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Title:
FLAP ASSEMBLY FOR A TURBINE
Document Type and Number:
WIPO Patent Application WO/2018/118896
Kind Code:
A1
Abstract:
The invention relates to a flap assembly for a turbine of an exhaust gas turbocharger comprising a sleeve on which a flap is arranged. The sleeve is configured at least partially as a hollow shaft and is designed to accommodate an axle so that the sleeve may be rotated about the axle in order to move the flap for opening and closing a valve.

Inventors:
ZAHORANSKY RADUZ (DE)
SCHOLZ GEORG (DE)
Application Number:
PCT/US2017/067278
Publication Date:
June 28, 2018
Filing Date:
December 19, 2017
Export Citation:
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Assignee:
BORGWARNER INC (US)
International Classes:
F02B37/18; F02B39/00
Domestic Patent References:
WO1998041744A11998-09-24
WO2015190362A12015-12-17
Foreign References:
DE102009007364A12010-08-05
US20070204616A12007-09-06
JP2013015103A2013-01-24
Other References:
None
Attorney, Agent or Firm:
PENDORF, Stephan A. et al. (US)
Download PDF:
Claims:
Claims

A flap assembly (10) for a turbine of an exhaust gas turbocharger comprising

a sleeve (200) on which the one flap (300) is arranged,

characterized in that the sleeve (200) is configured at least partially as a hollow shaft (210) and is designed to accommodate an axle (100) so that the sleeve (200) may be rotated about the axle (100) in order to move the flap (300) for opening and closing a valve.

The flap assembly according to Claim 1, characterized in that a lever arm (400) is additionally provided, wherein the lever arm (400) is coupled to the sleeve (200).

The flap assembly according to Claim 1 or Claim 2, characterized in that the flap assembly (10) additionally comprises a flange (500), wherein the flange (500) has a through passage (510) in which the sleeve (200) is rotatably mounted.

The flap assembly according to Claim 3, characterized in that the lever arm (400) is arranged in the area of a first end of the sleeve (200) on a first side of the flange (500), and the flap (300) is arranged on a second side of the flange (500) opposite the first side.

The flap assembly according to Claim 4, characterized in that the sleeve (200) is configured as open on a second end so that an axle (100) may be accommodated in the hollow shaft part of the sleeve (200) in this area.

The flap assembly according to any one of preceding Claims 3 through 5, characterized in that the sleeve (200) has a pin (220) in the area of the first end and thus on a closed end of the hollow shaft (210), wherein the pin (220) is mounted in the through passage (510).

7. The flap assembly according to any one of Claims 3 through 6, characterized in that biasing means (700) are provided between the lever arm (400) and the flange (500), in particular wherein the biasing means (700) comprise a disc spring.

8. A turbine for an exhaust gas turbocharger, comprising

a turbine housing (600);

a valve (800) which is suitable for guiding exhaust gas past a turbine wheel of the turbine; and

an axle (100);

characterized by a flap assembly (10) according to any one of the preceding claims.

The turbine according to Claim 8, characterized in that an axle section (110) of the axle (100) has a positive-locking, a force-locking, or a material connection to the turbine housing (600).

The turbine according to Claim 9, characterized in that the axle section (110) is delimited along the axle (100) by a collar (120), wherein the collar (120) is designed to function as a stop during mounting of the axle (100) in the turbine housing (600).

The turbine according to any one of Claims 8 through 10, characterized in that the axle (100) has, in an area that is accommodated by the sleeve (200), a first section (130) with a first diameter (Dl), a second section (140) with a second diameter (D2), and a third section (150) with a third diameter (D3), wherein the second section (140) is arranged between the first section (130) and the third section (150), in particular wherein the second diameter (D2) is smaller than the first diameter (Dl) and/or the second diameter (D2) is smaller than the third diameter (D3).

12. The turbine according to Claim 11, characterized in that the first diameter (Dl) is smaller than the third diameter (D3).

13. The turbine according to any one of Claims 10 through 12, characterized in that a flat area (614) is provided on an inwardly disposed surface (612) of a turbine wall (610) of the turbine housing (600) and interacts with the collar (120) of the axle (100) in order to determine a position of the axle (100) in the turbine housing (600).

