Shaft coking resolution using multiple variable bearing system design optimization for commercial vehicle turbochargers

摘要

In the design phase of a commercial vehicle turbocharger bearing system design, a previously [1] suggested analysis methodology was applied to take advantage of multiple challenging customer requirements such as lower shaft temperature, equal or lower power loss, low cost, good stability/reliability and short development schedule. The combination of these factors led to a major failure of the previous bearing system (baseline here). This failure warranted implementing multiple variable optimization technique. In addition to the bearing system analysis, a novel thermal modeling procedure was also used to predict the shaft temperatures. Analysis procedure reduced the number of actual tests and hardware preparation cycles. Small numbers of alternative solution were also chosen for validation testing. Suggested solution from the large analytical study and validation by tests led to the successful implementation of the new bearing configuration. This effort improved an already developed bearing analysis methodology and is increasingly becoming the new standard within the organization.