Flow Bench for Two-Stage Turbochargers STAGE 2

The bench Stage 2 represents the evolution of flussaggio dinamico, specifically designed for the management of dual-stage turbines.

From a data and measurement perspective, the system maintains the same capabilities as standard dynamic flow.

The real difference lies in the advanced management of the turbo configuration.

Dual-stage turbo management

A dual-stage turbo consists of:

• a small turbine
• a large turbine

Both operate in a coordinated way on the vehicle through a complex actuator system.

Actuator control

The Stage 2 bench is designed to handle advanced configurations:

• up to 5 actuators

combinations of:

• pneumatic actuators (pressure and vacuum)
• electronic actuators

The system integrates:

• 3 independent pneumatic lines, configurable in pressure or vacuum
• control of dedicated electronic actuators

This architecture allows a fully modular and realistic management of the system.

Simulation of real operation

The bench allows you to faithfully replicate the three main operating phases of a two-stage turbo:

• Phase 1 – Low speed - The small turbine works mainly
• Phase 2 – Intermediate speed - Both turbines operate in symbiosis, the actuators are modulated to coordinate the system
• Phase 3 – High speed - The large turbine comes into operation mainly, complete control of all the actuators involved

This simulation makes it possible to accurately reproduce the real behavior of the system on the vehicle.

Parameters and measurements

The Stage 2 bench retains all the features of dynamic flow:

• Rotation speed (RPM) via optical sensor
• Air flow entering the turbine
• Air flow on the compressor side (outlet to intercooler)

The analysis is always performed under multiple operating conditions and compared with target values.

Oil system configuration

Unlike standard systems, dual-stage configuration requires dedicated lubrication management:

• 2 oil supply lines (inlet)
• 2 drain lines (outlet)

This ensures the correct simultaneous operation of the two turbines during the test.

Operational Advantages

Essential for dual-stage

Tuning dual-stage turbines without a dedicated bench is highly critical:

• the system is complex and sensitive to adjustments
• even small errors compromise operation

Reduction in time and risk

An incorrect adjustment leads to:

• turbo removal and reinstallation
• much longer times compared to
• standard systems

With Stage 2 you can:

• to validate the system before installation
• to reduce errors and rework
• increase the reliability of the final result

Uniqueness on the market

The Stage 2 bench represents a solution currently unique in the aftermarket.

No competitor offers a system with the same level of:

• real simulation
• actuator control
• full dual-stage management

Magnetic fastening systems

A distinctive feature of our benches is the adoption of magnetic fastening systems, designed to simplify and speed up testing operations.

Unlike traditional systems based on bolted plates, which require time for assembly and disassembly, this solution allows for a quick and efficient setup.

Operational Advantages

• Elimination of rigid fastenings with screws and bolts
• Significant reduction in preparation times
• Greater practicality in connecting test hoses
• Quick setup on both turbo inlet and outlet sides

Realistic positioning

A further distinctive element is the respect of the actual installation position of the turbo:

• orientation consistent with that on the vehicle
• simulated air and exhaust flows under realistic conditions

This approach improves test accuracy, unlike many competing systems that use non-representative configurations.