The turbine according to any one of Claims 8 through 13, characterized in that the turbine housing (600) has a recess (630) through which the flap assembly (10) may be inserted into the turbine housing (600) and through which a part of the flap assembly (10) projects outside of the turbine housing (600) in the installed state so that the lever (400) is arranged outside of the turbine housing (600).

15. An exhaust gas turbocharger comprising a turbine according to any one of Claims 8 through 14.

Description:
FLAP ASSEMBLY FOR A TURBINE Field of the Invention

[0001] The present invention relates to a flap assembly for a turbine of an exhaust gas turbocharger, a turbine with a flap assembly of this type, and an exhaust gas turbocharger with a corresponding turbine.

Background Information

[0002] Increasingly more vehicles of the more recent generation are equipped with turbochargers. In order to achieve the target demands and the legal requirements, it is imperative to promote development in the complete drive train and also to optimize the individual components as well as the system as a whole with respect to their costs, reliability, and efficiency.

[0003] Exhaust gas turbochargers are known, for example, in which a turbine with a turbine wheel is driven by the exhaust gas flow of the internal combustion engine. A compressor wheel, which is arranged with the turbine wheel on a mutual shaft, compresses the fresh air taken in for the engine, by which means the pressure of the fresh air increases. By this means, the air or oxygen amount, available to the engine for combustion, is increased, which in turn leads to an increased output of the internal combustion engine. The pressure to be generated is thereby always a function of the exhaust gas amount to be supplied due to the coupling of the turbine wheel with the compressor wheel. In certain operating states, it is necessary to reduce or to control the drive energy acting on the compressor.

[0004] For this purpose, wastegate valves are used, among other things, which are arranged in a bypass channel. Exhaust gases may be guided through the wastegate valve and the bypass, and thus around the turbine, so that the complete exhaust gas amount no longer acts on the turbine wheel. These wastegate valves are designed mostly as flap valves which are actuated via an actuator which drives a rod assembly coupled to the valve. In known flap assemblies, the flap is coupled to a shaft which is mounted in a sleeve. The high wear, which is caused by the high number of actuations, the large forces that occur, and the high temperatures in this area, is problematic in these types of valve arrangements. In addition, the assembly of these types of valves arrangements is difficult.

[0005] The object of the present invention is accordingly to provide a flap assembly for a turbine of an exhaust gas turbocharger which may be easily installed and simultaneously has low susceptibility to wear.

Brief Summary of the Invention

[0006] The present invention relates to a flap assembly for a turbine of an exhaust gas turbocharger according to Claim 1, a turbine according to Claim 8, and an exhaust gas turbocharger according to Claim 15.

[0007] The flap assembly according to the invention has a sleeve on which a flap is arranged. The sleeve is configured at least partially as a hollow shaft and is designed to accommodate an axle so that the sleeve may be rotated about the axle in order to move the flap for opening and closing a valve. A flap assembly of this type has lower wear in comparison to know solutions. The flap assembly according to the invention offers a robust structure that is able to handle large forces that act on the flap and thus on the sleeve and the axle during operation of the turbocharger and during the actuation of the flap assembly. In addition, preassembly of the flap assembly outside of the turbine housing is possible so that the flap assembly may be used as a preassembled component and may be fixed in the turbine housing with an axle fixed therein. [0008] In configurations, a lever arm may additionally be provided, wherein the lever arm is coupled to the sleeve. A connecting piece may be provided on the lever arm to connect the lever arm to an actuator. [0009] In configurations, which are combinable with all previously described configurations, the flap assembly may additionally comprise a flange, wherein the flange has a through passage in which the sleeve is rotatably mounted. The lever arm may be arranged in the area of a first end of the sleeve on a first side of the flange, and the flap may be arranged on a second side of the flange opposite the first side. The sleeve may be configured as open on a second end so that the axle may be accommodated in this area in the hollow shaft part of the sleeve. The sleeve may have a pin in the area of the first end and thus on a closed end of the hollow shaft, wherein the pin is mounted in the through passage. At least one sealing device may be provided, in particular in the form of a sealing ring, preferably at least two sealing rings, between the sleeve and the flange.

