Ensuring high performance of internal combustion engines is at the core of modern mechanical engineering. In advanced countries, turbocharging is widely used to enhance output parameters and performance. In Russia, turbocharging is also rapidly being introduced into virtually all engine sizes. Along with increased power and improved specific engine performance, problems associated with premature turbocharger failures arise. Monitoring failures and identifying their causes is a priority at the current stage of technical operation development. In this regard, it is important to ensure the structural reliability of the internal combustion engine (ICE) and its individual systems. For example, the emphasis on installing highly accelerated ICEs leads to the 100% installation of turbocharger supercharging systems. At the same time, turbocharging requires precision manufacturing, storage, operation, and maintenance. Any deviations lead to a sharp increase in failures. A group of 15 KamAZ ICE units was selected for practical use. Extensive production testing of the turbochargers was conducted until failure occurred. A failure detection table was generated and experimental data was obtained. Statistical processing of operational data revealed a normal pattern of mileage-to-failure variation (the coefficient of variation did not exceed 13%). Mileage control accuracy was 3.37%. By the 100,000 km mark, the average radial clearance of the turbocharger bearing did not exceed 40 µm. The growth trend for radial clearance of the turbocharger bearing was virtually identical for the three turbochargers monitored. The obtained results may be useful to a wide range of specialists in mechanical engineering and automotive equipment operation.
operation, research, lubrication process, engine, turbocharger supercharging, bearing, mileage, service life
1. Perspektivnye tehnologii vosstanovleniya i uprochneniya detaley / I.H. Gimaltdinov, N.R. Adigamov, A.A. Muhametshin [i dr.]. Kazan': Kazanskiy gosudarstvennyy agrarnyy universitet, 2022. 102 s. ISBN: 978-5-6044928-5-7 EDN: https://elibrary.ru/OCVABN
2. Gasanov B.G., Harchenko E.V., Shishov A.V. Modelirovanie processa dvizheniya smazki v uzlah uplotneniya turbokompressorov dvigateley vnutrennego sgoraniya // Izv. vysshih uchebnyh zavedeniy. Severo-Kavkazskiy region. Tehnicheskie nauki. 2024. № 3(223). S. 55-60. DOI:https://doi.org/10.17213/1560-3644-2024-3-55-60 EDN: https://elibrary.ru/SNFXKW
3. Yudnikov E.A. Matematicheskoe modelirovanie dizel'nogo dvigatelya, oborudovannogo turbokompressorom s reguliruemym soplovym apparatom // Izv. vysshih uchebnyh zavedeniy. Mashinostroenie. 2024. № 1(766). S. 90-100. DOI:https://doi.org/10.18698/0536-1044-2024-1-90-100 EDN: https://elibrary.ru/WDCIKC
4. Ipatov A.G., Malinin A.V., Shmykov S.N. Povyshenie effektivnosti turbokompressorov DVS modifikaciey podshipnikovyh sopryazheniy // Remont. Vosstanovlenie. Modernizaciya. 2024. № 5. S. 8-12. DOI:https://doi.org/10.31044/1684-2561-2024-0-5-8-12 EDN: https://elibrary.ru/FWVEVU
5. Hudyakov V.S., Zadorozhnaya E.A., Ivanov D.Yu. Vliyanie teplovyh processov v korpuse podshipnikov turbokompressora na effektivnost' i rabotosposobnost' tribosopryazheniy // Vestnik Yuzhno-Ural'skogo gosudarstvennogo universiteta. Seriya: Mashinostroenie. 2024. T. 24, № 3. S. 27-37. DOI:https://doi.org/10.14529/engin240303 EDN: https://elibrary.ru/ELTTXZ
6. Kulakov A.T., Karagodin V.I., Yakubovich I.A. Obespechenie resursnyh i tehniko-ekspluatacionnyh pokazateley dizeley za schet vosstanovleniya turbokompressorov // Vestnik Moskovskogo avtomobil'no-dorozhnogo gosudarstvennogo tehnicheskogo universiteta (MADI). 2024. № 2(77). S. 71-81.
