Turbocharger Training Russia 2010 Rajesh Sendil – Area

Скачать презентацию Turbocharger Training Russia 2010 Rajesh Sendil – Area Скачать презентацию Turbocharger Training Russia 2010 Rajesh Sendil – Area

39632-turbo_cummins_2010_presentation.ppt

  • Количество слайдов: 158

>Turbocharger Training  Russia 2010    Rajesh Sendil – Area Sales Manager Turbocharger Training Russia 2010 Rajesh Sendil – Area Sales Manager UK, Ireland, Russia and Eastern Europe

>Agenda  Introduction to Cummins Inc. Cummins Turbo Technologies Overview Products and Technology 2010 Agenda Introduction to Cummins Inc. Cummins Turbo Technologies Overview Products and Technology 2010 Business update Aftermarket Support Examples of Current applications Turbochargers Failure Diagnosis Copy Turbochargers Technology

>Introduction to Cummins Inc Introduction to Cummins Inc

>Our Vision/Mission: VISION Making people’s lives better by unleashing the Power of Cummins. Our Vision/Mission: VISION Making people’s lives better by unleashing the Power of Cummins. MISSION Motivating people to act like owners working together. Exceeding customers’ expectations by always being the first to market with the best products. Partnering with our customers to make sure they succeed. Demanding that everything we do leads to a cleaner, healthier, safer environment. Creating wealth for all stakeholders.

>The New Cummins: Global presence Less cyclical More diversified  Low-cost producer Complementary businesses The New Cummins: Global presence Less cyclical More diversified Low-cost producer Complementary businesses working together Becoming the first choice of our customers

>Tim Solso   Chairman and CEO Tom Linebarger  President and Chief Operating Tim Solso Chairman and CEO Tom Linebarger President and Chief Operating Officer Jean Blackwell Executive Vice President – Corporate Responsibility and CEO – Cummins Foundation Bruce Carver Chief Information Officer Steve Chapman Group Vice President – China and Russia Jill Cook Chief Human Resource Officer Thad Ewald Vice President – Corporate Strategy and Business Development Ignacio Garcia Chief Manufacturing and Procurement Officer Mark Gerstle Chief Administrative Officer Marya Rose General Counsel and Corporate Secretary Floyd Rutan Executive Director – Cummins Business Services John Wall Chief Technical Officer Pat Ward Chief Financial Officer Cummins Inc

>Introduction to  Cummins Turbo Technologies Introduction to Cummins Turbo Technologies

>Overview Cummins Turbo Technologies is an autonomous Business Unit of Cummins Inc We are Overview Cummins Turbo Technologies is an autonomous Business Unit of Cummins Inc We are the leading designer and manufacturer of turbochargers for diesel and gas-derivative engines above 2.3 litres We have over 2000 employees globally Headquartered in the UK with global manufacturing facilities in; Brazil, China, Europe, India and USA along with dedicated technical centres in UK and China

>Global Customers: Global Customers:

>Business Strategy Be the first choice for customers through our market leading dependable technology Business Strategy Be the first choice for customers through our market leading dependable technology and innovative air handling solutions To profitably grow the business by delivering the best value turbocharger technology to our customers Focus on customer support excellence to achieve customer loyalty through the reliable supply of turbochargers Harnessing the skills and creativity of our employees to be the benchmark supplier of turbocharger technologies

>Products & Technology Products & Technology

>The commercial turbocharger market has seen steady growth over the past few years. This The commercial turbocharger market has seen steady growth over the past few years. This is expected to continue into the next decade and beyond Growth is driven by increasingly stringent government emissions legislation worldwide Turbocharging technology is seen as a key tool in enabling engine manufacturers to meet these strict criteria Market Drivers:

>To profitably grow the business by delivering the best value turbocharger technology to our To profitably grow the business by delivering the best value turbocharger technology to our customers. Focus on customer support excellence to achieve customer loyalty Reliable supply of turbochargers to all customers Easy to do business with Provide a financial return to ensure future technology investment and growth. Business Strategy:

>On-highway, heavy duty emissions legislation by country and date of introduction Emission Regulations On-highway, heavy duty emissions legislation by country and date of introduction Emission Regulations

