Power发动机功率与空气消耗有关Power developed by an engine is related to air consumption.33O2 发动机增加过多的燃油 Excess Fuel Added to Engine为什么增压-额外增加燃油 Why Turbocharge :Adding Extra Fuel34增加发动机体积Increasing engine size4cyl 4litre80HP247

23、 kg6cyl 6litre120 HP344 kg4cyl 4litre Turbo122 HP286 kg为什么增压-增加发动机体积 Why Turbocharge: Increasing Engine Size35Engine机械增压Supercharger空气过滤Air Filter275hp机械增压理论增加 200hp to 275hpTheoretical increase200hp to 275hp消耗Uses 50hpX实际 225hp Actual225hp为什么增压-机械增压 Why Turbocharge :Supercharging36为什么增压-涡轮增压 Why Tu

24、rbocharge :TURBOCHARGER涡轮增压器 TURBOCHARGER 利用排出的废气，无机械功率损耗，最高可提高功率 100%（30%-100%）37海拔较高时氧气不足导致燃油燃烧不充分，功率不够冒黑烟Less O2 at high altitude isinsufficient to burn all the fuel.Low power and black smoke.增压器可以增加发动机中氧气量，减少排污，增加功率Turbocharger rotates fasterto increase delivery of O2 to engine.Clean emissions a

25、nd power为什么增压-海拔功率补偿 Why Turbocharge: Altitude Compensation38为什么增压-保护环境 Why Turbocharge- Environmental Protection保护环境Environmental Protection 增压可以保护环境 降低噪音 减少排放的尾气污染39增压与中冷冷空气比热空气密度高Cold air has a higher density than warm air.向汽缸中输送冷空气=增加氧气含量=增加发动机功率Delivering cold air = more O2 per cylinder = more

26、engine power中冷降低空气温度因而增加其密度Aftercooling reduces the temperature thereby increasing the density.为什么增压-中冷 Why Turbocharge :Aftercooling40两种形式的中冷Two forms of aftercooling:空 - 空中冷Air to Air水 - 空中冷Water to Air为什么增压-中冷 Why Turbocharge :Aftercooling41为什么增压-中冷（空 - 水中冷） Why Turbocharge: Aftercooling Air to W

27、ater42为什么增压-中冷（空-空） Why Turbocharge: Aftercooling Air to Air43 Holset Engineering Co Ltd增压器组成部件-介绍 Turbocharger Components :Introduction主要部件 Major Components通用小件 Common Minor Components应用 Applications增压器工作原理 How a Turbocharger Works 44增压器组成部件-主要部件Turbocharger Components :Major Parts Holset Engineeri

28、ng Co Ltd主要部件 Major Parts 4 = ? 5 = ? 6 = ? 7 = ? 8 = ?14 = ? 45增压器组成部件-主要部件Turbocharger Components: Major Components Holset Engineering Co Ltd中间壳Bearing Housing扩压器DiffuserBackplate止推轴承Thrust Bearing定距套Thrust Collar轴封Oil Slinger压叶轮Compressor Wheel压壳Compressor Cover压端密封环Piston Ring Seal挡油板Oil Deflect

29、or涡轮壳Turbine Housing隔热板Heat Shield涡轮TurbineWheel轴承挡圈BearingCirclip涡端密封环Piston Ring Seal浮动轴承JournalBearing46增压器组成部件-主要部件Turbocharger Components: Major Components Holset Engineering Co Ltd你能说出以下部件名称？Can you namethe following components on the poster 538 61364 11 414 1236 16 7 8 31 33 47增压器组成部件-增压器铭牌Tu

30、rbocharger Components: Turbocharger Identification Holset Engineering Co Ltd.检查铭牌Check IdentificationH/AKZ总成号编 号型 号WH1E48增压器工作原理 How A Turbocharger Works增压器是如何工作的How does a turbocharger work ? 涡轮端The Turbine End 压气机端The Compressor End 润滑油供应The Oil Supply 密封环The Piston Ring Seals49增压器工作原理 How A Turbo

31、charger Works增压器是如何工作的How does a turbocharger work ? 小结Summary50增压器工作原理 How A Turbocharger Works 涡轮端 涡轮壳接到发动机排气管道上The turbine housing is bolted to the exhaust manifold of the engine. 废气驱动涡轮壳中的涡轮叶轮The waste exhaust gasses are used to rotate a turbine wheel which is housed in the turbine casing. 涡轮叶轮带

32、动同轴上的压叶轮The turbine wheel is connected to a common shaft which in turn rotates a compressor wheel.51 越多的废气通过涡轮壳，涡轮叶轮就转得越快As more gas passed through the turbine housing, the faster the turbine wheel rotates. 随着涡轮转速的增加，压叶轮转速也增加，这样更多的空气通过空滤器后进入压壳As the turbine wheel increases in speed, so does the comp