[0010] In configurations which are combinable with all previously described configurations, biasing means may be provided between the lever arm and the flange. In particular, the biasing means may comprise a disc spring. The biasing means pull the sleeve in the direction of the flange so that the hollow shaft part of the sleeve contacts the flange. By this means, an axial position of the sleeve on the axle is determined and vibration noises due to axial movements of the sleeve may be prevented.

[0011] In embodiments which are combinable with all previously described embodiments, the flange may be designed to be fixed on the turbine housing. In particular, the flange may have at least two holes in order to be fixed on the turbine housing via screw connections.

[0012] In configurations, which are combinable with all previously described configurations, the sleeve and the flap may together form an integral component. Alternatively, the sleeve and the flap may be fixedly connected to one another in the installed state of the flap assembly so that no relative movement between the sleeve and the flap is possible. By this means, that the sleeve is mounted on the axle, an integral or fixedly connected configuration of the sleeve and flap is enabled which brings with it corresponding manufacturing and assembly advantages. [0013] The invention additionally comprises a turbine for an exhaust gas turbocharger with a turbine housing, a valve that is suited for bypassing exhaust gas past a turbine wheel of the turbine, and an axle. The turbine additionally comprises a flap assembly according to any one of the previously described embodiments.

[0014] In configurations of the turbine, which are combinable with all previously described configurations, an axle section of the axle may have a positive-locking, a force-locking, or a material connection to the turbine housing.

[0015] In configurations of the turbine, which are combinable with all previously described configurations, the axle and the sleeve may be coupled to two opposite walls of the turbine housing so that the flap is arranged between these walls. [0016] In configurations of the turbine, which are combinable with all previously described configurations, the axle may have, in an area that is accommodated by the sleeve, a first section with a first diameter D 1 , a second section with a second diameter D2, and a third section with a third diameter D3. The second section may be arranged between the first section and the third section. The second diameter D2 may be smaller than the first diameter Dl, and/or the second diameter D2 may be smaller than the third diameter D3. The first diameter Dl may be smaller than the third diameter D3. A design of this type has many advantages: the producibility of such an axle is easy at simultaneously low costs for materials and manufacturing. In addition, the assembly is facilitated, as, for example, the risk of jamming during pushing the sleeve onto the axle is reduced. Due to the different diameters along the axle, the frictional power between the sleeve and axle is additionally optimized and by this means wear is minimized.

[0017] In configurations of the turbine, which are combinable with all previously described configurations, a flat area may be provided on an inwardly disposed surface of a turbine wall of the turbine housing, said flat area interacts with the collar of the axle in order to specify a position of the axle in the turbine housing. [0018] In configurations of the turbine, which are combinable with all previously described configurations, the turbine housing may have a recess through which the flap assembly may be inserted into the turbine housing and through which a part of the flap assembly projects outside of the turbine housing in the installed state so that the lever is arranged outside of the turbine housing. The flange may close the recess.

[0019] The invention additionally comprises a turbocharger with a turbine according to any one of the previously described embodiments.

Brief Description of the Drawings shows a view of one embodiment of the flap assembly according to the invention; shows a detail view of an axle of one embodiment of the flap assembly according to the invention.

Detailed Description of the Invention

[0020] Subsequently, embodiments of the flap assembly according to the invention or the turbine according to the invention with this type of flap assembly are described with reference to the figures. All details and advantages subsequently described apply both for the flap assembly according to the invention and also for a turbine with a flap assembly according to the invention or a complete exhaust gas turbocharger with a corresponding turbine.

