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Title:
A TURBO BEARING SYSTEM
Document Type and Number:
WIPO Patent Application WO/2019/078802
Kind Code:
A1
Abstract:
Turbo mechanism having a single-piece bearing structure with compressor side film forming holes and turbine side film forming holes, an internal groove, an axial support ring and a force support surface, which can bear axial loads along with the radial loads, comprising a single-piece bearing and a housing (10), an oil inlet channel (11) on said housing (10), an internal oil groove at the bottom of said oil inlet channel which enables lubrication of the bearing, a groove formed by a recess on the bearing which enables transfer of oil to the compressor side film forming holes and the turbine side film forming holes on the bearing, two installation recesses on the bearing which are angled at most 179.5° relative to each other and two assembly housings on the body which are angled at most 179.5° relative to each other.

Inventors:
KAYABAŞI İSKENDER (TR)
ALPAYA MERT (TR)
HAMPARYAN BURAG (TR)
ÇAKIL SEMIH (TR)
TEMİZ VEDAT (TR)
DOĞRU RIDVAN (TR)
Application Number:
PCT/TR2018/050602
Publication Date:
April 25, 2019
Filing Date:
October 17, 2018
Export Citation:
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Assignee:
BORUSAN TEKNOLOJI GELISTIRME VE ARGE A S (TR)
SUPSAN MOTOR SUPAPLARI SANAYII VE TICARET A S (TR)
International Classes:
F16C33/10; F01D25/16; F16C35/02; F16C35/067
Foreign References:
US20130309072A12013-11-21
CN104930052A2015-09-23
DE102016220460A12017-06-14
EP2706197A22014-03-12
DE102012206304A12013-10-17
US20150192066A12015-07-09
Attorney, Agent or Firm:
BİLEN SINAİ MÜLK. HİZ. DAN. MÜH. İTH. İHR. TİC. LTD. ŞTİ. (TR)
Download PDF:
Claims:
CLAIMS

The turbo mechanism having the single-piece bearing (50) structure with compressor side film forming holes (501 ) and turbine side film forming holes (502), the internal groove (503), the axial support ring (51 ) and the force support surface (52), which can bear axial loads along with the radial loads, characterized in that which said mechanism comprising a single-piece bearing (50) and a body (10), an oil inlet channel (1 1 ) on said body (10), an internal oil groove (1 1 1 ) at the bottom of said oil inlet channel (1 1 ) which enables lubrication of the bearing (50), a groove (504) formed by a recess on the bearing (50) which enables transfer of oil to the compressor side film forming holes (501 ) and the turbine side film forming holes (502) on the bearing (50), two installation recesses (512) on the bearing (50) which are angled at most 179.5° relative to each other and two assembly housings (103) on the body (10) which are angled at most 179.5° relative to each other.

Turbo mechanism according to Claim 1 which comprises a groove (504) formed by at least one recess which enables transfer of oil on the external surface of the bearing (50) and which extends at most along the external surface of said bearing (50).

Turbo mechanism according to Claim 1 which comprises a groove (504) formed by at least one recess which is shorter than the distance between the compressor side film forming holes (501 ) and the turbine side film forming holes (502) on the external surface of the bearing (50).

Turbo mechanism according to any one of Claim 1 or Claim 3 which comprises a groove (504) which facilitates formation of oil film by enabling transfer of oil received from the internal oil groove (1 1 1 ) located at the bottom part of the oil inlet channel (1 1 ) to the compressor side film forming holes (501 ) and to the turbine side film forming holes (502).

Turbo mechanism according to Claim 1 which comprises two installation recesses (512) which are angled 170° relative to each other and which enables installation of the bearing (50) to the bearing housing (101 ) of the body (10) such that the groove (504) of the bearing (50) is mounted upright.

6. Turbo mechanism according to Claim 1 which comprises two assembly housings (103) which are angled 170° relative to each other and which are suitable with the fixing screws (54) that fix the bearing (50) to the body (10).

