Marine diesel engine turbocharger test bench

This customer is one of the world's leading manufacturers of large diesel engines, turbochargers and complete drive systems. The company manufactures diesel engines for shipping, power generation, and heavy road and rail vehicles - with power ranges from 116 to 9000kW. Turbocharger performance determines overall engine performance fuel consumption and emissions. They are subjected to high levels of thermal and mechanical stress. They can rotate up to 90,000 rpm, are exposed to temperatures of up to 750 ºC and a pressure ratio of 5.0.

Customer requirement:

Two existing turbocharger test benches where upgraded with the latest TopMessage and ProfiSignal data logging systems from Delphin Technology. The test bench is designed to test the most critical areas and to optimize the robustness, efficiency and operation of the components. The customer was also considering more advanced test scenarios with more inputs in the future and therefore a modular system was required to have the ability to upgrade the system easily with more I/O channels.

Solution:

For this test bench application about 80 analog signals and about 20 digital I/O channels where required. The analog inputs record pressures, volume flows, valve position, and temperatures. The counter inputs measure rotation speed. The system was installed in a control cabinet with the following modules.

Hardware:

1 TopMesage Master with 1 GB memory and ProfiBus DP Slave interface;

3 TopMessage Slave extension units;

6 ADVT modules with 90 Analog inputs for temperature & pressure measurement;

1 DIOT module for digital I/Os pulse & speed measurement.

Software:

ProfiSignal Basic with 250 channel input for HMI mimic building.

A high level of accuracy was especially necessary for the temperature measurements (+/- 0,2 K). The ProfiBus-DP Slave interface of the TopMessage was important to integrate the system to the PLC system which is controlling the overall test cycle.

Benefits:

The customer considered the following benefits for this project:

The first test run was performed after 2 days of installation. The installation and configuration of all the sensors was easy as no additional converter and signal conditioning unit was required. The system is very reliable. The configuration of individual mimics and HMI screens could be done easily.

More information: TopMessage >>

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