Flow Bench for Two-Stage Turbo STAGE 2X

STAGE 2X is an integrated solution that combines variable geometry flow testing and high-speed core assembly balancing in a single platform.

Designed to optimize the turbocharger remanufacturing process, it allows verification of both the correct operation of the VNT system and the dynamic behavior of the rotating assembly, reducing operating times and eliminating the need to move between different workstations.

Variable Geometry Control

STAGE 2X enables static turbocharger flow testing by verifying the correct management of airflow through the variable geometry system.

During the test, measurements are performed under three different operating conditions:

• Open geometry
• Intermediate position
• Closed geometry

The measured values are compared with the data stored in the database, allowing quick identification of anomalies or incorrect adjustments.

High-Speed Balancing

In addition to fluid-dynamic verification, the system enables high-speed balancing of the core assembly, simulating operating conditions very close to real-world use.

The bench can reach speeds of up to 250,000 RPM and uses highly sensitive sensors to detect:

• Dynamic imbalance
• Vibrations
• Rotational speed (RPM)

This phase allows correction of any imbalance that could compromise the reliability, noise level, and service life of the turbocharger.

Analyzed Parameters

Thanks to the integration of both functions, STAGE 2X allows the acquisition of:

Flow Testing Parameters

• Turbine-side airflow rate
• Variable geometry verification
• Comparison with reference values

Dynamic Parameters

• Rotational speed (RPM)
• Rotating assembly vibrations
• Dynamic imbalance correction

The combination of these data provides complete turbocharger verification before the final assembly stages.

Operational Benefits

The integration of static flow testing and high-speed balancing offers significant production advantages:

Greater Efficiency

• Reduced setup times
• Single workstation
• Less component handling
• Faster and more organized process

Greater Reliability

• Variable geometry verification
• Monitoring of the core assembly's dynamic behavior
• Reduced risk of rework
• Higher quality of the remanufactured turbocharger

Summary

STAGE 2X allows simultaneous verification and optimization of variable geometry operation and core assembly balancing, providing a compact and highly efficient solution for professional turbocharger remanufacturing.

It provides:

• Variable geometry control
• Balancing up to 250,000 RPM
• Reduced processing times
• Greater reliability of the final result