>Product Focus Cummins Turbo Technologies has developed advanced turbocharging technologies to enable engine manufacturers Product Focus Cummins Turbo Technologies has developed advanced turbocharging technologies to enable engine manufacturers to meet strict emissions criteria and engine performance requirements Can offer a portfolio of technology to meet our strategic customers’ target markets: Holset VGT™ with electric actuation Turbo compound System Serial 2 Stage M Squared™

>Product Range Product Range

>Holset HE Range A new technology platform for future emissions engines: Holset VGT with Holset HE Range A new technology platform for future emissions engines: Holset VGT with electric & pneumatic actuation options High pressure ratio compressors including Titanium option High durability Advanced control capability Speed & inlet air temperature measurement Fully modulating control valves (DCon) with remote intelligence option (ICon) Low flow turbine stages with wastegate for EGR engines Enhanced MWE for improved compressor map width

>Holset Product Features Cast Aluminium:  Standard technology  Very cost effective and suitable Holset Product Features Cast Aluminium: Standard technology Very cost effective and suitable for mid-range turbochargers Not suitable for those with high duty cycles Cast Titanium: Can withstand high temperatures Effective metal to use in heavy duty turbochargers Titanium is a cost premium Cummins Turbo Technologies use a number of different methods and materials to create its impellers. Each give different durability vs cost benefits:

>Holset Product Features Machined from solid (MFS) Aluminium: Casting process can create defects that Holset Product Features Machined from solid (MFS) Aluminium: Casting process can create defects that become weaknesses in the metal The MFS process reduces such defects considerably Cost effective solution over Cast Ti for increasing durability MFS Titanium: Reduces the possibility of defects seen with casting process Process is slow and expensive Suitable for heavy duty turbochargers with high duty cycles Semi Solid Mould (SSM) Aluminium: Process shapes the wheels at high temperatures and cooled to set Fewer defects than casting process A cost effective alternative to using MFS

>2010 Business Update 2010 Business Update

>First fit volumes Global Turbocharged Engine Market First fit volumes Global Turbocharged Engine Market

>A Global Presence A Global Presence

>Global Capacity Global Capacity

>Turbo Technologies Worldwide  Sales & Volume History Turbo Technologies Worldwide Sales & Volume History

>Commercial Diesel Market Shares (2009) Commercial Diesel Market Shares (2009)

>Aftermarket Support Aftermarket Support

>Aftermarket & Distribution Network Focused on serving OEM global service networks Specialised service, packaging Aftermarket & Distribution Network Focused on serving OEM global service networks Specialised service, packaging & logistics Dedicated facilities: USA, China, Europe, India and Brazil 24 hour, 7 day per week coverage Extended opening hours Multi-lingual Staff OEM Remanufacturing Service Independent channel of distributors Local expertise, coverage of old, ex-OE production product, capable of specialised logistics service

>Service/Spare Parts Focused on serving OEM global service networks Specialised service, packaging & logistics Service/Spare Parts Focused on serving OEM global service networks Specialised service, packaging & logistics Dedicated facilities: USA, China, Europe, India and Brazil 24 hour, 7 day per week coverage Extended opening hours Internet Ordering Multi-lingual Staff OEM Remanufacturing Service Independent channel of distributors Local expertise, coverage of old, ex-OE production product, capable of specialised logistics service

>UK Operations Aftermarket, UK Technical Centre, UK Technical Centre, UK UK Operations Aftermarket, UK Technical Centre, UK Technical Centre, UK

>Dewas, India  India Operations Dewas, India India Operations

>Palmetto, USA  USA Operations Leeds Avenue, USA Palmetto, USA USA Operations Leeds Avenue, USA

>China Operations Wuxi, China China Operations Wuxi, China

>Sao Paulo, Brazil  Brazil Operations Sao Paulo, Brazil Brazil Operations

>Amersfoort, The Netherlands  Holland Operations Amersfoort, The Netherlands Holland Operations

>Examples of Current Applications Examples of Current Applications

>Peterbilt with Paccar MX engine and Cummins ISX15 – US10 500 series Holset VGT Peterbilt with Paccar MX engine and Cummins ISX15 – US10 500 series Holset VGT with electric actuation on Paccar MX 400 series Holset VGT with electric actuation on Cummins ISX15

>Scania Euro IV Turbo Compound Engine Holset 500 series fixed geometry turbocharger and Holset Scania Euro IV Turbo Compound Engine Holset 500 series fixed geometry turbocharger and Holset 700 series power turbine

