Session: 24-03 Advances in Design & Analyses

Paper Number: 127151

127151 - Compressor Blade Vibrations of Next Generation of Turbocharger With Focus on Damping: Simplified Prediction and AI-Based Evaluation 

Recently, Accelleron launched the X300-L series, marking the begin of a new era in turbocharger technology. This innovative platform-based approach simplifies service procedures but also provides adaptability to respond to diverse demands caused by a certain variety of future fuels. The integration of enhanced power densities, standardized components, and a modular design results in a decrease in frame sizes and variants. Consequently, individual core components (i.e., compressor wheel or turbine impeller) are necessarily not only more compact and more powerful but also extend their utility across a wider range of applications.

The landscape of numerical and experimental methods that are involved during a modern development process of new turbochargers easily extents the scope of a single contribution. Accurate blade vibration analysis is a key topic and essential to identify potential performance issues, mitigate fatigue and wear, and prevent disastrous failures. To allow a more detailed insight, this paper presents a comprehensive study on compressor blade vibrations - with a particular focus on damping as one of the most important aspects with regard to high-cycle fatigue.

First, a simplified method is adopted to predict critical damping ratios of specific blade vibration resonances. This approach incorporates inputs as modal parameters (like natural frequency and mode shape) and operational conditions (fluid density and speed of sound), all of which are conveniently accessible during the preliminary design phase.

Second, a blade vibration measurement is carried out employing both Strain Gauges and Blade Tip Timing, two cutting-edge methodologies that demonstrate exceptional mutual consistency and complement each other. The dynamic stress of five chosen resonance crossings is investigated to primarily underline the robustness against high-cycle fatigue and show the agreement between strain gauge and tip timing measurements.

Third, experimental data from several resonance crossing recorded with strain gauges are feed into an AI-driven methodology utilizing Deep Learning, enabling the assessment of genuine damping ratios for these resonances. Subsequently, a comparison is presented, contrasting the new damping evaluation (AI based on strain gauge measurement) with state-of-the-art solution (SDOF-Fit of tip timing data) as well as the predicted damping ratios of the first part.

In conclusion, this paper not only highlights the exceptional performance of the compressor with respect to HCF but also underscores its accelerated development through the use of reliable data from the early design phase and the application of this AI-driven methodology. The modern measurement techniques offer a remarkable precision that allow a high trust in numerical methods. The proposed method offer practical tools for engineers in the field, facilitating the development of more reliable and efficient turbocharging systems for future applications.

Presenting Author: Robby Weber Turbo Systems Switzerland Ltd

Presenting Author Biography: 2015, Master of Science in Mechanical Engineering at BTU Cottbus in Germany
2019, PhD in Mechanical Engineering at BTU Cottbus in Germany
Numerical Simulation of Blade Vibrations of axial compressor of flight engines and radial turbines of turbocharges, both at a standstill condition
since 2020 at Turbo Systems Switzerland (formerly known as ABB Turbocharging) as R&D Principal Engineer
Extension of the previous scope with experimental blade vibration testing

Authors:

Robby Weber Turbo Systems Switzerland Ltd
Matthias Glatt Turbo Systems Switzerland Ltd