7. Malinin A.V., Volkov K.G., Dorodov P.V. Teoreticheskie issledovaniya vliyaniya keramicheskogo antifrikcionnogo pokrytiya v podshipnikovyh sopryazheniyah na dinamiku rotora turbokompressora // Vestnik Izhevskoy gosudarstvennoy sel'skohozyaystvennoy akademii. 2024. № 3(79). S. 122-128. DOI:https://doi.org/10.48012/1817-5457_2024_3_122-128 EDN: https://elibrary.ru/KZKQCM
8. Galiev I.G., Kulakov A.T., Galimov A.R. Obosnovanie parametra rabotosposobnosti turbokompressora // Uchenye zapiski Krymskogo inzhenerno-pedagogicheskogo universiteta. 2021. № 2(72). S. 251-256. DOI:https://doi.org/10.34771/UZCEPU.2021.72.2.048 EDN: https://elibrary.ru/UJDNEQ
9. Burcev A.Yu. Povyshenie rabotosposobnosti turbokompressora DVS primeneniem avtonomnogo smazochno-tormoznogo ustroystva na mobil'nyh energeticheskih sredstvah, ekspluatiruyuschihsya v sel'skom hozyaystve: special'nost' 05.20.03 "Tehnologii i sredstva tehnicheskogo obsluzhivaniya v sel'skom hozyaystve": dis. … kand. tehn. nauk / Burcev Aleksandr Yur'evich. Chelyabinsk, 2017. 267 s. EDN: https://elibrary.ru/ZHHFEB
10. Ershov S.V., Gasan A.V. Kriterii ocenki inercionnosti turbokompressorov // Nauka i voennaya bezopasnost'. 2024. № 1(36). S. 22-25.
11. Diagnosis of a turbocharger using a portable Multi-channel sound meter-vibrometer / A.R. Asoyan, A.Yu. Malakhov, A.E. Kuntsevich [et al.] // Science Journal of Transportation. 2024. No. 1(17). P. 87-96. EDN: https://elibrary.ru/TZKQBW
12. Ipatov A.G., Volkov K.G., Malinin A.V. Vosstanovlenie vala rotora turbokompressora TKR-7S-6 dvigatelya vnutrennego sgoraniya // Tehnicheskiy servis mashin. 2024. T. 62, № 2. S. 97-104. DOI:https://doi.org/10.22314/2618-8287-2024-62-2-97-104 EDN: https://elibrary.ru/HKLQKU
13. Gusel'nikov A.S. Vliyanie ekspluatacionnoy skorosti na parametr potoka otkazov elementov sistemy pitaniya dvigateley avtomobiley KAMAZ-43118 // Transportnoe mashinostroenie. 2024. № 2(26). S. 40-48. DOI:https://doi.org/10.30987/2782-5957-2024-2-40-48 EDN: https://elibrary.ru/DBLBFD
14. Burcev A.Yu. Povyshenie ekspluatacionnoy nadezhnosti turbokompressorov dvigateley vnutrennego sgoraniya // Dostizheniya nauki - agropromyshlennomu proizvodstvu: LII Mezhdunar. nauch.-tehn. konf., Chelyabinsk, 24-26 yanvarya 2013 goda. Tom 3. Chelyabinsk: Chelyabinskaya gosudarstvennaya agroinzhenernaya akademiya, 2013. S. 28-34. EDN: https://elibrary.ru/UGUFTJ
15. Svechnikov A.A., Chernova V.I. Povyshenie effektivnosti smazki podshipnikovogo uzla turbokompressora // Vestnik transporta Povolzh'ya. 2024. № 6(108). S. 27-31.