>Volvo New HDEP Engine Platform – Euro IV Holset 500 series fixed geometry Volvo New HDEP Engine Platform – Euro IV Holset 500 series fixed geometry

>Holset 500 series fixed geometry turbocharger with a Holset 800 series axial power turbine Holset 500 series fixed geometry turbocharger with a Holset 800 series axial power turbine Axial Power Turbine – Euro VI/EPA 10

>Ford F250 Pick-up  Holset HE221W Ford F250 Pick-up Holset HE221W

>Chrysler Dodge Ram 07 – EPA 07 Holset HE351Ve Chrysler Dodge Ram 07 – EPA 07 Holset HE351Ve

>Iveco Cursor Engines for Stralis – Euro IV Holset HE431V – Cursor 8 Holset Iveco Cursor Engines for Stralis – Euro IV Holset HE431V – Cursor 8 Holset HE531V – Cursor 10 Holset HE551V – Cursor 13

>Daewoo CNG City Bus – Euro III   Holset HX50G Daewoo CNG City Bus – Euro III Holset HX50G

>Pisten Bully 400 Holset 400 series wastegate Pisten Bully 400 Holset 400 series wastegate

>Griffon Military Hovercraft 4 x Holset 500 series wastegate Griffon Military Hovercraft 4 x Holset 500 series wastegate

>Turbochargers Explained Turbochargers Explained

>Advantages of Turbochargers In turbochargers the exhaust gas energy which would normally be wasted Advantages of Turbochargers In turbochargers the exhaust gas energy which would normally be wasted is used to drive a turbine, which in turn drives a compressor to deliver compressed air to the engine. The advantages of a turbocharged engine are: lower fuel consumption lower emissions better torque characteristics lower weight and smaller engine package lower engine noise

>More Power Required 4cyl 4litre 80HP 247 kg Turbocharged 4cyl 4litre 122HP 286 kg More Power Required 4cyl 4litre 80HP 247 kg Turbocharged 4cyl 4litre 122HP 286 kg 6cyl 6litre 120HP 344 kg Choice is either; Increase the size of engine or fit a turbocharger.

>Major Components of a Turbocharger  Bearing Housing Compressor Wheel Turbine Housing Turbine Wheel Major Components of a Turbocharger Bearing Housing Compressor Wheel Turbine Housing Turbine Wheel Compressor Cover

>How a Turbocharger Works  The Turbine End      The How a Turbocharger Works The Turbine End The Compressor End The Oil Supply

>How a Turbocharger Works The turbine housing is bolted to the exhaust manifold of How a Turbocharger Works The turbine housing is bolted to the exhaust manifold of the engine. The waste exhaust gasses are used to rotate the turbine wheel which is housed in the turbine casing.Turbine temperatures up to 760 deg C The turbine wheel is connected to a common shaft which in turn rotates a compressor wheel.

>How a Turbocharger Works As more gas passed through the turbine housing, the faster How a Turbocharger Works As more gas passed through the turbine housing, the faster the turbine wheel rotates. As the turbine wheel increases in speed, so does the compressor wheel. This creates a sucking process and pulls air into the compressor cover from the atmosphere (filtered). The faster the wheels spin the, the more air is sucked in.

>How a Turbocharger Works As the air is sucked into the  compressor cover, How a Turbocharger Works As the air is sucked into the compressor cover, it is forced through a diffuser area. This compresses the air and forces it into the engine This process causes the air to increase in temperature, up to 200 degrees C

>

>Typical Turbocharger components   Wastegate actuator Wastegated turbine housing Oil inlet Turbine wheel Typical Turbocharger components Wastegate actuator Wastegated turbine housing Oil inlet Turbine wheel Impeller Wheel Turbine inlet Exhaust Outlet Compressor Housing Bearing Housing

>T = 21°C Air Filter  T = 25°C Comp T = 180°C After T = 21°C Air Filter T = 25°C Comp T = 180°C After cooler T = 40°C Turb Exhaust Manifold Inlet Manifold T= 690°C T = 550°C Silencer T = 400°C Typical Engine System

>Bearing System Journal Bearings fully floating bearings - allows higher clearances, so higher oil Bearing System Journal Bearings fully floating bearings - allows higher clearances, so higher oil flows for cooling oil film thicknesses of 0.008 to 0.015 mm leaded bronze allow high degrees of imbalance Thrust Bearing taper land bearing phosphor bronze or sintered iron thrust loads of 100 - 2000 N (size dependent) typical oil film thickness 0.008 - 0.015mm Has to withstand high temperatures, hot shut down, soot loading in the oil, contaminants, oil additives, dry starts.

