Variable vane mechanism of a turbocharger with a predetermined blade clearance

Abstract

A method of manufacturing a variable vane mechanism includes: arranging a vane and a spacer between a first support structure and a tool member of a tool. The method further includes: bringing a first inner surface of the first support structure into abutment against a first side surface of the vane, and bringing a second side surface of the vane into abutment against an opposing surface of the tool member, such that a control surface of the spacer protrudes from the first support structure by a predetermined distance. The method further includes: fixedly attaching the spacer to the first support structure with the control surface of the spacer protruding from the first support structure by the predetermined distance. The method further includes: bringing a second support structure into abutment on the control surface of the spacer to define a gap between the first support structure and the second support structure, wherein the vane is disposed within the gap.

Description

Technical Field

[0001] The present disclosure generally relates to a variable vane mechanism for a turbocharger and, more particularly, to a variable vane mechanism for a turbocharger having a predetermined vane clearance. Background Art

[0002] Some vehicles include turbochargers, superchargers, and / or other devices for enhancing the performance of an internal combustion engine. More specifically, these devices are capable of increasing the efficiency and power output of the engine by forcing additional air into the combustion chamber of the engine.

[0003] In some cases, a turbocharger system may include a variable vane mechanism, which is often referred to as a cartridge (cartridge structure, cartridge assembly, etc.). The mechanism may be included on the turbine section of the turbocharger system. It may include one or more support structures and a plurality of vanes that move relative to the (one or more) support structures to selectively change flow parameters in the exhaust gas supply to the turbine impeller. The vanes may be moved, for example, in accordance with the operating speed of the engine.

[0004] The vanes may be supported by the support structure via fasteners, etc. A certain amount of clearance space may exist between the vanes and the (one or more) support structures to allow relative movement of the vanes. However, an excessive clearance space may allow leakage, which degrades the operating efficiency or other performance characteristics of the turbocharger.

[0005] Accordingly, it is desirable to provide such a variable vane mechanism that provides a predetermined amount of clearance space between the vanes and the support structure. In addition, it is desirable to provide an improved manufacturing method for forming such a variable vane mechanism. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, in conjunction with the accompanying drawings and this background art discussion. Summary of the Invention

[0006] In one embodiment, a method of manufacturing a variable vane mechanism is disclosed. The method includes: disposing a vane and a spacer between a first support structure and a tool member of a tool. The method further includes: abutting a first inner surface of the first support structure against a first side surface of the vane, and abutting a second side surface of the vane against an opposing surface of the tool member, such that a control surface of the spacer protrudes from the first support structure by a predetermined distance. The method further includes: fixedly attaching the spacer to the first support structure while the control surface of the spacer protrudes from the first support structure by the predetermined distance, with the first inner surface abutting the first side surface and the second side surface abutting the opposing surface. The method further includes: after fixedly attaching the spacer to the first support structure, abutting a second support structure against the control surface of the spacer to define a gap between the first support structure and the second support structure, wherein the vane is disposed within the gap.

[0007] Additionally, a variable vane mechanism for a turbocharger is disclosed. The variable vane mechanism includes: a first support structure; a second support structure; and a vane disposed within a gap defined between the first support structure and the second support structure. The vane is supported for movement within the gap. The variable vane mechanism further includes a spacer having a first portion and a second portion. The first portion is supported by the first support structure, and the second portion is supported by the second support structure to maintain a width dimension of the gap and a vane clearance dimension. The width dimension is measured from the first support structure to the second support structure. The vane clearance dimension is measured between the vane and at least one of the first support structure and the second support structure. The spacer extends partially through the first support structure.

[0008] In an additional embodiment, a method of manufacturing a variable vane mechanism is disclosed. The method includes: selecting a thickness of a shim according to a predetermined vane clearance dimension of the variable vane mechanism. The method further includes: disposing a vane and a spacer between a first support structure and a tool member of a tool. The tool member includes a base and the selected shim. Additionally, the method includes: abutting a first inner surface of the first support structure against a first side surface of the vane, abutting a second side surface of the vane against the shim, and abutting a control surface of the spacer against the base, such that the control surface of the spacer protrudes from the first support structure by a predetermined distance. Additionally, the method includes: fixedly attaching the spacer to the first support structure while the control surface of the spacer protrudes from the first support structure by the predetermined distance, with the first inner surface abutting the first side surface and the second side surface abutting the shim. Additionally, the method includes: after fixedly attaching the spacer to the first support structure, abutting a second support structure against the control surface of the spacer to define a gap between the first support structure and the second support structure, wherein the vane is disposed within the gap at the predetermined vane clearance dimension. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure will be described below with reference to the following drawings, in which like reference numerals represent like elements, and in which:

[0010] Figure 1 is a schematic view of a turbocharger system according to an exemplary embodiment of the present disclosure;

[0011] Figure 2 is Figure 1 a perspective sectional view of a turbocharger of the turbocharger system;

[0012] Figure 3 is according to an exemplary embodiment of the present disclosure Figure 2 a perspective view of a variable vane mechanism of the turbocharger;

[0013] Figure 4 is a schematic sectional view of a variable vane mechanism according to an exemplary embodiment of the present disclosure;

[0014] Figures 5 to 8 is a schematic sectional view illustrating a method of manufacturing a variable vane mechanism according to an exemplary embodiment of the present disclosure Figure 4 of;

[0015] Figure 9 is a schematic sectional view of a variable vane mechanism according to an additional exemplary embodiment of the present disclosure;

[0016] Figures 10 to 11 is a schematic sectional view illustrating a method of manufacturing a variable vane mechanism according to an additional exemplary embodiment of the present disclosure Figure 9 of; and

[0017] Figure 12 is a schematic sectional view of a variable vane mechanism and a method of manufacturing the variable vane mechanism according to an additional exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0018] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application thereof and the use of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the foregoing background art or the following detailed description.

[0019] Broadly speaking, the example embodiments disclosed herein include a turbocharger having a variable vane mechanism (cylinder, cylinder structure, cylinder assembly, etc.). The variable vane mechanism may include certain features that improve the operating performance of the turbocharger. Moreover, the features of the present disclosure may increase the manufacturability of the variable vane mechanism. As will be discussed, due to one or more features of the present disclosure, the clearance between the vane and one or more support structures can be selectively and precisely controlled in a repeatable manner. Additionally, the predetermined clearance can be relatively small, thereby limiting leakage and resulting in increased operating efficiency.

[0020] Figure 1 FIG. 4 is a schematic view of an example turbocharger system 100 that includes a turbocharger 112. The turbocharger 112 generally includes a turbocharger housing 101 and a rotor 102. The rotor 102 is configured to rotate about a rotor axis of rotation 103 within the turbocharger housing 101. The rotor 102 may be supported to rotate about the axis 103 via one or more bearings (not shown). In some embodiments, the rotor 102 may be rotatably supported by a thrust bearing and a plurality of journal bearings. Alternatively, other bearings may be included.

[0021] As shown in the illustrated embodiment, the turbocharger housing 101 may include a turbine housing 105, a compressor housing 107, and a bearing housing 109. The bearing housing 109 may be disposed between the turbine housing 105 and the compressor housing 107. Moreover, in some embodiments, the bearing housing 109 may contain the bearings of the rotor 102.

[0022] Additionally, the rotor 102 includes a turbine impeller 111, a compressor impeller 113, and a shaft 115. The turbine impeller 111 is substantially located within the turbine housing 105. The compressor impeller 113 is substantially located within the compressor housing 107. The shaft 115 extends along the axis of rotation 103 through the bearing housing 109 to connect the turbine impeller 111 to the compressor impeller 113. Thus, the turbine impeller 111 and the compressor impeller 113 rotate together about the axis 103.

[0023] The turbine housing 105 and the turbine impeller 111 cooperate to form a turbine (i.e., a turbine section, a turbine stage) that is configured to circumferentially receive a high-pressure and high-temperature exhaust gas flow 121 from an engine (e.g., from an exhaust manifold 123 of an internal combustion engine 125). The turbine impeller 111 (and thus the rotor 102) is driven by the high-pressure and high-temperature exhaust gas flow 121 to rotate about the axis 103, and the exhaust gas flow becomes a lower-pressure and lower-temperature exhaust gas flow 127 that is released into a downstream exhaust pipe 126. In other embodiments, the engine 125 may be another type, such as a diesel-fueled engine.

[0024] The compressor housing 107 and the compressor impeller 113 cooperate to form the compressor section (i.e., the compressor stage) of the turbocharger system 100. The compressor impeller 113, which is driven to rotate by a turbine impeller 111 driven by exhaust gas, is configured to compress the received input air 131 (e.g., ambient air, or pressurized air from a previous stage in a multi-stage compressor) into a pressurized air stream 133 that is ejected circumferentially from the compressor housing 107. The compressor housing 107 may have a shape (e.g., a volute shape or other shape) configured to guide and pressurize the air blown from the compressor impeller 113. Due to the compression process, the pressurized air stream 133 is characterized by an increased temperature that exceeds the temperature of the input air 131.