[0021] Figure 1 shows an embodiment of flap assembly 10 according to the invention. Flap assembly 10 is thereby depicted in Figure 1 as installed in a turbine housing 600 of a turbine. Flap assembly 10 has a sleeve 200 on which a flap 300 is arranged. Sleeve 200 and flap 300 may thereby together form an integral component. Alternatively, sleeve 200 and flap 300 may be fixedly connected to one another in the installed state of the flap assembly so that no relative movement between sleeve 200 and the flap 300 is possible. As is clear in Figure 1, sleeve 200 is configured at least partially as hollow shaft 210. Hollow shaft 210 is thereby configured in such a way that it may accommodate an axle 100 so that sleeve 200 may be rotated about axle 100. As is shown in Figure 1, flap 300 is arranged on the outer periphery of hollow shaft 210. Axle 100 and sleeve 200 are coupled in the installed state of flap assembly 10 to two opposite walls 610, 620 of turbine housing 600 so that flap 300 is arranged between these walls 610, 620. During the rotation of sleeve 200 about axle 100, flap 300 is moved for opening and closing a valve 800. This valve 800 may, for example, depict a wastegate valve and be arranged in a wall of turbine housing 600. The wastegate valve may open or close, for example, a bypass.

[0022] Flap assembly 10 according to the invention has a lower wear in comparison to known solutions for flap assemblies. In addition, flap assembly 10 according to the invention offers a robust structure that is able to handle large forces that act on flap 300 and thus on sleeve 200 and axle 100 during operation of the turbocharger and during the actuation of flap assembly 10. The configuration according to the invention of flap assembly 10 additionally facilitates preassembly of flap assembly 10 outside of turbine housing 600, so that flap assembly 10 may be used as a preassembled component in turbine housing 600 and may be fixed with axle 100 fixed therein.

[0023] Figure 1 shows that flap assembly 10 additionally has a lever arm 400. Lever arm 400 is coupled to sleeve 200. A connecting piece 410, which may function, for example, for connecting lever arm 400 to an actuator, is provided on lever arm 400. The actuator, for example, a pneumatic or hydraulic actuator, may thus actuate flap assembly 10 and ensure an opening or closing of flap 300.

[0024] Flap assembly 10 additionally comprises a flange 500. Flange 500 has a through passage 510 in which sleeve 200 is rotatably mounted. Flange 500 is designed to be fixed on turbine housing 600. In the embodiment from Figure 1, flange 500 has at least two holes for this purpose in order to be fixed on turbine housing 600 via screw connections 520, 530. In alternative embodiments, flange 500 may be fixed on turbine housing 600 via a rivet connection, via a clamping connection, or via a welded connection. [0025] As is shown in Figure 1, lever arm 400 is arranged in the area of a first end of the sleeve 200 on a first side of flange 500, and flap 300 is arranged in contrast on a second side of flange 500 opposite the first side. Figure 1 additionally shows that sleeve 200 is configured as open on its second end, so that in this area axle 100 may be inserted into the hollow shaft part of sleeve 200. A pin 220 extends, thus on a closed end of hollow shaft 210, in the area of the first end of sleeve 200. The pin is thereby mounted in through passage 510 and thus functions as a rotary joint for sleeve 200 (see Figure 1). Two sealing rings are shown between sleeve 200 and flange 500 in the embodiment in Figure 1. Alternatively, only one sealing ring or more than two sealing rings may be provided. The sealing ring(s) is/are arranged in particular around pin 220. The sealing ring(s) may be provided, for example, in the form of O-rings. [0026] An embodiment is shown in Figure 1 in which biasing means 700 are provided between lever arm 400 and flange 500. These biasing means 700 may, for example, comprise a disc spring. Biasing means 700 pull sleeve 200 in the direction of flange 500 so that the hollow shaft part of sleeve 200 contacts flange 500. By this means, an axial position of the sleeve on the axle is determined and vibration noises due to axial movements of the sleeve may be prevented. Flange 500 has a projection or collar on its inwardly disposed lateral surface, in the area where sleeve 200 contacts (see Figure 1). Due to this projection or collar, the contact surface between sleeve 200 and flange 500 is minimized. This leads to a reduction of the friction caused when flap assembly 10 is actuated and sleeve 200 rotates relative to flange 500. Alternatively, this projection or collar may also be designed on the outer wall of the closed end of hollow shaft 210.