>A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the turbine – thus limiting turbo speed & boost pressure. Typically the wastegate valve is only opened at high engine speeds & loads (used to prevent turbo speed or boost pressure from exceeding safe levels). Turbocharger Basics – Wastegates

>Wastegate Turbocharger Wastegate Turbocharger

>Wastegate Turbocharger Wastegate Mechanism: Actuator-linkage-valve Wastegate Turbocharger Wastegate Mechanism: Actuator-linkage-valve

>Wastegate Turbocharger Wastegate Turbocharger

>Wastegate Check Apply 3 bar (300 kPa) air pressure  to ensure that the Wastegate Check Apply 3 bar (300 kPa) air pressure to ensure that the wastegate actuator is not leaking or stuck. Check for air leakage

>Turbocharger  Failure Analysis Turbocharger Failure Analysis

>Turbocharger Failure Analysis The purpose of analysing a ‘failed’ turbocharger is to determine the Turbocharger Failure Analysis The purpose of analysing a ‘failed’ turbocharger is to determine the root cause of failure. We also need to determine who is responsible. We need to prevent a reoccurrence - whether it is a Cummins Turbo Technology problem or a customer / end user problem. If the problem is Cummins Turbo Technologies we need to ‘fix’ it. If the problem is the customer’s we need to work with and support them, to ensure it doesn’t happen again.

>Customer Reported Faults Leak oil Broken Wheel Low power Noisy Gas leakage Seized Excess Customer Reported Faults Leak oil Broken Wheel Low power Noisy Gas leakage Seized Excess bearing wear Broken shaft Smoke

>Failure Data Date in Service ( DIS ) Date of failure ( DOF ) Failure Data Date in Service ( DIS ) Date of failure ( DOF ) Service Life ( Hours,Kms,Mls ) Application ( Truck,Bus,Off road,Genset ) Duty Cycle ( City bus,stand by genset,General freight ) Country in Service Reason for removal from vehicle. ( Need to be specific, not just leak oil or broken ) Turbocharger Serial Number ( Date of manufacture ) Assembly Number Customer Number is applicable Model

>Warranty Analysis    How can we determine the root  cause of Warranty Analysis How can we determine the root cause of the problem?

>Customer Responsibility Customer Responsibility

>Disassembly & Inspection Check for compressor end foreign object damage by looking in the Disassembly & Inspection Check for compressor end foreign object damage by looking in the intake. AIR INTAKE

>Foreign Object Damage Compressor End Damage to the blade tips Cause : Rags,wrenches,nuts,screws,parts from Foreign Object Damage Compressor End Damage to the blade tips Cause : Rags,wrenches,nuts,screws,parts from the intake filter.

>Disassembly & Inspection Check the turbine intake for signs of solid objects. Note! Except Disassembly & Inspection Check the turbine intake for signs of solid objects. Note! Except in severe cases the turbine housing needs to be removed (in order to inspect the blade tips). TURBINE INLET

>Foreign Body Turbine End Foreign Body Turbine End

>Disassembly & Inspection Check the overall appearance corresponds with the data supplied. (i.e. claim Disassembly & Inspection Check the overall appearance corresponds with the data supplied. (i.e. claim data is 10,000kms, but turbo appears to have been in use for much longer . Check axial and radial clearances. Clearances can be found in the CTT Service Data Sheet (current version can be downloaded from www.Holset.co.uk - Parts & Service section)

>Disassembly & Inspection Remove the compressor housing Remove the core assy from the turbine Disassembly & Inspection Remove the compressor housing Remove the core assy from the turbine housing Remove the turbine housing and compressor cover and check for any wheel “touches” or “rubs” on the profile.

>Disassembly & Inspection Remove the compressor wheel and check for signs of excessive oil Disassembly & Inspection Remove the compressor wheel and check for signs of excessive oil on the backface.This could be due to oil carryover past the compressor seal ring. Check condition of the seal ring when removed. The most common cause of oil leakage, is a blocked air intake filter.

>Disassembly & Inspection Remove the shaft & wheel,check for any heat discolouration and any Disassembly & Inspection Remove the shaft & wheel,check for any heat discolouration and any wear on the shaft.