[0025] The pressurized air stream 133 may be directed through an air cooler 144 (i.e., an intercooler), such as a convective-cooled charge air cooler. The air cooler 144 may be configured to dissipate heat from the pressurized air stream 133, thereby increasing its density. The resulting cooled and pressurized output air stream 146 is directed into the intake manifold 148 of the internal combustion engine 125, or alternatively is directed into a subsequent stage of a series of compressors. The operation of the system 100 may be controlled by an ECU 150 (engine control unit) that is connected to the rest of the system via a communication link 152.

[0026] Now referring to Figure 2 , additional details of the turbocharger 112 according to an example embodiment will be discussed. For clarity, portions of the turbocharger housing 101 and other parts are hidden. Elements of a radial coordinate system are also shown for reference, such as the axis of rotation 103 of the rotor 102, a representative radial axis 202, and an arrow 204 indicating the circumferential direction extending around the axis 103.

[0027] As shown, the turbine housing 105 may include an inlet pipe 128 and a downstream exhaust pipe 126. The downstream exhaust pipe 126 may be substantially centered on the axis 103, and the inlet pipe 128 may be disposed substantially perpendicular to the axis 103. Additionally, the turbine housing 105 may include a volute flow structure 129 disposed between the inlet pipe 128 and the exhaust pipe 126. In some embodiments, the inlet pipe 128, the volute flow structure 129, and the downstream exhaust pipe 126 may be integrally attached as an integral unit (e.g., as a casting).

[0028] The turbine impeller 111 may be supported for rotation and housed within the volute flow structure 129 of the turbine housing 105. Additionally, a variable vane mechanism 200 (i.e., a barrel, barrel assembly, etc.) may be disposed within the volute flow structure 129. The variable vane mechanism 200 and the turbine impeller 111 may be substantially coaxial and centered about axis 103, where the variable vane mechanism 200 surrounds the outer radial edge of the turbine impeller 111.

[0029] During operation, the inlet pipe 128 may receive an exhaust gas flow 121 from the engine 125, and the exhaust gas flow 121 may be redirected to flow about axis 103 within the volute flow structure 129 and flow radially inward through the variable vane mechanism 200 to drive the turbine impeller 111. Then, the exhaust gas flow 127 may exit via the downstream exhaust pipe 126.

[0030] Figure 3 The variable vane mechanism 200 according to an exemplary embodiment of the present disclosure is shown separately. In Figure 4 The variable vane mechanism 200 is also schematically represented in a cross-section of.

[0031] Generally, the variable vane mechanism 200 may include a first support structure 212 (i.e., a nozzle ring, etc.). The first support structure 212 may be a rigid and robust member that is disc-shaped and / or annular in shape. The first support structure 212 may include an inner surface 260 and an opposite outer surface 262. The first support structure 212 may be fixed to the turbine housing 105, as Figure 2 represented. The first support structure 212 may be substantially centered about axis 103.

[0032] The variable vane mechanism 200 may further include a second support structure 206 (i.e., an insert, a tube, etc.). The second support structure 206 may be a rigid and robust member that is annular in shape. (For clarity, Figure 2 The sector of the annular second support structure 206 is hidden in). The second support structure 206 may include an inner surface 264 and an opposite outer surface 266. In some embodiments, the second support structure 206 may include an inner lip 268 that projects from the outer surface 266 and is fixed to the turbine housing 105. The second support structure 206 may be arranged such that the inner surface 264 faces the inner surface 260 of the first support structure 212. The inner surface 264 of the second support structure 206 may be substantially parallel and spaced apart from the inner surface 260 of the first support structure 212 so as to define a gap 269 therebetween.

[0033] The variable vane mechanism 200 may further include a plurality of vanes 218. The vanes 218 may be substantially similar to each other. The vanes 218 may be disposed within a gap 269 between a first support structure 212 and a second support structure 206, and circumferentially spaced apart from each other substantially equidistantly about an axis 103. Each vane 218 may have an airfoil shape and may include a first side surface 270 and a second side surface 272. The vane 218 may also have a thickness 271 ( Figure 4 ) measured from the first side surface 270 to the second side surface 272. The first side surface 270 may be opposite to an inner surface 260 of the first support structure 212. The second side surface 272 may be opposite to an inner surface 264 of the second support structure 206.