7. Turbo mechanism having a single-piece bearing (50) structure with compressor side film forming holes (501 ) and the turbine side film forming holes (502), the internal groove (503), the axial support ring (51 ) and the force support surface (52) which can bear axial loads along with the radial loads, characterized by comprising a single-piece bearing (50) and a body (10), an oil inlet channel (1 1 ) on said body (10), an internal oil groove (1 1 1 ) at the bottom part of said oil inlet channel (1 1 ) which enables lubrication of the bearing (50), the recess which is positioned between the said bearing housing (101 ) and the bearing (50) and which extends along the bearing housing (101 ) and which enables transfer of oil to the compressor side film forming holes (501 ) and the turbine side film forming holes (502) on the bearing (50), two installation recesses (512) positioned on the bearing (50) and two assembly housings (103) positioned on the body (10).

8. Turbo mechanism according to Claim 7 which comprises a recess positioned inside the bearing housing (101 ) at the bottom side at the same level as the internal oil groove (1 1 1 ) which facilitates formation of oil film by enabling transfer of oil received from said internal oil groove (1 1 1 ) to the compressor side film forming holes (501 ) and to the turbine side film forming holes (502).

Description:
A TURBO BEARING SYSTEM TECHNICAL FIELD

The invention is related to a turbo system that enables increasing combustion efficiency and hence the motor power by delivering higher amounts of compressed air into the cylinders in internal combustion engines. Specifically, the invention is related to the turbo bearing that increases efficiency and power obtained from engines having a small cylinder volume that has lower cost, that is a single-piece component and that can bear axial loads.

PRIOR ART

Turbo systems are rotating devices that increase combustion performance by delivering efficient compressed air into the cylinders in internal combustion engines. A turbo is generally driven by a turbine and the turbine and the compressor impeller are connected to each other by a shaft. By driving the turbine, the compressor impeller draws the air, compresses it and discharges into the cylinders. So, power obtained by combustion with this denser air is increased. Thus, in internal combustion engines, higher powers can be obtained with turbochargers compared to naturally aspirated engines.

The turbines present within the turbocharge systems used today are rotated by the exhaust gas released from the internal combustion engine after combustion. In super charge systems that operate by similar methods, the compressor is driven by engine instead of the turbo turbine. The most significant advantage of the turbocharge systems is that the mechanical losses are minimal and that they can be easily applicable to engines with small cylinder volumes.

Modern turbos used in the automotive industry may reach up to 250.000 rpm rotational speed. In such cases, the importance of bearing comes into play in order to avoid damage of the turbo shaft due to extensive friction. Turbo bearing systems usually comprise of journal bearings made of bronze material and axial thrust bearings. It is of critical importance that the high-speed rotating parts operate without contacting surrounding parts.

In the current turbos, the film layer is formed by the film forming holes on the journal bearing and/or the grooves located inside the bearing and the friction inside the bearing is minimized by said film layer. Turbo bearing systems can be divided into two, which are Rotating Floating Ring Bearing (RFRB) and Semi Floating Ring Bearing (SFRB). In RFRB systems, two films are formed which are between the central body and the bearing and between the bearing and the shaft.

In SFRB systems, there is only one hydrodynamic oil film between the shaft and the bearing and single-piece bearing structure enables a better control of the rotor assembly. The external oil film formed in these systems is used for damping purposes.

The RFRB turbos that are usually implemented to small power engines in the market basically comprise two shaft bearings (journal bearings), one spacer, one axial thrust ring, and one axial thrust bearing. The SFRB turbos are generally used in engines with more power, the bearing is provided by a single-piece structure.