>Disassembly & Inspection Remove the circlip Remove the oil seal plate Remove the O-ring Disassembly & Inspection Remove the circlip Remove the oil seal plate Remove the O-ring seal Check for damage to the O-ring seal

>Disassembly & Inspection Remove the oil slinger from the oil seal plate. Check for Disassembly & Inspection Remove the oil slinger from the oil seal plate. Check for wear or score marks in the bore. Remove the seal ring

>Disassembly & Inspection Remove the thrust bearing and thrust collar,check for blockage of the Disassembly & Inspection Remove the thrust bearing and thrust collar,check for blockage of the oil feed holes ( a common cause of thrust failure ). Check for heat discolouration and scoring marks of both the bearing and collar. If excessive radial clearance was found it is likely that the journal bearings will also be damaged.

>Silicone Applied to Oil Inlet Gasket Do not use silicone Silicone Applied to Oil Inlet Gasket Do not use silicone

>Foreign Body Blocking the Oil Supply to the Thrust Bearing Silicone blocking oil to Foreign Body Blocking the Oil Supply to the Thrust Bearing Silicone blocking oil to the thrust bearing

>

>Blocked Thrust Bearing Foreign object blocking the oil feed to the thrust system Cause Blocked Thrust Bearing Foreign object blocking the oil feed to the thrust system Cause : Silicone from the oil feed pipe fitting. Cleanliness during service intervals,filters and oil.

>Disassembly & Inspection Remove the compressor-end outer circlip and remove the journal bearing. Look Disassembly & Inspection Remove the compressor-end outer circlip and remove the journal bearing. Look for scoring marks on both the outside (OD) and inside (ID) diameters, this can be caused by oil contamination ( dirt ) in the oil. Remove the turbine-end bearing. This bearing will normally be a much darker colour than the compressor bearing (due to higher operating temperature).

>Oil Dirt Ingress Cause :  Service intervals overdue Cleanliness during service Poor quality Oil Dirt Ingress Cause : Service intervals overdue Cleanliness during service Poor quality oil Poor quality filters

>Oil Dirt Ingress Shaft wear from oil dirt ingress Oil Dirt Ingress Shaft wear from oil dirt ingress

>Oil Contamination New bearing Contaminated bearing Check the colour of the bearing, a natural Oil Contamination New bearing Contaminated bearing Check the colour of the bearing, a natural darkening with age is acceptable. A duller,powdery surface is an indication of engine coolant in the oil - the same appearance will normally also be found on the thrust bearing.

>Oil Delay Bronze particles on the shaft Causes :Restricted oil feed pipes.  Oil Delay Bronze particles on the shaft Causes :Restricted oil feed pipes. Low oil level in the sump Blocked oil filter Long periods on Non – use Lack of priming

>Oil Starvation Cause : Oil pump failure       Oil Starvation Cause : Oil pump failure Broken oil feed pipe No oil in engine.

>Hot Shutdown - Overheating Cause:  Hot shutdown of the engine, poor quality lub. Hot Shutdown - Overheating Cause: Hot shutdown of the engine, poor quality lub. oil, infrequent service intervals, check for heavy carbon deposit in the bearing housing.

>Hot Shutdown Oil Drain Blocked oil drain  cavity Oil Leakage Hot Shutdown Oil Drain Blocked oil drain cavity Oil Leakage

>Hot Shutdown - Overheating Hot Shutdown - Overheating

>Time (secs) 0 360 60 120 180 240 300 140 180 220 260 300 Time (secs) 0 360 60 120 180 240 300 140 180 220 260 300 340 Bearing Temperature oC Hot Shut Down from Peak Torque 3 min Idle 2 min Idle 1 min Idle Temp Limit of CD Oil Failure Diagnosis: Hot Shutdown

>Oil Leakage External - Common Causes :  Loose / Damaged oil inlet and Oil Leakage External - Common Causes : Loose / Damaged oil inlet and oil drain fittings. If fitting a new gasket and tightening the fittings does not stop the leak,then look for a damaged oil line or leaking centre housing. Internal Compressor & Turbine - Common Causes : Restriction in the turbo oil drain will ‘force’ oil past the split ring seals at both the turbine and compressor ends. Oil leakage at both ends simultaneously is a good indicator that this may be the problem Engine blow by pressure - which can be due to the engine crankcase vent being blocked by damage,plugging or icing.

