TBsonio
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Second Life. First Choice. Turbocharger overhaul – The right turn for a sustainable business With improved balancing quality and profitability in the overhaul of turbochargers

TURBOCHARGER OVERHAUL THE RIGHT TURN FOR A SUSTAINABLE BUSINESS Turbochargers in the fast lane Today there are around 230 million vehicles running on Europe's roads, about one-third of which are equipped with turbochargers. Forecasts indicate that this number will double again by the year 2020. The reasons for this rapid development of turbocharged engines are the increasingly strict fuel consumption and emission regulations. This is being counteracted by consistent downsizing of engines. So as not to compromise the performance of engines with much smaller capacity, turbochargers are being...

Commercial vehicles Almost all new vehicles with petrol or diesel engines are equipped with turbochargers. A high performance level coupled with very good efficiency is only possible with the use of turbochargers. For years now, turbocharging has provided the high level of economy and performance needed for the engines of commercial vehicles, construction and agricultural machines. Shipping Durable, reliable and economical, these are the key requirements for large engines, in which turbocharging has already been standard for many years. A market with a future. A decision with foresight....

Schenck has for many years offered balancing equipment for overhauling turbochargers, based on high-quality machines for demanding, high volume production. Two machines are used for balancing during overhaul: The TBcomfort for preliminary balancing of the turbine rotors and compressor wheels, and the TBsonio for high-speed balancing of the complete core assembly. Why is balancing so important? even achieve speeds of 300,000 rpm. At such We are repeatedly asked why balancing is so speeds, even the smallest unbalances cause pro- important when repairing turbochargers. This nounced...

sophisticated measures are required when repairing high-quality turbochargers in order to ensure smooth operation and a long service life. For this purpose, and in the first step, the individual components and the pre-assembled rotor assembly are carefully balanced at low speed on the TBcomfort. This greatly reduces the initial unbalance, and is the basis for the next step – balancing of the complete core assembly on the TBsonio. Without thorough preliminary balancing, it would almost be impossible to bring the complete core assembly back into tolerance. And what is worse: the bearings...

Low-speed balancing – the basis for a long second life The TBcomfort creates the basis for a high-quality overhaul: In the first step the initial unbalance of the components is removed and the mounted rotor assembly is secured. This creates the requirement for subsequent high-speed balancing. This process is made easy by the simple and logical operation of the TBcomfort, the ergonomic design of the complete system and its high precision. For example, the easy mounting of the rotor in the machine with 6 the convenient one-hand overslung belt drive assembly. Or the protective guard, which...

The wide weight range extends your business Turbocharger components and rotor assemblies weighing up to 16 kg can be perfectly balanced on the TBcomfort. Due to its wide weight range, it is also possible to balance turbochargers of commercial and construction vehicles or marine engines. Easy setup without calibration runs No calibration runs are required with the TBcomfort. The setup of the machine requires only the input of the rotor's geometric data on the measuring unit – the machine is now ready to start. TBcomfort – Monoblock machine – quick set-up and commissioning – Large weight...

High-speed balancing Maximum speed for highest quality Low-vibration – at the end of the overhaul process the core assembly is accelerated with compressed air on the TBsonio and is then balanced under largely realistic conditions. Only after this process does the turbocharger have such a low residual unbalance that it reaches a quality level comparable with a new turbocharger. Turbochargers are one of the most complex applications encountered in balancing. The reasons are the 8 elastic behaviour of the rotors, the high balancing speeds and the required accuracy. With its sophisticated...

Clean and safe Residual quantities of oil escaping during mounting and dismantling of the core assembly are collected in the oil basin and fed back to the central oil tank. Perfectly mounted with the core assembly adapter The different core assembly types are mounted on the machine with the aid of an adapter ring. These can be ordered easily from our Webshop for fast delivery. An ingenious solution – non-contacting indexing aid You just have to magnetise the rotor, and you are ready to start the measuring run. Our noncontacting SR70 sensor then scans the magnetically applied zero degree...

CAB measuring units – easy operation, maximum precision Both machines are equipped with our proven CAB measuring units. In the case of the TBcomfort, this is our new CAB 820. It offers peak performance due to outstanding precision and high reliability – combined with a genuinely easy and much-praised touchscreen operating concept. You will fnd everything you need for balancing on just two main screens and a third optional screen – clearly displayed and logically structured. The measuring unit CAB920SmartTouch used with the TBsonio has been developed for use in our production machines. It...

SilenceLine – outstanding noise insulation When a turbocharger is operated at operating speed, it produces a very loud, high-frequency noise, especially if it is not perfectly balanced. With our SilenceLine concept, which includes various measures for the reduction of operating noise, the noise emission of the TBsonio is less than 67dB* – allowing both machines to be operated in any workshop without additional noise protection measures. * (measured at 168,000 rpm with a master core assembly type GT15) More flexibility for your business The central machine frame is made of mineral casting....