In PCT document No.WO2007005478, a type of turbocharge bearing and related components are described. Said bearing comprises holes on its outer side that enable oil film formation. While said holes are effective in oil film formation, they can't guarantee high turbo efficiency at high rotational speeds. In EPO document No.EP1002185, a kind of integrated bearing system is described. The bearing has a recessed structure that enables internal oil film formation. Moreover, said bearing also includes a grooved structure which enables lubrication at the axial thrust bearing part. In the context of said embodiment, it is specifically suitable for small volume engines, but not for high-speed turbos. In Turkish Patent and Trademark Foundation patent document No.TR201715924, a type of single-piece turbo bearing is described. Said turbo bearing bears the axial loads acting on the turbo bearing by internal grooves thereof and it provides ease of production and assembly by its single-piece body structure. However, in accordance with the lubrication system of the turbo, it comprises oil grooves suitable with the radial film forming holes contained within the bearing of the turbo body. Specifically, the oil channel which enables transfer of oil to the film forming holes on the turbine side is machined on the turbo body by a drill from the compressor side. Said process extends the production process performed on the turbo body and increases production cost. Thus, there exists a need for bringing a novelty for turbo bearing and body structure in said product. Consequently, all the problems mentioned above make it necessary to bring a novelty in the related field.

OBJECT OF THE INVENTION

The present invention makes it necessary to solve the abovementioned problems and bring a technical novelty in the related field.

The main object of the invention is to provide a turbo mechanism structure that is suitable for use in big and small volume internal combustion engines, that can be used at high speeds, that enables better axial load bearing by forming an oil film layer in axial direction via its bearing, that enables reduction of friction and power loss when compared to alternative types and that provides a lower production cost.

Another object of the invention is to provide a more efficient hydrodynamic bearing system by forming a better radial oil film.

Another object of the invention is to reduce production cost of the turbo system by reducing the number of steps in turbo production process. Another object of the invention is to provide support and damping to control axial and radial movement of the turbo shaft and impellers.

Another object of the invention is to reduce production cost by the single-piece structure of the turbo bearing as an alternative to turbo bearings with at least five pieces.

Another object of the invention is to provide ease of assembly and hence saving in labor by the single-piece bearing instead of complicated systems during assembly of the turbo. Another object of the invention is to increase the efficiency of the turbocharge mechanism. Another object of the invention is to extend the life of the turbo charge mechanism.

Another object of the invention is to enable axial load bearing by developing single-piece semi-floating bearing systems.

Another object of the invention is to increase the efficiency of the hydrodynamic bearing system developed as an alternative to mechanical ball bearings. BRIEF DESCRIPTION OF THE INVENTION

In order to achieve all of the above-mentioned objects that are obvious from the detailed description provided below, the present invention is related to a single-piece turbo bearing that can bear axial loads along with the radial loads. The invention is related to a turbo mechanism having a bearing structure that is a single- piece component which can bear axial loads along with radial loads and which includes compressor side film forming holes and turbine side film forming holes, internal groove, axial support ring and force support surface, characterized by comprising a single-piece bearing and body, an oil inlet channel on said body, an internal oil groove under said oil inlet channel to enable lubrication of the bearing, a groove which is formed by a recess on the bearing and which enables transfer of oil to the compressor side film forming holes and turbine side film forming holes on the bearing and two installation recesses on the bearing which are angled at most 179.5° relative to each other and two installation housings on the body which are angled at most 179.5° relative to each other. Another preferred embodiment of the invention comprises the groove formed by at least one recess that lies at most along the external surface of the said bearing to provide transfer of oil through the external surface of the bearing.

Another preferred embodiment of the invention comprises the groove formed by at least one recess on the external surface of the bearing which is shorter than the distance between the compressor side film forming holes and the turbine side film forming holes. Another preferred embodiment of the invention comprises the groove that facilitates formation of oil film by enabling transfer of oil received from the internal oil groove located under the oil inlet channel to the compressor side film forming holes and to the turbine side film forming holes.

Another preferred embodiment of the invention comprises two installation recesses angled 170° relative to each other which enable installation of the bearing into the bearing housing of the body such that the groove of the bearing is positioned upright. Another preferred embodiment of the invention comprises two installation housings angled 170° relative to each other which are suitable to the fixing screws that fix the bearing into the body.