[0027] As already mentioned at the outset, Figure 1 shows flap assembly 10 according to the invention in an installed state in a turbine housing 600 of a turbine. Axle 100 is arranged in turbine housing 600. As is clear in Figure 1, axle 100 thereby projects from an inwardly disposed surface 612 of wall 610 of turbine housing 600 into the interior of turbine housing 600. In addition, a flat area 614 is provided on inwardly disposed surface 612 of wall 610 of turbine housing 600 and interacts with collar 120 of axle 100 in order to determine a position of axle 100 in turbine housing 600 and to function as a stop during the mounting of axle 100 in turbine housing 600.

[0028] As shown in Figure 1, an axle section 110 is delimited along axle 100 by collar 120. Axle section 110 functions for mounting axle 100 in turbine housing 600 and may be connected to turbine housing 600, for example, via a positive- locking, a force-locking, or a material connection. In particular, axle 100 may be connected rotatably fixed to turbine housing 600 using one of these types of connections. For example, axle section 110 may be arranged on one end of axle 100 and connected to turbine housing 600 via a press-fit. Axle section 110 is thereby arranged in a corresponding hole in turbine housing 600 (see Figure 1). Alternatively, axle section 110 may have, for example, a thread and be screwed into a threaded hole in turbine housing 600. It is alternatively possible that axle 100 is welded to turbine housing 600. It may be provided, for example, that axle section 110 protrudes through the hole in turbine housing 600 and is welded to turbine housing 600 from the outside.

[0029] As depicted in Figure 1, turbine housing 600 has a recess 630 through which flap assembly 10 may be inserted into turbine housing 600. In the installed state of flap assembly 10 in turbine housing 600, a part of flap assembly 10 also projects outside of turbine housing 600 so that lever 400 is arranged outside of turbine housing 600. As is likewise clear in Figure 1, flange 500 closes recess 630 in the installed state of flap assembly 10. [0030] Figure 2 shows a second embodiment for axle 100 of flap assembly 10. Axle 100 from Figure 2 has, in an area that is accommodated by sleeve 200, a first section 130 with a first diameter Dl, a second section 140 with a second diameter D2, and a third section 150 with a third diameter D3. In the example from Figure 2, second section 140 is arranged between first section 130 and third section 150. In addition, second diameter D2 is smaller than first diameter Dl and third diameter D3. In addition, first diameter Dl is smaller than third diameter D3. The diameter D4 of the collar is greater than diameters Dl through D3 of first through third sections 130, 140, and 150 of axle 100. The diameter D5 of axle section 110, which is accommodated in turbine housing 600, is smaller than diameter D4 of collar 120. Diameter D5 of axle section 110 is, however, greater than diameters Dl through D3 of first through third sections 130, 140, and 150 of axle 100 in the example shown in Figure 2. Diameter D5 of axle section 110 may, however, also be smaller than diameter D3 or diameter D2 or diameter Dl in alternative configurations. A design of this type of axle 100 with different diameters has many advantages: the producibility of such an axle 100 is easy at simultaneously low costs for materials and manufacturing. In addition, the assembly is facilitated, as, for example, the risk of jamming during pushing sleeve 200 onto axle 100 is reduced. Due to the different diameters along axle 100, the frictional power between sleeve 200 and axle 100 is additionally optimized and by this means wear on flap assembly 10 is minimized.

[0031] The invention additionally comprises a turbocharger with a turbine or a flap assembly 10 according to any one of the previously described embodiments.

Although the present invention has been described and is defined in the attached claims, it should be understood that the invention may also be alternatively defined according to the following embodiments: 1. A flap assembly (10) for a turbine of an exhaust gas turbocharger comprising

a sleeve (200) on which the one flap (300) is arranged,

characterized in that the sleeve (200) is configured at least partially as a hollow shaft (210) and is designed to accommodate an axle (100) so that the sleeve (200) may be rotated about the axle (100) in order to move the flap (300) for opening and closing a valve.

2. The flap assembly according to Embodiment 1, characterized in that a lever arm (400) is additionally provided, wherein the lever arm (400) is coupled to the sleeve (200).

3. The flap assembly according to Embodiment 2, characterized in that a connecting piece (410) is provided on the lever arm (400) in order to connect the lever arm to an actuator.