[0034] As Figure 3 and Figure 4 shown, the vane 218 may be fixed to a rod 274 that extends through a hole in the first support structure 212. Opposite ends of the rod 274 may be attached to respective arms 276 that are disposed adjacent to an outer surface 262 of the first support structure 212. In other words, the rod 274 may extend completely through the thickness of the first support structure 212 in the region illustrated in Figure 4 . As Figure 3 shown, the arm 276 may be pivotally attached to a synchronizing ring 278. The synchronizing ring 278 may be supported for rotational movement relative to the first support structure 212 about the axis 103. Such rotation may in turn cause the vane 218 to rotate about an axis 280 of the rod 274 between a first position and a second position. The plurality of vanes 218 may be operatively attached to the synchronizing ring 278 in this manner. Thus, rotation of the synchronizing ring 278 may cause the vanes 218 to move (e.g., rotate) substantially synchronously within the gap 269 relative to the first support structure 212 and the second support structure 206.

[0035] The variable vane mechanism 200 may further include an actuator 250 ( Figure 2 ). The actuator 250 may be configured to drive the synchronizing ring 278, the arm 220, and the vanes 218 to rotate relative to the first support structure 212 and the second support structure 206. In some embodiments, the actuator 250 may include an electric motor. The actuator 250 may also communicate with a processor of the ECU 150 ( Figure 1 ). Thus, the ECU 150 may generate control commands and send them to the actuator 250 to selectively move the synchronizing ring 278 and the vanes 218. For example, the processor may receive one or more inputs (e.g., signals corresponding to current engine speed, exhaust gas characteristics, etc.). The processor may determine a target position of the vanes 218 based on these inputs according to control logic, one or more algorithms, etc. Then, the processor may generate control signals that cause the actuator 250 to actuate the vanes 218 to the determined position.

[0036] During operation, the vanes 218 may be selectively rotated about their respective axes 280 to affect the exhaust gas flow 121. Thus, the vanes 218 may be moved to selectively change the pressure parameters of the gas flow when the gas flow 121 is delivered to the turbine impeller 111. The vanes 218 may be moved, for example, in accordance with the speed of the engine 125 to maintain the high efficiency of the turbocharger 112.

[0037] As Figures 2 to 4 shown, the variable vane mechanism 200 may additionally include one or more spacers 214. In some embodiments, there may be at least three spacers 214. The spacers 214 may be spaced apart substantially equidistantly about the axis 103. The spacers 214 may be substantially similar to each other. The spacers 214 may be rigid elongated members having a longitudinal axis 277. The spacers 214 may be configured as rods, columns, substantially cylindrical structures, and the like. As Figure 4 shown in the embodiment of, for example, the spacers 214 may be elongated generally cylindrical structures. The spacers 214 may have a width dimension 230 (i.e., diameter) that varies along their longitudinal length. In other embodiments, the width dimension 230 may be substantially constant along substantially the entire length of the spacers 214. The spacers 214 may be integral one-piece members made of a rigid material such as metal. The spacers 214 may include a first portion 224, a second portion 226, and an intermediate portion 228. The first portion 224 and the second portion 226 may be disposed at opposite longitudinal ends of the spacer 214, and the intermediate portion 228 may be longitudinally disposed between the first portion 224 and the second portion 226. The intermediate portion 228 may include a protrusion 232 that projects radially outward from the longitudinal axis 277 of the spacer 214. In some embodiments, the protrusion 232 may be a collar that extends continuously and annularly about the longitudinal axis 277 of the spacer 214. The protrusion 232 may include a control surface 234 that faces the second portion 226 of the spacer 214. The control surface 234 may be configured to control the spacing between the first support structure 212 and the second support structure 206, as will be discussed.

[0038] The spacer 214 can be supported on and / or by the first support structure 212 and the second support structure 206 to thereby maintain the width 222 of the gap 269 as being substantially constant. The width 222 can be measured between the inner surface 260 of the first support structure 212 and the inner surface 264 of the second support structure 206 (and perpendicular to the inner surface 260 of the first support structure 212 and the inner surface 264 of the second support structure 206). The spacer 214 can at least contact and abut the first support structure 212 and / or the second support structure 206 so as to be "supported" by the first support structure 212 and / or the second support structure 206. In some embodiments, the spacer 214 can be fixedly attached to the first support structure 212 and / or the second support structure 206 so as to be "supported" by the first support structure 212 and / or the second support structure 206. Additionally, in some embodiments, the spacer 214 can be received in the first support structure 212 and / or the second support structure 206 so as to be "supported" by the first support structure 212 and / or the second support structure 206.

