Selected Issues of the Internal Combustion Engine Turbocharger Operation

A combustion engine turbocharger works in most difficult conditions due to high temperatures of the fuels it is driven by, vibrations and high rotational speeds of its shaft up to 200 thousand rpm. In addition, under these conditions, there are difficulties with lubrication of the blade axes. Thus, the combustion engine turbocharger is exposed to the damages occurring during the engine operation process. The frequency of damages was determined on the basis of tests for a selected group of vehicles. The object of detailed author’s own research was the Audi 3.0 V6 TDI engine of the Audi A6 C6 car which cooperated with a Borg Warner turbocharger with a variable angle of turbine steering wheel blades. These positioners are also exposed to adverse conditions: mainly vibrations and high temperatures. They are subjected to frequent damages, which often affect the engine control parameters. An analysis of the positioner element damage as well as a group of testers to assess their technical condition was made. The evaluated testers were allowed only to determine the efficiency of the turbocharger, but without indicating its technical condition or its positioner separately. Consequently, the author’s own research methodology and the construction of a new tester for the electromechanical turbocharger adjuster was developed. The necessary tests for the vehicle mileage up to 350,000 km were carried out. The self-designed tester can also estimate the degree of electromechanical wear of the positioner in the engine supercharging system as well as the resistance of its movements resulting from the pollution of the VTG turbocharger mechanism with the turbine steering wheel positioner, with variable geometrical parameters.