Failure’s identification of turbochargers of internal combustion engines by means of multi-functional test stand

A turbocharger is a relatively simple, but very precisely made component working in conditions, which should be considered hard. Due to hard working conditions, among others: high exhaust temperatures, very high rotational speeds reaching up to 250 000 rpm, precise design and difficult assembly, turbochargers should be considered particularly subject to damage and failure. It is confirmed by data showing an increasing number of failures of such components, which is caused, among others, by the increasing number of vehicles equipped with turbochargers. The considerable cost of a new turbocharger and its relatively easy disassembly coupled with easy access to spare parts in Poland result in establishing of ever more new companies remanufacturing this type of device. The effectiveness of repairs carried out in such plants varies strongly, often being of poor quality due to lack of knowledge, both practical and theoretical, inadequate training of personnel, and many other factors. A common problem, faced by the companies remanufacturing turbochargers, is the lack of tools allowing to reliably checking the selected parameters relevant for subsequent use of remanufactured components. In connection to that in article have been presented identification of common failures occur in turbochargers. Moreover, conception of multi-functional diagnostic test stand have been also presented. Such method will be an extremely useful tool for verifying the effectiveness of repairs, which will be important in terms of their subsequent use (confirmation, that the repair has been performed properly), environmental protection and in case of conflict between the customer and the company (certifying, that the repair has been performed properly). No equipment or other technological solution enabling to achieve aims described above in practice is produced in Poland or abroad.