Research On Testing System For Turbocharger Of DF Series Diesel Locomotive

Electric locomotive plays main role in Chinese trunk railway, but diesel locomotive isstill an indispensable part in many areas and positions. Currently, the number of diesellocomotives is about10,600units. Such a large number of locomotives are essential tomaintain the order of rail transportation. Turbocharger is an important component group ofdiesel locomotive. According to the researches, locomotive’s breakdown has accounted fornearly20%owing to turbocharger’s malfunction. Therefore, a well working turbocharger isan important condition for the security of rail transportation. Turbocharger Testing System isdesigned to test and verify the performance of turbocharger.The paper introduced the principle of turbocharger test and analyzed the correct methodfor turbocharger performance parameters in special conditions. The performance curvesobtained with the test data is not accurate due to the change of Reynolds number. So a methodused to provide guidance for the application and performance analyzing of turbocharger inspecial conditions is designed. According to the requirement of test, we designed a testingsystem. Based on the testing system, circulatory system is designed, and we completed thedesign of intake and exhaust ancillary system, fuel system, lubrication system and coolingsystem.For the weaknesses in controlling of previous testing systems, the paper had the designof automatic control equipment with an Omron CJ2PLC as master device. This device canused to improve the accuracy of controlling. The PLC can receive data from sensors andinstruments in order to make control and judgment. And we retain the function of manualcontrol in case of emergency. Automatic control process contains five conditions: initialrunning test, oil seal structure test, self-cycle test, standardize point performance test and idlerunning test. This system can control the fuel motors by drives to change turbocharger speed,and has the ability of regulating turbocharger conditions by controlling self-cycle valve andexit valve of compressor. The factor, power balance between turbine and compressor, ofholding turbocharger in self-cycle state is analyzed.Test data’s processing and preservation were done by PC software. We used industrialcomputer as the carrier with the data processing and analysis KingView software platform ofBeijing YaKong company. The software can complete the data storage and computing andmap according to the results of the calculation speed curves of compressor performance suchas graph, etc. In the end, it is a summary of the whole thesis, including the advantage and thedisadvantage of thesis design method with the discussing of the future research trend.