DBST-20
Large turbo core balancer, 30kg capacity, low-speed operation with leak test
Maximal weight, kg
Maximum compressor wheel diameter, mm
Advanced balancing for heavy-duty turbochargers
The balancing stand model DBST-20 is a special equipment of resonance type designed for low-speed balancing of turbocharger cartridges weighing up to 30 kg. It is multifunctional and is capable of balancing not only large cartridges but also standard size cartridges used in trucks, cars and other special vehicles, provided the appropriate accessories are available.
The equipment was developed to solve the tasks of turbocharger repair shops, but the high performance and versatility of the stand allow its use in manufacturing and research enterprises engaged in the design and manufacture of turbochargers.
With the help of the balancer you can solve such problems:
- Correction of technological imbalance occurred after assembly of the cartridge.
- Checking for oil leakage.
- Running-in of the assembled cartridge.
- Check the residual imbalance and the quality of the cartridge assembly.
- Coarse and fine oil filters prevent soot and metal chips from entering the cartridge during imbalance correction and balancing, ensuring the safety of the turbocharger parts when working with the bench;
- Safe rotation speed of the turbocharger rotor shaft allows for a quality run-in of the assembled cartridges without risks, which significantly increases the reliability of the unit after the repair;
- Creation of turbocharger operating conditions by the stand oil system allows to make sure of the absence of oil leakage from the cartridge after its assembly, taking the quality control of the assembly operation to a new level;
- Adjustment of oil temperature and pressure as well as compressed air pressure makes it possible to create ideal conditions for work with any type of turbocharger providing quality results;
- Cabinet-type protective cover ensures safe and comfortable work for the bench operator and people nearby.
Functions and features of the hardware-software complex PAK-1:
- Calculation of “permissible unbalance” and “test weight” will eliminate the need for complex mathematical calculations;
- Vector based unbalance averaging improves balancing accuracy and shortens the measurement cycle by combining multiple unbalance vectors into one;
- A balancing history allows the assessment of the correction of unbalance by viewing previous measuring results, thus making it possible to determine and correct errors quickly and to raise your qualifications as a specialist;
- Monitoring of rotor speed, unbalance magnitude and angular position in “real time” to instantly identify and eliminate external factors affecting the balance.
CHRA-Specific Post-Assembly Balancing
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Large turbocharger specialization – Specifically designed for low-speed balancing of heavy-duty truck, specialty equipment, railroad, marine, and industrial turbocharger cartridges weighing up to 30 kg. This enlarged version of the DBST-10 addresses the demanding requirements of commercial and industrial turbocharger applications where size and weight exceed standard automotive specifications.
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Extended dimensional capacity – Accommodates turbochargers up to 300 mm diameter with rotor wheel spacing ranging from 50-600 mm, covering the complete spectrum of heavy-duty turbocharger configurations. The substantial size capability ensures compatibility with large diesel engines used in trucks, marine vessels, locomotives, and industrial power generation applications.
- Low-speed final balancing specialization – Engineered specifically for post-assembly balancing of turbocharger rotor assemblies within their own housings, eliminating “technological” unbalance that occurs during cartridge assembly processes. This final balancing stage ensures optimal turbocharger performance after all components are integrated into their operational configuration.
- External element correction capability – Designed for unbalance correction using only externally accessible rotor elements including wheel nuts and turbine shaft bosses after housing assembly. This approach enables comprehensive balancing without disassembly while accommodating the limited access typical of completed turbocharger cartridges.
- 0.4 g·mm/kg ultra-precision measurement – Achieves exceptional balancing accuracy specifically calibrated for turbocharger CHRA applications where minute unbalances significantly impact performance. This precision level ensures optimal turbocharger operation and extended bearing life in demanding automotive applications.
- Reinforced torsion vibration suspension – Strengthened suspension system provides high-accuracy vibration transmission despite the increased mass and dynamic forces of heavy-duty turbochargers. The reinforced design ensures reliable measurement quality and structural integrity throughout extended service life in demanding industrial environments.
- Air-powered rotation system – Pneumatic system operating at 0.6 MPa provides clean, reliable shaft rotation without contamination concerns typical of mechanical drive systems. The air drive eliminates potential oil contamination while ensuring smooth, controlled rotation for accurate measurement.
- Cabinet-type protective enclosure – Working area enclosed by cabinet-style casing with integrated local lighting ensures operator safety during high-speed turbocharger testing. The protective enclosure contains potential component separation while providing optimal visibility for precision work.