33、ressor wheel. This creates a sucking process and pulls air into the compressor cover from the atmosphere (filtered)增压器工作原理 How A Turbocharger Works52 压气机端 转速越快吸进去的空气越多The faster the wheels spin , the more air is sucked in.空气进入压壳后通过扩压面As the air is sucked into the compressor cover, it is forced throu

34、gh a diffuser area. 扩压面使空气压力增大并压入发动机This compressors the air and forces it into the engine 增压器工作原理 How A Turbocharger Works53 这过程导致空气温度上升，有时达到200度This process causes the air to increase in temperature, sometimes upto 200 degrees C 增压器工作原理 How A Turbocharger Works54 润滑系统： 增压器与发动机使用同样的机油The oil used i

35、n a turbocharger is the same as that used for your engine. 机油既作为润滑油又作为冷却油The oil is used as both a lubricant and a coolant. 机油加压后进入中间壳，通过浮动轴承和止推系统It is fed under pressure into the bearing housing, through to the journal bearings and thrust system.增压器工作原理 How A Turbocharger Works55 浮动轴承可以自由浮动转动The Jo

36、urnal Bearings are a free floating rotational type. 为了能正常工作，浮动轴承与中间壳及轴间应建立油膜To perform correctly, the journalbearings should float between a filmof oil (i.e. between bearing & shaft,& bearing & bearing housing.) 油脏，进油孔堵塞将导致增压器严重损坏Dirty oil, or blockages in the oil supply holes can cause serious dama

37、ge to the turbocharger.增压器工作原理 How A Turbocharger Works56密封系统： 在增压器涡端和压端都有密封环环 Piston Ring Seals, can be foundat both ends of the turbocharger 密封环的作用是有效密封以免废气和空气进入中间壳They are designed to keep the exhaust pressure out of the bearing housing, and the air pressure out of the bearing housing. 涡端压端孔腔表面必须

38、光滑无划痕The surface finish on both Turbine & Compressor end bore must be smooth and score free. 增压器工作原理 How A Turbocharger Works57小结 Summary 压气机壳的作用是什么？ What is the function of the Compressor Housing ? 增压器里机油的作用是什么？ What is the function of the oil in the turbocharger ? 增压器涡轮壳的作用是什么？ What is the functio

39、n of the Turbine Housing ?增压器工作原理 How A Turbocharger Works58HX系列增压器介绍 Introducing The HX-Range Holset Engineering Co LtdHX25(代替 H1C/E Replaces H1C/D/E)为 56 - 134 bhp (075 - 100kW ）发动机配套Designed for diesel engines rated between56 - 134 bhp (075 - 100kW)4升发动机用Fitted on 4 ltr engines性能优越，包括有：水冷中间壳增压器 带

40、放气阀增压器Optional Features Include:Watercooled Bearing Housings.Wastegate Versions. 59 Holset Engineering Co Ltd HX30/35/40(代替 H1C/D/E Replaces H1C/D/E) 为功率在120 - 330 bhp (090 - 240 kW）范围的发动机配套 Designed for diesel engines rated between 120 - 330 bhp (090 - 240 kW) 4升到6升发动机用 Fitted on 4 and 6 ltr engine

41、s 性能优越，包括：水冷涡轮壳 水冷中间壳 配天然气发动机及带放气阀的增压器 Optional Features Include: Watercooled Turbine Housings. Watercooled Bearing Housings. Gas Engine Versions. Wastegate Versions.HX系列增压器介绍 Introducing The HX-Range60 Holset Engineering Co LtdHX50/55 (替代 H2C/D Replaces H2C/D)配套发动机功率范围 290 - 455 bhp (220 - 340 kW ）

42、Designed for diesel engines rated between290 - 455 bhp (220 - 340 kW)10 升和 11 升发动机用 Fitted on 10 and 11 ltr engines 性能优越，包括：水冷涡轮壳 水冷中间壳 配天然气发动机及带放气阀的增压器 Optional Features Include: Watercooled Turbine Housings. Watercooled Bearing Housings. Gas Engine Versions. Wastegate Versions. HX系列增压器介绍 Introduci

43、ng The HX-Range61 Holset Engineering Co Ltd HX60 (替代 HC3 Replaces HC3) 配套发动机功率范围 320 - 530 bhp (240 - 400 kW) Designed for diesel engines rated between 320 - 530 bhp (240 - 400 kW) 14 升和 16 升发动机配套 Fitted on 14 and 16 ltr engines 性能优越，包括：水冷涡轮壳 带放气阀的增压器及带进气消音罩的增压器 Optional Features Include: Watercoole