>Oil Leakage Restriction Oil Leakage Restriction

>Oil Leakage - Compressor  An inlet ‘depression’(vacuum) greater than 25 in water will Oil Leakage - Compressor An inlet ‘depression’(vacuum) greater than 25 in water will ‘pull’ oil past the compressor end split ring seal. THIS WILL NOT DAMAGE THE TURBO UNLESS THE THRUST BEARING FAILS. Typical cause is a blocked air intake filter or collapsed intake pipe.

>Compressor End Oil Leakage Compressor End Oil Leakage

>Compressor End Oil Leakage Compressor End Oil Leakage

>Oil Leakage Oil Leakage

>Blow By Recirculation Future legislation may prohibit all uncontrolled engine emissions, including crankcase blow-by Blow By Recirculation Future legislation may prohibit all uncontrolled engine emissions, including crankcase blow-by gases. CCV systems filter the crankcase emissions from engine piston rings valve stem leakage turbocharger seal leakage air compressor leakage These are generally routed to the turbocharger compressor inlet

>Compressor fouling due to CCV system   Oil deposit build up can be Compressor fouling due to CCV system Oil deposit build up can be significant over a period of time

>Impeller LCF - Defects Duty cycle Defect presence raises local stresses and initiates fatigue Impeller LCF - Defects Duty cycle Defect presence raises local stresses and initiates fatigue Defects have variety of sizes and appearances There are three common failure locations - back face, suction side exducer blade root and the bore (highest stresses) Back Face

>Impeller LCF - Defects  Blade Root - Inclusion Blade root - Linear/oxide blow Impeller LCF - Defects Blade Root - Inclusion Blade root - Linear/oxide blow

>Impeller LCF - Defects Bore Bore inclusion Bore cavity Cause of failure could also Impeller LCF - Defects Bore Bore inclusion Bore cavity Cause of failure could also be due to overspeed

>Machined From Solid Impeller  MFS Overview Machined From Solid Impeller MFS Overview

>x1 - Base Material Fatigue Properties x2 - Material selection and processing  x1 - Base Material Fatigue Properties x2 - Material selection and processing Base materials properties improved in MFS impellers due to increased alloy content and fine grain structure from forging process Inherently low level of oxides in wrought alloy used to make MFS impellers Fine grain structure in MFS leads to improved fatigue life

>MFS Impeller MFS Impeller

>x1 - Base Material Fatigue Properties x2 - Material selection and processing Fine grain x1 - Base Material Fatigue Properties x2 - Material selection and processing Fine grain structure in MFS leads to improved fatigue life Cast microstructure Forged microstructure

>Defect (casting process) related failures not experienced in MFS impellers Oxide casting defect Defect (casting process) related failures not experienced in MFS impellers Oxide casting defect

>Balance - Related Failures Balance failures due to a manufacturing problem  (hence Holset Balance - Related Failures Balance failures due to a manufacturing problem (hence Holset Responsibility) usually occur in very early life. (i.e. most within 500 km). If a balance failure occurs in late life - it is normally caused by wheel foreign-object damage, turbo overspeed or tampering) Balance failure causes: Parts misaligned Rotor parts replaced without check-balancing Incorrect parts used.

>Closed crankcase ventilation system Engine Compressor inlet Intercooler Exhaust Crankcase blowby gases Filter system Closed crankcase ventilation system Engine Compressor inlet Intercooler Exhaust Crankcase blowby gases Filter system

>Copy Turbochargers Copy Turbochargers

>Copy Turbos Introduction: Copies are flooding the market from China &Brazil. Many varieties Hosel, Copy Turbos Introduction: Copies are flooding the market from China &Brazil. Many varieties Hosel, Hovte, Hobest and Honesty! They look good (to the untrained eye) Cheap: Approx. 1/2 price of original Holset Turbo

>Copy Turbos Back to Back Engine tests:  Three copies tested Results follow findings Copy Turbos Back to Back Engine tests: Three copies tested Results follow findings of wastegate settings Low boost and air flow Generally lower total efficiency, by up to 10% This would result in loss of power, higher fuel consumption and higher emissions.