[0039] As shown, for example, in the illustrated embodiment in Figure 4 the first portion 224 can be received within the first spacer orifice 240 of the first support structure 212 to be supported by the first support structure 212. The first portion 224 extends to a predetermined depth 275 of the orifice 240. The depth 275 can be measured from the edge of the orifice 240 (at the first inner surface 260) to the terminus 249 of the first portion 224 of the spacer 214.

[0040] Moreover, the first portion 224 can be fixedly attached to the first support structure 212 to thereby be supported. Figure 4 Such an attachment 236 is schematically illustrated in. For example, the attachment 236 can be a weld produced by a welding process (e.g., a laser welding process). In additional embodiments, the attachment 236 can be a friction fit attachment between the outer surface of the first portion 224 and the inner surface of the first spacer orifice 240 (i.e., an attachment that is held together primarily due to frictional forces). In some embodiments, the first portion 224 can be knurled to increase the strength of the attachment 236. The attachment 236 can be disposed along the axis 277 at any point where the first portion 224 is fixed to the first spacer orifice 240. The attachment 236 is shown midway between the edge of the first spacer orifice 240 and the terminus 249 of the spacer 214; however, the attachment 236 can be considered to be located at any position along the depth 275 (including at the edge of the orifice 240).

[0041] Additionally, in some embodiments, the second portion 226 may be fixedly attached to the second support structure 206 to be thereby supported. In some embodiments, the second portion 226 may be riveted to the second support structure 206. More specifically, as shown, the second portion 226 may be received in the second spacer aperture 242, and the second portion 226 may include an enlarged rivet head 241. Accordingly, the second portion 226 may be retained within the second spacer aperture 242, where the lower side of the rivet head 241 abuts the outer surface 266 and the control surface 234 abuts the inner surface 264. When assembled, the first portion 224 of the spacer 214 may be received within the first support structure 212, the second portion 226 may be received within the second support structure 206, and the intermediate portion 228 may extend across the gap 269 of the variable vane mechanism 200.

[0042] The spacer 214 may be configured to define the width 222 of the gap 269 of the variable vane mechanism 200. Specifically, the width 222 may be controlled according to the distance 299 between the first inner surface 260 and the abutment of the control surface 234 and the second inner surface 264. In other words, the distance 299 may be the amount by which the control surface 234 projects from the first inner surface 260. The spacer 214 may be configured to maintain (at a substantially constant dimension) the width 222 of the gap 269. For example, the spacer 214 may limit the movement of the first support structure 212 along the axis 103 toward the second support structure 206 (e.g., due to a compressive load on the vane mechanism 200, due to thermal expansion, etc.).

[0043] Furthermore, by maintaining the size of the gap 269, the spacer 214 may maintain the vane clearance dimension 229 of the vane 218, as Figure 4 shown. The vane clearance dimension 229 may be equal to the width 222 of the gap 269 minus the thickness 271 of the vane 218. In Figure 4 this, the vane 218 is shown positioned directly adjacent to the inner surface 260 of the first support structure 212 such that the vane clearance dimension 229 is only apparent between the second side surface 272 of the vane 218 and the inner surface 264 of the second support structure 206. In other words, the vane clearance dimension 229 is shown as the amount of space between the second side surface 272 and the region 291 of the inner surface 264 that is directly opposite the second side surface 272. However, it will be appreciated that the vane 218 may be spaced from the first support structure 212 such that at least a portion of the clearance dimension 229 may be defined between the first side surface 270 of the vane 218 and the inner surface 260 of the first support structure 212.

[0044] In Figure 4In an embodiment, the inner surface 260 of the first support structure 212 is substantially planar, and the inner surface 264 of the second support structure 206 is also substantially planar. Moreover, the control surface 234 is substantially coplanar with the inner surface 264. Accordingly, the distance 299 by which the control surface 234 protrudes from the first inner surface 260 controls the width 222 of the clearance 269. Accordingly, the distance 299 also controls the clearance size 229 of the variable vane mechanism 200. Similarly, the penetration depth 275 of the spacer 214 within the first support structure 212 can control the width 222 and the vane clearance size 229. As will be discussed, various manufacturing methods are disclosed herein that can be used to selectively control the depth 275 of the spacer 214 within the spacer orifice 240 and / or the distance 299 between the attachment portion 236 and the control surface 234 of the spacer 214. Thus, the vane clearance size 229 can be selectively controlled during the assembly of the variable vane mechanism 200.