Another preferred embodiment of the invention comprises single-piece axial support rings in connection with each other, at least one compressor side film forming hole and at least one turbine side film forming hole that enable formation of oil film thereon, the internal grooves that lies along the force support surface which connects said compressor side film forming hole and said turbine side film forming hole to the external surface of the axial support ring and the force support surface, support surface recess on the force support surface and ring surface recess on the axial support ring and lubrication holes in relation with the internal grooves on the axial support ring and the force support surface.

Another preferred embodiment of the invention comprises the single-piece bearing with the axial support ring which controls the axial movement of the rotor assembly and which enables axial load bearing. Another preferred embodiment of the invention comprises at least one internal groove, inside the bearing, parallel to the axis of said bearing, between the compressor side film forming holes and the axial support ring surface which enables formation of the axial oil film.

Another preferred embodiment of the invention comprises the internal groove that connects each compressor side film forming hole to the axial support ring surface.

Another preferred embodiment of the invention comprises at least one internal groove inside the bearing, parallel to the axis of said bearing, between the force support surfaces which forms the turbine side external surface of the bearing, which enables formation of the axial oil film. Another preferred embodiment of the invention comprises the internal groove that connects each turbine side film forming hole to the force support surface.

Another preferred embodiment of the invention comprises at least one ring surface recess on the axial support ring surface, of the oil received from the lubrication holes on the axial support ring surface. Another preferred embodiment of the invention comprises at least one support surface recess on the force support surface, of the oil received from the lubrication holes on the force support surface.

Another preferred embodiment of the invention comprises at least one ring surface recess formed by a radial recess and at least one support surface recess formed by a radial recess.

Another preferred embodiment of the invention comprises six ring surface recesses and six support surface recesses.

Another preferred embodiment of the invention comprises the single-piece bearing having axial support ring structure, made of brass material which controls axial movement of the rotor assembly and which enables axial load bearing.

Another preferred embodiment of the invention comprises the single-piece bearing made of brass material which controls axial movement of the rotor assembly and which enables axial load bearing.

Another preferred embodiment of the invention comprises the single-piece bearing made of metal material which controls axial movement of the rotor assembly and which enables axial load bearing.

Another preferred embodiment of the invention comprises the single-piece bearing made of metal alloy material which controls axial movement of the rotor assembly and which enables axial load bearing. Another preferred embodiment of the invention comprises a single-piece bearing and body, an oil inlet channel on said body, an internal oil groove under said oil inlet channel which enables lubrication of the bearing, the recess which lies along the bearing housing and positioned between the said bearing housing and the bearing external surface and which enables transfer of oil to the compressor side film forming holes and the turbine side film forming holes of the bearing and two installation recesses on the bearing and two installation housings on the body.

Another preferred embodiment of the invention comprises a recess inside the bearing housing at bottom with the same level as the internal oil groove which facilitates formation of oil film by enabling transfer of oil received from said internal oil groove to the compressor side film forming holes and the turbine side film forming holes.

The scope of the invention is stated in the claims and it cannot be limited with what is described as an example in this brief and detailed description. It is apparent that a person skilled in the art can present similar embodiments in the light of what is described above without departing from the main scheme of the invention.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 shows the cross-section perspective view of the bearing body.

Figure 2 shows the front view of the turbo bearing.

Figure 3 shows the perspective view of the turbo bearing. Figure 4A shows the exploded view of the turbo bearing before assembly and Figure 4B shows the perspective view of the turbo bearing after assembly.

Figure 5A and 5B show the perspective view of the turbo bearing.

Figure 5C and 5D show two different cross-sections of the turbo bearing.

DESCRIPTION OF REFERENCE NUMBERS IN FIGURES

10. Body

101 . Bearing housing

102. Oil pocket

103. Assembly housing inlet channel

1 . Internal oil groove

outlet channel

essor impeller

. Back plate

e impeller

. Heat shield g

. Compressor side film forming hole . Turbine side film forming hole . Internal groove

5030. Lubrication hole

. Groove

ial support ring

. Ring surface recess

. Installation recess

rce support surface

. Support surface recess drain opening

ing screw

r sleeve DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, a turbo bearing system of the invention is described by non-limiting examples in order to provide a better understanding of the subject.