>Copy Turbos Holset Vs Copy 1 Copy Turbos Holset Vs Copy 1

>VIDEO VIDEO

>Copy MAN Turbo Copy turbo – See nut, machining and the shape of the Copy MAN Turbo Copy turbo – See nut, machining and the shape of the struts. HOLSET genuine turbo

>Copy MAN Turbo Copy Turbo – No washers on the screws,machining,flat on  the Copy MAN Turbo Copy Turbo – No washers on the screws,machining,flat on the wastegate rod. PS – ignore the shape of the bracket. Genuine Genuine

>Copy MAN Turbo Copy turbo – Hose clip and hole in the capsule Holset Copy MAN Turbo Copy turbo – Hose clip and hole in the capsule Holset

>Impeller Locknut Copy Genuine Impeller Locknut Copy Genuine

>Oil Seal Plate Retaining Ring Copy Genuine Difference Machined Oil Seal Plate Retaining Ring Copy Genuine Difference Machined

>Compressor Housing Retaining Ring Copy Genuine Machined Difference Compressor Housing Retaining Ring Copy Genuine Machined Difference

>Turbine Housing Screws Copy Genuine Turbine Housing Screws Copy Genuine

>Installing a Turbocharger Installing a Turbocharger

>Fitting a Replacement Turbocharger Each HOLSET turbocharger is designed to match a specific engine Fitting a Replacement Turbocharger Each HOLSET turbocharger is designed to match a specific engine specification (power, speed, charge cooling etc). The turbocharger dataplate information includes: Assy Number Serial Number Customer Number It is important that the Assy Number shown is the correct number for that engine, per the engine manufacturers specifications. DO NOT REMOVE THE DATA PLATE

>Fitting a Replacement Turbocharger It is important that the engine intake / exhaust systems Fitting a Replacement Turbocharger It is important that the engine intake / exhaust systems are checked for debris. It is recommended that the air intake filter is changed using only OEM genuine parts

>Fitting a Replacement Turbocharger Check that the oil inlet and drain flanges are clean Fitting a Replacement Turbocharger Check that the oil inlet and drain flanges are clean and free from obstruction. Replace the gaskets

>Fitting a Replacement Turbocharger Replace the oil and filter using only OEM recommended parts Fitting a Replacement Turbocharger Replace the oil and filter using only OEM recommended parts and specified oil grade & classification.

>Fitting a Replacement Turbocharger  Ensure the engine manifold mounting flange and studs are Fitting a Replacement Turbocharger Ensure the engine manifold mounting flange and studs are in good condition and are not warped or bent. Check for any cracks. Check the oil intake line is free from dirt or carbon, if in any doubt - replace the line and fittings with new ones. Mount the turbocharger on the manifold and check that the turbine inlet gaskets fits correctly.

>Fitting a Replacement Turbocharger The orientation of the bearing housing or compressor housing may Fitting a Replacement Turbocharger The orientation of the bearing housing or compressor housing may require changing, to align correctly with the air, oil and water connections. Make sure all fasteners are tightened to the specified torque when the orientation is set. Take care not to damage any ‘O’ rings when changing the orientation of the compressor housing as this could cause air leakage. See Holset Service Manual for the recommended torque settings

>Fitting a Replacement Turbocharger Connect the oil drain line  and then fill the Fitting a Replacement Turbocharger Connect the oil drain line and then fill the turbocharger oil feed hole with clean engine oil. Slowly rotate the rotor by hand.

>Fitting a Replacement Turbocharger Connect the oil inlet line and the remaining external fittings Fitting a Replacement Turbocharger Connect the oil inlet line and the remaining external fittings to the turbocharger. Pull out the fuel stop and crank over the engine using the starter motor, until normal operating engine oil pressure is developed. Check for any oil leaks from the connections.

>Fitting a Replacement Turbocharger Start the engine and idle,checking that all air,gas and oil Fitting a Replacement Turbocharger Start the engine and idle,checking that all air,gas and oil connections are tight and free from leakage. Tighten any fastenings as required. Use soapy water to help detect air and gas leaks.