[0045] It will be appreciated that the variable vane mechanism 200 can be constructed differently from the illustrated embodiment without departing from the scope of the present disclosure. As a result, the spatial relationship between the spacer 214 and the support structures 212, 206 can be different. Similarly, the spatial relationship between the spacer 214 and the vane 218 can be different from the illustrated spatial relationship. For example, without departing from the scope of the present disclosure, the control surface 234 and the inner surface 264 of the second support structure 206 can be in different planes. In these cases, the manufacturing methods of the present disclosure can be adapted accordingly to provide a predetermined depth 275 dimension and / or distance 299 dimension.

[0046] It should be noted that the spacer 214 is partially received within the first support structure 212. In other words, the first portion 224 extends partially into the first spacer orifice 240 of the first support structure 212. Accordingly, the terminus 249 of the first portion 224 is spaced from the outer surface 262 of the first support structure 212 by a distance 251. This feature provides various advantages. For example, this feature can make the variable vane mechanism 200 more compact. Moreover, as will be discussed, this feature can improve the manufacturability, manufacturing efficiency, etc. of the variable vane mechanism 200 and / or the turbocharger 112.

[0047] In contrast to the first portion 224, the second portion 226 of the spacer 214 can extend completely through the second support structure 206. The second support structure 206 can be held on one side between the annular protrusion 232 and the rivet head 241. Moreover, the terminus 282 of the second portion 226 defined on the rivet head 241 can protrude from the outer surface 266 of the second support structure 206. As will be discussed, this attachment of the second support structure 206 can provide manufacturing efficiency.

[0048] Now reference will be made toFigures 5 to 8 A method of manufacturing the variable vane mechanism 200 will be discussed. It will be appreciated that the method and / or various features of the method can be employed to manufacture Figures 2 to 4 embodiments and / or other embodiments that also manufacture the variable vane mechanism 200. In some embodiments, the manufacturing techniques of the present disclosure can improve the operating performance of a turbocharger. These manufacturing methods can increase manufacturing efficiency, accuracy, repeatability, and the like. As will be discussed, due to the manufacturing methods of the present disclosure, the vane clearance 229 can be selectively and precisely controlled in a repeatable manner. Additionally, the vane clearance 229 can be relatively small, thereby limiting leakage and resulting in increased operating efficiency.

[0049] The manufacturing method can begin as Figure 5 represented. As shown, the vane 218 can be attached to the rod 274, and the rod 274 can be inserted through the first support structure 212. In some embodiments, the arm 276 can be attached to the rod 274 at an end opposite the vane 218. As Figure 6 shown, the spacer 214 can be inserted into the spacer orifice 240. Multiple vanes 218 and spacers 214 can be similarly arranged using the first support structure 212.

[0050] These components can be disposed within a tool 300 for assembly. In some embodiments, the tool 300 can be a press or other related mechanism. The tool 300 can include a first tool member 302 (e.g., a first die) and a second tool member 304 (e.g., a second die). The first tool member 302 can include a first contact area 301. The second tool member 304 can include a second contact area 305 and a third contact area 309. The second contact area 305 can be defined on a gasket 307. The gasket 307 can be an annular member, such as a washer (i.e., a shim washer). The gasket 307 can have a substantially constant and relatively small thickness 306. In some embodiments, the gasket 307 can be supported by a planar surface of the base 308 of the second tool member 304 (removably attached to the planar surface of the base 308 of the second tool member 304). The third contact area 309 can be defined on this flat surface of the base 308, closest to the spacer orifice 311 of the base 308.

[0051] In some embodiments, the gasket 307 can be removably supported by the base 308. Thus, in some embodiments, the gasket 307 can be used with another gasket and replaced with another gasket (e.g., another gasket 307 having a different thickness 306). In additional embodiments, the gasket 307 and the base 308 can be integrally attached to be integral, and the gasket 307 can project from the base 308 at a distance equal to the thickness 306.

[0052] The first tool member 302 and the second tool member 304 may be supported for movement such that the first contact area 301 and the second contact area 305 move linearly toward each other parallel to the axes 103, 280, 277. As Figure 7 shown, the tool 300 may be operated (manually or automatically) to move the first contact area 301 into abutting contact with the outer surface 262 of the first support structure 212, to move the second contact area 305 into abutting contact with the second side surface 272 of the vane 218, and to move the third contact area 309 into abutting contact with the control surface 234 of the spacer 214. This movement may also advance the spacer 214 into the spacer orifice 240 and / or into the spacer orifice 311. A slight compressive pressure may be applied along the axis 103, as indicated by the arrow 320, to maintain the abutting contact between the inner surface 260 and the first side surface 270, between the second side surface 272 and the second contact area 305, and between the control surface 234 and the third contact area 309. It will be appreciated that the gasket 307 may be shaped to contact multiple (e.g., each) vane 218 and provide a clearance with the spacer 214 and / or other components.