4. The flap assembly according to any one of the preceding embodiments, characterized in that the flap assembly (10) additionally comprises a flange (500), wherein the flange (500) has a through passage (510) in which the sleeve (200) is rotatably mounted.

5. The flap assembly according to Embodiment 4, characterized in that the lever arm (400) is arranged in the area of a first end of the sleeve (200) on a first side of the flange (500), and the flap (300) is arranged on a second side of the flange (500) opposite the first side.

6. The flap assembly according to Embodiment 5, characterized in that the sleeve (200) is configured as open on a second end so that an axle (100) may be accommodated in the hollow shaft part of the sleeve (200) in this area. The flap assembly according to any one of preceding Embodiments 4 through 6, characterized in that at least one sealing device, in particular in the form of a sealing ring, preferably at least two sealing rings, is provided between the sleeve (200) and the flange (500).

The flap assembly according to any one of preceding Embodiments 4 through 7, characterized in that the sleeve (200) has a pin (220) in the area of the first end and thus on a closed end of the hollow shaft (210), wherein the pin (220) is mounted in the through passage (510).

The flap assembly according to any one of preceding Embodiments 4 through 8, characterized in that biasing means (700) are provided between the lever arm (400) and the flange (500), in particular wherein the biasing means (700) comprise a disc spring.

The flap assembly according to any one of preceding Embodiments 4 through 9, characterized in that the flange (500) is designed to be fixed on the turbine housing (600), in particular in that the flange (500) has at least two holes in order to be fixed on the turbine housing via screw connections (520, 530).

The flap assembly according to any one of the preceding embodiments, characterized in that the sleeve (200) and the flap (300) together form an integral component, or

the sleeve (200) and the flap (300) are fixedly connected to one another in the installed state of the flap assembly (10) so that no relative movement between the sleeve (200) and the flap (300) is possible.

A turbine for an exhaust gas turbocharger, comprising

a turbine housing (600);

a valve (800) which is suitable for guiding exhaust gas past a turbine wheel of the turbine; and

an axle (100); characterized by a flap assembly (10) according to any one of the preceding embodiments.

The turbine according to Embodiment 12, characterized in that an axle section (110) of the axle (100) has a positive-locking, a force-locking, or a material connection to the turbine housing (600).

The turbine according to Embodiment 13, characterized in that the axle section (110) is delimited along the axle (100) by a collar (120), wherein the collar (120) is designed to function as a stop during mounting of the axle (100) in the turbine housing (600).

The turbine according to any one of Embodiments 12 through 14, characterized in that the axle (100) and the sleeve (200) acre coupled to two opposite walls (610, 620) of a turbine housing (600) so that the flap (300) is arranged between these walls (610, 620).

The turbine according to any one of Embodiments 12 through 15, characterized in that the axle (100) has, in an area that is accommodated by the sleeve (200), a first section (130) with a first diameter (Dl), a second section (140) with a second diameter (D2), and a third section (150) with a third diameter (D3).

The turbine according to Embodiment 16, characterized in that the second section (140) is arranged between the first section (130) and the third section (150).

The turbine according to Embodiment 16 or Embodiment 17, characterized in that the second diameter (D2) is smaller than the first diameter (Dl) and/or the second diameter (D2) is smaller than the third diameter (D3).

The turbine according to Embodiment 18, characterized in that the first diameter (Dl) is smaller than the third diameter (D3). The turbine according to any one of Embodiments 14 through 19, characterized in that a flat area (614) is provided on an inwardly disposed surface (612) of a turbine wall (610) of the turbine housing (600) and interacts with the collar (120) of the axle (100) in order to determine a position of the axle (100) in the turbine housing (600).

The turbine according to any one of Embodiments 12 through 20, characterized in that the turbine housing (600) has a recess (630) through which the flap assembly (10) may be inserted into the turbine housing (600) and through which a part of the flap assembly (10) projects outside of the turbine housing (600) in the installed state so that the lever (400) is arranged outside of the turbine housing (600).

The turbine according to Embodiment 21, characterized in that the flange (500) closes the recess (630).

An exhaust gas turbocharger comprising a turbine according to any one of Embodiments 12 through 22.