>Technology Technology

>Holset VGT® Overview Holset VGT® Overview

>Turbocharger Basics – Fixed Geometry Turbochargers consist of an exhaust-gas driven turbine connected to Turbocharger Basics – Fixed Geometry Turbochargers consist of an exhaust-gas driven turbine connected to and driving a radial compressor, providing a boosted air supply to the engine. At a given engine speed, turbo speed (hence boost pressure) can be changed ONLY by changing fuel-rate. - i.e. at a fixed fuelling rate, boost pressure is also fixed. Turbine Stage Compressor Stage Bearing System

>A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the turbine – thus limiting turbo speed & boost pressure. Typically the wastegate valve is only opened at high engine speeds & loads (used to prevent turbo speed or boost pressure from exceeding safe levels). Turbocharger Basics – Wastegates

>Turbocharger Basics Turbocharger Basics

>VGT - Electronic Control Strategy   1 Wastegate Valve Open VGT - Electronic Control Strategy 1 Wastegate Valve Open

>VGT - Electronic Control Strategy   1 VGT - Electronic Control Strategy 1

>Holset VGTTM – Performance benefit Holset VGTTM – Performance benefit

>By continuously varying the turbine housing’s critical area the exhaust gas can now vary By continuously varying the turbine housing’s critical area the exhaust gas can now vary the speed of the turbo, boost pressure and exhaust manifold pressure – independent of engine speed and load. Various ways of achieving Variable Geometry (VG) Variable Geometry (VG) - Basics

>Swing Vane – non Holset Variable Geometry (VG)   Turbine wheel is surrounded Swing Vane – non Holset Variable Geometry (VG) Turbine wheel is surrounded by a ring of nozzle guide vanes. Flow area varied by changing the angle of these vanes in unison.

>Holset VGTTM  - One Piece Sliding Nozzle Holset VGTTM - One Piece Sliding Nozzle

>Holset VGTTM  - One Piece Sliding Nozzle Fewer moving parts Nozzle carried and Holset VGTTM - One Piece Sliding Nozzle Fewer moving parts Nozzle carried and moved by 2 rods Fewer potential wear sites

>VGT a VGT a

>Holset VGTTM  - One Piece Sliding Nozzle Nozzle ring fully closed  Holset VGTTM - One Piece Sliding Nozzle Nozzle ring fully closed Min. turbine volute exit area Max. exhaust manifold pressure Max. shaft speed Max. turbo boost Nozzle ring in mid position Reducing turbine volute exit area Increasing exhaust manifold pressure Increasing shaft speed Increasing turbo boost Nozzle ring fully open Max. turbine volute exit area Min. exhaust manifold pressure Min. shaft speed Min. turbo boost

>VGT System - Pneumatic Actuation VGT System - Pneumatic Actuation

>Actuator development for VGTTM 2002 Electric Type 1 1998 Pneumatic 2007 Electric Type 2 Actuator development for VGTTM 2002 Electric Type 1 1998 Pneumatic 2007 Electric Type 2

>1 2007 Type 2 SMART electric actuation 1 2007 Type 2 SMART electric actuation

>2007 Type 2 SMART electric actuation 2007 Type 2 SMART electric actuation

>VGT System - Electronic Actuation VGT System - Electronic Actuation

>No external moving parts – direct fit on bearing housing On-board microprocessor – relieves No external moving parts – direct fit on bearing housing On-board microprocessor – relieves load on engine ECU Position request from engine ECU via CAN network Sends status message back to engine ECU: Actual position v target position Internal temperature Motor effort 2007 Type 2 SMART electric actuation

>An on-board thermistor monitors temperature. Current limiting is applied if the internal temperature exceeds An on-board thermistor monitors temperature. Current limiting is applied if the internal temperature exceeds a safe limit. Motor-effort is monitored, and a de-rate applied under limiting conditions. Has integral event log: 250 error codes – retrievable through OBD connection – or via Holset hardware and software 2007 Type 2 SMART electric actuation

>Aspect Actuator “T” Cable Std USB cable  Interface Box Holset SOFTWARE  Aspect Actuator “T” Cable Std USB cable Interface Box Holset SOFTWARE Interface Box Aspect System: Interface Hardware & Software 2007 Type 2 SMART electric actuation

>2007 Type 2 SMART electric actuation Diagnosis   We can see the number 2007 Type 2 SMART electric actuation Diagnosis We can see the number of hours run and life history e.g what temperature and load – and for how long

>Variable Geometry benefits include: Modulate EGR flow-rate Reduce emissions Higher engine power density Increase Variable Geometry benefits include: Modulate EGR flow-rate Reduce emissions Higher engine power density Increase engine ‘usable’ speed range Increase low speed torque Improve transient response & ‘driveability’ Enhance engine braking Turbocharger Basics – Variable Geometry

>Any Questions?   Thank You Any Questions? Thank You