16. Obosnovanie vozmozhnosti diagnostirovaniya podshipnikovogo uzla turbokompressora po rashodnym harakteristikam v srede MATLAB / I.I. Kurbakov, A.P. Inshakov, M.S. Kurbakova [i dr.] // Tehnika i oborudovanie dlya sela. 2023. № 9(315).S. 31- 35. DOI:https://doi.org/10.33267/2072-9642-2023-9-31-35 EDN: https://elibrary.ru/ZORSRC
17. Savenkov N.V., Sergeev N.V. Osobennosti primeneniya i izgotovleniya turbokompressorov avtomobil'nyh DVS // Stroitel' Donbassa. 2023. № 4(25). S. 35-39. EDN: https://elibrary.ru/HHOPMF
18. Spektral'nyy analiz gazodinamicheskih harakteristik pul'siruyuschih potokov gaza v vypusknoy sisteme porshnevogo dvigatelya / L.V. Plotnikov, Yu.M. Brodov, B.P. Zhilkin [i dr.] // Izvestiya vysshih uchebnyh zavedeniy. Problemy energetiki. 2022. T. 24, № 1. S. 114-125. DOI:https://doi.org/10.30724/1998-9903-2022-24-1-114-125 EDN: https://elibrary.ru/MRBUUE
19. Nikolaev V.S., Tischenko I.V. Matematicheskoe modelirovanie dinamiki rotora turbomashiny na lepestkovyh gazodinamicheskih podshipnikah pri vozdeystvii vibracii // Holodil'naya tehnika. 2022. № 3. S. 165-179. DOI:https://doi.org/10.17816/RF111753 EDN: https://elibrary.ru/KRWDPQ
20. Pyzhankin G.V., Dolmatov A.O. Meropriyatiya po povysheniyu koefficienta zapasa krutyaschego momenta dizelya // Vestnik Altayskogo gosudarstvennogo agrarnogo universiteta. 2022. № 8(214). S. 102-107. DOI:https://doi.org/10.53083/1996-4277-2022-214-8-102-107 EDN: https://elibrary.ru/NQDOUE
21. K voprosu vtorichnogo ispol'zovaniya eksergii vypusknyh gazov v avtotraktornyh silovyh ustanovkah / G.M. Krohta, E.N. Homchenko, N.A. Usatyh [i dr.] // Traktory i sel'hozmashiny. 2022. T. 89, № 3. S. 197-205. DOI:https://doi.org/10.17816/0321-4443-106855 EDN: https://elibrary.ru/TUACEG
22. Galiev I.G., Parlyuk E.P., Ziganshin B.G. Modernizaciya smazochnoy sistemy podshipnika turbokompressora dizel'nogo dvigatelya // Vestnik Kazanskogo gosudarstvennogo agrarnogo universiteta. 2021. T. 16, № 3(63). S. 67-71. DOI:https://doi.org/10.12737/2073-0462-2021-67-71 EDN: https://elibrary.ru/QQSGUF
23. Ipatov A.G., Ivanov A.G., Malinin A.V. Povyshenie effektivnosti raboty turbokompressora modifikaciey podshipnikovyh sopryazheniy // Vestnik Izhevskoy gosudarstvennoy sel'skohozyaystvennoy akademii. 2022. № 3(71). S. 59-63. DOI:https://doi.org/10.48012/1817-5457_2022_3_59-63 EDN: https://elibrary.ru/AEWVOL
24. Gavrilov K., Hudyakov V., Rulevskiy A. The optimization of microgeometric parameters of hydrodynamic heavy loaded tribounits of a forced internal combustion engine // Tribology in Industry. 2021. Vol. 43. No 3. P. 413-419. DOI:https://doi.org/10.24874/ti.1091.04.21.07 EDN: https://elibrary.ru/PVMMZU
25. Zadorozhnaya E., Hudyakov V., Sibiryakov S. Theoretical and experimental investigations of the rotor vibration amplitude of the turbocharger and bearings temperature // Tribology in Industry. 2017. Vol. 39, No. 4. P. 452-459. DOI:https://doi.org/10.24874/ti.2017.39.04.04 EDN: https://elibrary.ru/XXDHVB
26. Miner M.A. (1945). Cumulative damage in fatigue. Journal of Applied Mechanics, 12(3), 159-164.
27. Palmgren A. (1924). Die Lebensdauer von Kugellagern. Zeitschrift des Vereins Deutscher Ingenieure, 68(14), 339-341.
28. Manson S S. Fatigue: A complex subject - some simple approximations. Exp Mech, 1965, 5(7): 193-226. EDN: https://elibrary.ru/SKGTFM
29. Hil'be Dzh. M. (2005). Obzor SigmaPlot 9.0. The American Statistician, 59(1), 111-112. DOI:https://doi.org/10.1198/000313005X24651
30. Bertrand C.A. Graphing Wizardry // Science. 2000. Vol. 289, No. 5486. P. 1894. EDN: https://elibrary.ru/DIRUMT
31. Kalinina V.N., Solov'ev V.I. Analiz dannyh. Komp'yuternyy praktikum: ucheb. posobie. M.: Kompaniya KnoRus, 2016. 168 s. (Bakalavriat). ISBN: 978-5-406-04895-5 EDN: https://elibrary.ru/VTEYZB
32. Nasledov A.D. IBM SPSS Statistics 20 i AMOS: professional'nyy statisticheskiy analiz dannyh // SPb.: Piter, 2013. 416 s. ISBN: 978-5-496-00107-6 EDN: https://elibrary.ru/TBMLGF
33. Analiz dannyh: uchebnik / V.S. Mhitaryan, M.Yu. Arhipova, T.A. Dubrova [i dr.]. M.: YuRAYT, 2016. 503 s. (Bakalavr. Akademicheskiy kurs). ISBN: 978-5-9916-5591-0