[0053] The thickness 306 of the gasket 307 may be predetermined and selected such that in Figure 7 the position shown, the spacer 214 is positioned within the spacer orifice 240 at a predetermined depth 275, and the control surface 234 projects a predetermined distance 299 from the first inner surface 260. In some embodiments, due to the friction fit, the first portion 224 of the spacer 214 may be fixedly attached to the first support structure 212 at this position. In other words, due to the stroke of the tool 300, the first portion 224 is press-fitted into the orifice 240 at a predetermined depth 275. Alternatively or additionally, a welding tool 350 may be used to weld the spacer 214 to the first support member 212. In some embodiments, the welding tool 350 may be a laser welding tool. The weld attachment 236 may be provided at a predetermined location. Thus, as Figure 7 represented, the thickness 271 of the vane 218 controls the depth 275 at which the spacer 214 is attached and the distance 299 at which the control surface 234 projects from the inner surface 260.

[0054] Subsequently, as Figure 8 shown, the first support structure 212, the vane 218, and the attached spacer 214 may be removed from the tool 300. At this time, the spacer 214 is fixedly attached to the first support structure 212 at a predetermined depth 275 and / or projects at a predetermined distance 299. At this time, the second side surface 272 is spaced from the control surface 234 by a distance substantially equal to the clearance dimension 229.

[0055] Next, the second support structure 206 can be attached to the second portion 226 of the spacer 214, as Figure 4 shown. As mentioned above, the second portion 226 can be inserted into the spacer aperture 242, and then the second portion 226 can be riveted to the second support structure 206. In some embodiments, an orbital riveting tool 381 can be used for the riveting process. The tool 381 can be positioned at an angle 383 relative to the axis 277 of the spacer 214 and can be reciprocated to deform the terminal 282 and form the rivet head 241. At this time, the clearance dimension 229 can be set.

[0056] Now referring to Figure 9 , additional embodiments of the vane mechanism 400 will be discussed. Additional embodiments of the manufacturing method will be discussed in accordance with Figure 10 and Figure 11 . In addition to what is mentioned below, there can be features similar to those of Figures 4 to 8 . Components corresponding to the components of Figures 4 to 8 will be referred to with corresponding reference numerals increased by 200.

[0057] As Figure 9 shown, similar to the embodiments discussed above, the spacer 414 can include a cylindrical first portion 424 and an annular protrusion 432. The first portion 424 can be partially received within the first support structure 412. However, the second portion 426 of the spacer 414 (the portion supported on and by the second support structure 406) is different from the spacer 214 discussed above. In the illustrated embodiment, the second portion 426 is defined by a control surface 434 of the protrusion 432, and the control surface 434 is defined at the terminal 482 of the spacer 414. Similar to the above embodiments, the control surface 434 abuts the inner surface 464 of the second support structure 406; however, the second portion 426 remains outside the second support structure 406 rather than being received within the second support structure 406.

[0058] Furthermore, the second support structure 406 can be disc-shaped, having a substantially planar and continuous inner surface 464 and a substantially planar and continuous outer surface 466. As shown, the outer surface 466 can abut against the opposing surface 483 of the turbine housing 405. In some embodiments, a biasing member 481 can be disposed between the turbine housing 405 and the second support structure 406. The biasing member 481 can bias the second support structure 406 toward the control surface 434 of the spacer 414. When the vane mechanism 200 is subjected to normal operating loads, the biasing force provided by the biasing member 481 can be sufficient to maintain contact between the inner surface 464 and the control surface 434.

[0059] AsFigure 10 As shown in, the first tool member 502 can be substantially similar to the above embodiments. However, the second tool member 504 can be different. The spacer 507 can be integrally attached to the base 508 so as to be integral. The spacer 507 can project from the base 508, as Figure 10 indicated by 506 in.

[0060] As Figure 11 shown in, the tool 500 can be actuated to bring the first side surface 470 into abutting contact with the inner surface 460, bring the second side surface 472 into abutting contact with the second contact area 505, and bring the control surface 434 into abutting contact with the third side contact area 509. The spacer 414 can be fixed in place by friction, by adding welds, or by including other attachment portions 436.

[0061] Subsequently, as Figure 9 shown in, the second support structure 406 can abut against the control surface 434, thereby providing a predetermined blade clearance dimension 429. Finally, the variable vane mechanism 400 can be disposed within the turbine housing 405, where the biasing member 481 biases the second support structure 406 against the support surface 434 and maintains the clearance dimension 429 as being substantially constant.

