Description

Custom built pressure testing stand for truck turbochargers in the automotive industry. Our device enables the end users to test and flush tested turbocharges during one mounting operation. Operating range is from 0-50 bar and because of that we use multistage vertical pump KSB Movitec with precise control and frequency inverter. And for higher pressures is used an intensifier controlled by pneumatic proportional valve. Thanks to this solution this product can be used for testing wide range of pressures inside one unit, decreasing the need for space in your facility. 

Operation

1. The operator connects the pressurized object to the inlet and outlet hoses.
2. The operator scans the code with a reader and secures the work area with protective plexiglass shields.
3. On the touchscreen, the operator reviews the pre-set data, which the control system has retrieved from the database. The retrieved data will include information about the pressure test procedure (flushing frequency and duration, test pressure and holding time, allowed pressure drop, blow-off time, etc.). The operator can adjust the test parameters if needed.
4. The operator starts the entire process of flushing, pressure testing, and blow-off (drainage). Flushing is performed using a stainless steel centrifugal pump. The MOVITE pump is then controlled via a frequency converter to achieve the desired pressure up to 20 bar. For pressure tests up to 50 bar, the high-pressure pump, is activated.
5. Once the desired pressure is reached, the pressurized object (turbocharger) is closed, and the holding period begins, during which the pressure drop is measured according to preset limits (OK/NOK) using a calibrated pressure sensor.
6. The pressurized object is then depressurized, and drainage is initiated.
7. If the operator notices on the control cylinder that a significant amount of water remains in the pressurized object, they can manually initiate the blow-off using a push-button switch.
8. After the pressure test is completed, a report is generated and the file is saved on the network in a predefined location.

Construction

• fully stainless steel frame

• stainless steel tank

• stainless steel pressure media piping with corrosion inhibitor

Control method

• using a 15" touch control panel with preset pressure modes

• fully automated pressure cycle

• customized

Safety features

• Protective guarding monitored by safety sensors

Application

Automated pressure testing of turbocharger castings after the machining process.

Specifications