44、d Turbine Housings. Wastegate Versions. Inlet Suppression HX系列增压器介绍 Introducing The HX-Range62HX 系列增压器改进The HX-Range Improvements Holset Engineering Co Ltd HX30/35/40 新的止推系统 New thrust system 一只中间壳 One piece bearing housing 压壳卡环 Compressor cover circlip HX50/55 新的止推系统 New thrust system HX60 压气机效率更高M

45、ore efficient compressor stage63动平衡的重要性The Importance of Balance动平衡介绍 Balancing - Introduction64为什么要动平衡 Why Balance影响动平衡的零件 Which Parts Affect Balance转子动平衡 Rotor Balance不平衡因素 Out-of -Balance Forces动平衡介绍Balancing Introduction65为了使轴承系统在增压器高速运转时能正常工作To enable the bearing system to survive at the turboc

46、hargers high rotational speeds.HX25W 200k rpm = 3333 rev/sec H1C/HX35 140k rpm = 2333 rev/secH1E/HX40 130k rpm = 2166 rev/secH2/HX50 115k rpm = 1916 rev/sec为了提高增压器的使用寿命和耐久性To increase the durability and lifetime of a turbocharger in service.减少增压器发出的躁声To reduce the noise emitted from the turbocharger

47、. 动平衡-为什么要动平衡 Balancing: Why Balance66 涡轮 T/W 涡轮头部 Nose动平衡 Balancing需要平衡的零部件 Component Balance涡轮背面Turbine WheelBackface影响动平衡的零件 Which Parts Affect Balance67动平衡 Balancing需要平衡的零部件 Component Balance压叶轮背面 Backface压叶轮外圆Impeller Diameter压叶轮头部Impeller Nose 压叶轮 C/W68涡轮叶轮 Turbine Wheel压叶轮 Impeller定距止推套 Thrus

48、t Spacer轴封 Oil Slinger锁紧螺母 Locknut动平衡 Balancing转子平衡 Rotor Balance69转动转子部件 Rotate rotorassembly. 测量转子不平衡量Measureout-of-balanceforce.动平衡 Balancing转子平衡 Rotor Balance70000 - 36090180270动平衡 Balancing转子平衡 Rotor Balance71000 - 36090180270动平衡 Balancing转子平衡 Rotor Balance72定距止推套/轴封上刻线Mark thrust spacer,oil sl

49、inger.压叶轮上刻线Mark impeller bossand locknut动平衡 Balancing对准动平衡刻线 Aligning Components轴端And the shaft endHX35W 1.4 - 1.4 gm mm.0019 - .0019 oz ins轴封上刻线73动平衡-导致不平衡可能的原因 Balancing: Possible Causes of Poor Rotor balance导致不平衡可能的原因 Possible Causes of Poor Rotor balance74部件不平衡Poor Component Balance 涡轮部件或压叶轮损坏D

50、amaged components (Impeller / Turbine)压叶轮与轴配合问题Fit of the compressor wheel on the shaft. 轴碰弯Bend in the shaft. 动平衡-导致不平衡可能的原因 Balancing: Possible Causes of Poor Rotor balance75压叶轮背面质量状况不好Condition of the compressor wheel backface.定距止推套与轴封配合面平面度不好Squareness of the thrust collar and slinger mating sur

51、faces.锁紧螺母的平面度不好，锁紧螺母与轴螺纹配合不好Squareness of the locknut and quality of the thread fit.动平衡-导致不平衡可能的原因 Balancing: Possible Causes of Poor Rotor balance76装配时相关零件的动平衡刻线未对准（涡轮部件、压叶轮、轴封、定距止推套动平衡-导致不平衡可能的原因 Balancing: Possible Causes of Poor Rotor balance77以下内容可选78压气机compressor stage涡轮turbine stage增压器性能 per

52、formance压气机compressor stage涡轮turbine stage增压器增压器性能 performance压气机compressor stage涡轮turbine stage79压气机compressor压气机性能曲线compressor map空气流量air flow压比pressure ratio增压器转速turbo speed80压气机compressor压气机的高效运行有一定范围。在压气机特性曲线的中心部位，增压器能以高的效率为发动机提供空气。但围绕中心存在着三个不能运行的区域：The efficient operation of the compressor has

53、 boundaries. In the heart of the map the turbocharger will supply air to the engine at high efficiency. However there are three no go regions that surround the heart where the engine should not run.压气机阻塞compressor choke压气机喘振compressor surge转速限制limiting speed81压气机阻塞choke阻塞时，压气机内的气流速度接近声速。流量是如此之大，以至于叶轮的通道被阻塞，实际上流量再也