Turbocharger Sensor Used to Monitor Operating Parameters Based on Vibration Analysis

Large-size diesel engines used in power generators, locomotives and ships require the use of turbochargers in order to provide them with optimal operating point. These turbochargers often work under very hard conditions - high temperatures, vibrations, aggressive exhaust gases - causing component wear and demanding periodic service. The blades and bearing elements are the most sensitive parts. The operating conditions, especially overloading and excessive speed, are often responsible for the premature failure of the device. Failure to notice early signs of degradation and the approaching need for service may lead to a serious damage. Some turbocharger units use devices that monitor the environmental and operating conditions, e.g. rotational speed. However, these are complex and hence costly systems. This article presents a compact device designed to be installed on a turbocharger, equipped with a number of environmental sensors, such as pressure, humidity, temperature, and interfaces to connect further external sensors. The most important feature of the device is that it is equipped with a set of built-in accelerometers for the analysis of vibrations, and for estimating the rotational speed without the use of a dedicated rotational speed sensor. The device can be equipped with bluetooth low energy wireless connectivity and internal non-volatile memory for data collection. On-board processing power helps to compute and interpret the results. Thanks to this, it is possible to determine normal and abnormal working conditions of the turbocharger, its overloads, overheating or excessive system pressure. This data, regularly collected, is very useful for predictive maintenance.