Advanced Hydraulic Simulation System
- Oil wedge recreation technology – Integrated hydraulic system with 0.5 MPa operating pressure creates protective “oil wedge” between turbocharger components, simulating actual operating conditions during balancing. This technology enables realistic testing while protecting valuable components from contact damage during rotation.
- Triple-stage oil purification system – Hydraulic oil undergoes three levels of purification ensuring turbocharger component safety and enabling unbalance correction without cartridge removal from the machine. The comprehensive purification system maintains oil cleanliness critical for accurate simulation of operational lubrication conditions.
- 12-liter oil station with thermal control – Large-capacity oil tank reduces maintenance frequency while thermal relay and thermocouple system provides precise temperature regulation. The substantial oil volume ensures consistent hydraulic performance with viewing window for oil condition monitoring throughout extended balancing sessions.
- Oil leak detection capability – Integrated system enables post-assembly oil leak testing of turbocharger cartridges, combining balancing and quality control functions in a single operation. This dual capability streamlines turbocharger quality assurance while reducing handling and setup time.
Universal CHRA Compatibility System
- Universal cartridge connectivity – Design accommodates cartridges from all manufacturers and types through comprehensive adapter systems, ensuring maximum versatility for diverse industrial turbocharger service requirements. The universal connectivity eliminates equipment limitations when servicing mixed fleets of industrial equipment.
- Middle housing mounting system – Turbocharger installation utilizes mounting surfaces of the middle housing with working pressure and temperature oil supply to support bearings. This mounting approach simulates actual operational conditions while providing secure positioning for accurate measurement and correction procedures.
- Comprehensive adapter kit – Complete adapter set accommodates virtually all modern heavy-duty turbocharger manufacturers including specialized configurations with reduced oil supply requirements. The extensive adapter range eliminates compatibility limitations in diversified industrial service facilities.
The PAK-1 unbalance measuring unit represents the latest generation of measuring complexes for dynamic balancing, combining high precision, stability, and ease of use. It’s designed to tackle a wide range of rotor balancing tasks, from simple to the most complex, requiring precise measurements.
Based on an industrial fanless computer with a touchscreen and a multi-channel measuring unit, the system ensures reliability and a long service life, even under intensive use. The PAK-1 utilizes a universal measuring path and modern component base, allowing for equally high accuracy when working with all types of rotors.
Its intuitive interface, self-calibration capability, and automation of key operations make the complex a convenient tool for both experienced specialists and beginners.
Features of the PAK-1 System:
- High-precision dynamic balancing for rotors of any configuration.
- Industrial fanless PC with touchscreen and multi-channel measuring unit.
- Setup using trial runs with calibration weights on production rotors.
- Self-calibration by the operator, eliminating annual service adjustment costs.
- Calculation of permissible unbalance values, even without technical documentation.
- Determination of control weight mass to simplify setup for a specific rotor.
- Real-time display of unbalance magnitude and angular position, including “highlighting” of the correction zone.
- Automatic measurement start upon reaching a set speed and automatic stop after cycle completion.
- Display of unbalance magnitude in grams, gmm, gcm, gmm/kg.
- Vector and exponential averaging for working with moving elements and in noisy conditions.
- Additional functions that significantly simplify the balancing process and expand the technological capabilities of the balancing machine.
- Generation and printing of balancing reports directly from the system.
- USB ports and Ethernet interfaces for connecting a printer, data storage, and integration into a local network.
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Parameter |
Value |
|---|---|
|
Maximum turbocharger weight, kg |
30 |
|
Maximum turbocharger diameter, mm |
280 |
|
Distance between the centers of turbocharger rotor wheels, mm |
50 – 230 |
|
Maximum achievable rotor rotation frequency, rpm |
10000 |
|
Minimal achievable residual specific unbalance, gmm/kg |
0.4 |
|
Nominal operating pressure of the lubrication system, MPa |
0.5 |
|
Required pneumatic system pressure, MPa |
0.6 |
|
Power input, kW |
1.5 |
|
Power supply parameters |
230V ± 10%, 1 Ph, 50Hz ± 1 |
|
Balancing system |
PAK-1 |
|
Overall machine dimensions (length x width x height), mm |
1120 x 620 x 1290 |
|
Machine weight, kg |
250 |
|
Requirements for foundation |
The machine is mounted on a standard hard floor in workshop |
- Oil tank with oil heating for 12 l – 1 pc.
- Adapter kit for installation of all types of turbines, including turbines with a lower oil supply – 1 set.
- Operations manual of the machine with acceptance test report and a schematic circuit diagram – 1 pc.
- Operations manual of balancing system with acceptance test report – 1 pc.
The package allows you to install the entire range of turbines from modern manufacturers.