The invention is specifically related to the single-piece, low-cost turbo bearing that increases the power and efficiency obtained from small cylinder engines and that can bear axial loads along with radial loads. The invention is characterized by comprising a single-piece bearing (50) and a body (10), an oil inlet channel (1 1 ) on said body (10), an internal oil groove (1 1 1 ) under said oil inlet channel (1 1 ) that enables lubrication of the bearing (50), a groove (504) formed by a recess on the bearing (50) that enables transfer of oil to the compressor side film forming holes (501 ) and to the turbine side film forming holes (502) on the bearing (50), two installation recesses (512) on the bearing (50) that are angled at most 179.5° relative to each other and two installation housings (103) on the body (10) that are angled at most 179.5° relative to each other.

Figure 1 shows a cross-section of the perspective view of the body (10). The turbine impeller (30) is connected to the rear end of the shaft (40) which passes through the bearing (50) positioned inside the body (10). The compressor impeller (20) is installed on the front end of said shaft (40). The back plate (201 ) is located between the compressor impeller (20) and the body (10).

Figures 5A and 5B shows the perspective view of the turbo bearing. The turbo bearing comprises the external groove (504), turbine side film forming holes (502) and the compressor side film forming holes (501 ). Figure 5D shows the cross-section where the internal grooves (503) of the turbo bearing can be seen. As seen in the figures, the bearing (50) is a single-piece component and preferably made of brass material.

In the turbo system of the invention, the axial support ring (51 ) in connection with said bearing (50) is positioned on the compressor impeller (20) side. The axial support ring (51 ) is manufactured integral with the bearing (50).

There is the heat shield (301 ) on the back of the turbine impeller (30) which protects the body (10) from the exhaust heat. Thus, the bearing (50) part of the turbo is protected from the overheating and the turbo can be operated at the desired performance. On the front side, the single-piece bearing (50) comprises the axial support ring (51 ), the compressor side film forming holes (501 ) and the turbine side film forming holes (502) which enables formation of oil film inside the bearing (50) and internal grooves (503) in connection with the compressor side film forming holes (501 ) and the turbine side film forming holes (502) which enable formation of axial oil film around the bearing (50). As seen in Figure 2, the finger sleeve (60) is located between the compressor impeller (20) and the axial support ring (51 ) of the bearing (50). Thus, the predetermined spacing between the axial support ring (51 ) and the compressor impeller (20) mounted on the shaft (40).

The turbo system of the invention comprises the external groove (504) that is a groove form shaped by at least one recess which lies at most all along the external part of the bearing (50). On the upper part of the body (10) of the invention, the oil outlet channel (12) is located on the bottom part of the oil inlet channel (1 1 ). The oil sent into the body (10) enables flow of oil onto the groove (504) of the bearing (50) through the internal oil groove (1 1 1 ) connected to the oil inlet channel (1 1 ). The oil enables transfer of oil to the compressor side film forming hole (501 ) and the turbine side film forming hole (502) through said groove (504). Said oil inlet channel (1 1 ), oil outlet channel (12) and the internal oil groove (1 1 1 ) are machined by boring the body (10) during production. In another preferred embodiment of the invention, in the process, the grooves are manufactured by machining or by molding the body.

The oil filled into the bearing (50) through the oil drain opening (53) of the bearing (50) is transferred to the oil outlet channel (12) over said opening. Another preferred embodiment of the invention comprises one oil drain opening (53).

As seen in Figure 4A, the body (10) comprises the bearing housing (101 ) suitable with the bearing (50) therein. By said bearing housing (101 ), the bearing (50) is fixed and lubricated inside the body. Inside the said bearing housing (101 ), outside the compressor side film forming holes (501 ) and the turbine side film forming holes (502), there are two oil pockets (102). Said oil pockets (102) are formed by recesses shaped on the inner surface of the said bearing housing (101 ) around the bearing housing (101 ). The oil flowing onto the bearing through the oil inlet channel (1 1 ) and the internal oil groove (1 1 1 ) enables formation of oil film around the bearing (50) of the compressor side film forming holes (501 ) and the turbine side film forming holes (502) that the bearing (50) has, via the oil pockets (102). As seen in Figure 4A and Figure 4B, the bearing (50) is fixed to the bearing housing (101 ) inside the body (10) by at least one and preferably two fixing screws (54) over the installation recess (512) of the axial support ring (51 ) and the assembly housing (103) of the body (10). During fixing, the bearing (50) is loose fixed. The bearing (50) is prevented from turning during operation of the turbo by said fixing screws (54). In the preferred embodiment of the invention, said installation recess (512) and the assembly housing (103) are produced at an angle that is at most 179.5° and preferably 170° relative to each other. Thus, the faulty installation of the bearing (50) is prevented and the groove (504) of said bearing (50) is located always on the topmost position.

By driving the turbine impeller (30) of the turbo, by the compressor side film forming holes (501 ) and the turbine side film forming holes (502) of the bearing (50) which supports and enables the shaft (40) to rotate, a hydrodynamic oil film is formed inside said bearing (50).

Figures 5C and 5D show the cross-section of the bearing (50). As seen in the figure, the bearing (50) comprises internal grooves (503) opening to the turbine side film forming holes (502) and the compressor side film forming holes (501 ). An axial oil film is formed around the bearing (50) by said internal grooves (503). The lubrication hole (5030) structure is positioned where the internal grooves (503) mentioned in Figure 5A are connected to the axial support ring (51 ) surface. Said lubrication hole (5030) is located on the surface for each internal groove (503). In a similar structure, there is lubrication hole (5030) on the force support surface (52) of the bearing (50) where each internal groove (503) opens to the surface.

The formed oil film provides hydrodynamic bearing and friction and power loss on the shaft (40) is minimized. Since said oil film covers the entire tangential surface, the friction on the surface is minimized and bearing is performed. Thus, the high-speed turbo bearings can be realized without any problems.

By the ring surface recesses (51 1 ) of the axial support ring (51 ) and the support surface recesses (521 ) of the force support surface (52), the axial load bearing capacity of the bearing (50) is increased. During rotation, the oil is transferred to the ring surface recesses (51 1 ) and the support surface recesses (521 ) through the oil grooves (503) that open to the axial support ring (51 ) and the force support surface (52) via the lubrication holes (5030) in connection with the compressor side film forming holes (501 ) and the turbine side film forming holes (502).

As seen in Figure 1 , the internal oil groove (1 1 1 ) that enables flow of oil between the bearings (50) and the oil inlet channel (1 1 ) on the upper part of the body (10) is located inside the body (10). The oil sent into the turbo through the oil inlet channel (1 1 ) is transferred onto the groove (504) formed by a recess of the bearing (50) via the internal groove (1 1 1 ). The oil is conveyed to the compressor side film forming holes (501 ) and the turbine side film forming holes (502) by said groove (504). The lubrication is performed reliably by the oil pockets (102) on the body (10). The oil film is formed on the internal surface of the bearing by the shaft (40) rotating inside the bearing (50). The tangentially formed oil film enables bearing of the turbo and provides support against radial forces. The transfer of oil to the axial surface is enabled by the internal grooves (503) of the bearing (50). Axial load bearing capacity is increased by the ring surface recess (51 1 ) and the support surface recess (521 ). Another preferred embodiment of the invention comprises a single-piece bearing (50) and the body (10), an oil inlet channel (1 1 ) on said body (10), an internal oil groove (1 1 1 ) on the bottom of said oil inlet channel (1 1 ) which enables lubrication of the bearing (50) and the recess that is located between the bearing (50) external surface and the said bearing housing (101 ) which extends along the bearing housing (101 ) and which enables transfer of oil to the turbine side film forming holes (502) and to the compressor side film forming holes (501 ) on the bearing (50). By the said recess inside the body (10), the oil is conveyed to the compressor side film forming holes (501 ) and the turbine side film forming holes (502) on the bearing (50) through the internal oil groove (1 1 1 ).