[0062] Now referring to Figure 12 , additional embodiments of the present disclosure will be discussed. Except as mentioned below, this embodiment can be substantially similar to the Figures 9 to 11 embodiment. Components corresponding to the Figures 9 to 11 components will be identified with corresponding reference numerals increased by 200.

[0063] The spacer 614 can be substantially shaped as a straight cylinder. Moreover, the spacer 614 can have a rounded (e.g., circular) cross-section taken through the spacer axis 677. This cross-section can remain substantially constant along the axis 677. The spacer width (e.g., diameter 679) can remain substantially constant along most of its length. This is in contrast to the embodiments of the spacers 214, 414, which vary in diameter along their length due to the annular protrusions 232, 432. It will be appreciated that the Figure 12 spacer 614 can be manufactured relatively simply and inexpensively. Thus, the spacer 614 can generally reduce the manufacturing cost.

[0064] As Figure 12As shown, similar to the embodiments above, tool 700 can be used to press the first tool member 702 against the first support structure 612 and press the spacer 707 of the second tool member 704 against the blade 618. This action can thus position the spacer 614 at a predetermined depth 675 within the spacer orifice 640. One or more fixed attachments 636 can be established between the spacer 614 and the first support structure 612. The attachment 636 can be a friction fit established by pressing the first portion 624 into the orifice 640. The attachment 636 can be a weld formed by a laser welding process. The attachment 636 can be established to fix the control surface 634 at a predetermined distance 699 from the first inner surface 660.

[0065] Similar to Figure 9 the embodiments, once the spacer 614 is attached to the first support structure 612, the second support structure can be supported on the spacer 614. The second support structure can abut against the control surface 634 such that the spacer 614 maintains a predetermined clearance dimension 629. Similar to Figure 9 it, a biasing member can be included to bias the second support structure against the control surface 634.

[0066] As mentioned above, the spacer 707 can be removable and replaceable. In some embodiments of the present disclosure, at least two turbochargers can be designed: a first turbocharger and a second turbocharger. The method of the present disclosure can include: pre-determining a first blade clearance dimension for the first turbocharger and a different second blade clearance dimension for the second turbocharger. In some embodiments, a computer-generated model can be used to determine the different blade clearance dimensions. In some embodiments, a first spacer can be selected to form a blade mechanism for the first turbocharger, and a different second spacer (or a series of stacked spacers) can be selected to form a blade mechanism for the second turbocharger. The thickness of the first spacer can be determined based on the desired first blade clearance dimension of the first turbocharger. The thickness of the second spacer can be determined based on the desired second blade clearance dimension of the second turbocharger. The selected first spacer as discussed above can be used to manufacture a blade mechanism for the first turbocharger to provide the first blade clearance dimension. The selected second spacer as discussed above can be used to manufacture a blade mechanism for the second turbocharger to provide the second blade clearance dimension.

[0067] Thus, the manufacturing techniques of the present disclosure can improve the operating performance of the turbocharger. The spacers 214, 414, 614 can maintain accurate and precise blade clearance dimensions, which thereby provides high operating efficiency for the turbocharger 112. The method of the present disclosure can improve manufacturing efficiency, accuracy, repeatability, etc.

[0068] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that a vast number of variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit in any way the scope, applicability, or configuration of the present disclosure. On the contrary, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiments of the present disclosure. It should be understood that various changes may be made in the functions and arrangements of the elements described in the exemplary embodiments without departing from the scope of the present disclosure as set forth in the appended claims.

Claims

1. A method of manufacturing a variable vane mechanism, the method comprising: Arranging a vane and a spacer between a first support structure and a tool member of a tool; Bringing a first inner surface of the first support structure into abutment against a first side surface of the vane, and bringing a second side surface of the vane into abutment against an opposite surface of the tool member, such that a control surface of the spacer projects from the first support structure by a predetermined distance; With the control surface of the spacer projecting from the first support structure by the predetermined distance, fixedly attaching the spacer to the first support structure while bringing the first inner surface into abutment against the first side surface and bringing the second side surface into abutment against the opposite surface; And After fixedly attaching the spacer to the first support structure, bringing a second support structure into abutment on the control surface of the spacer to define a gap between the first support structure and the second support structure, the vane being disposed within the gap; Providing a shim to the tool member, the shim having a predetermined thickness corresponding to a predetermined vane gap dimension, the vane gap dimension being measured between the vane and at least one of the first support structure and the second support structure.

2. The method according to claim 1, wherein The spacer extends partially through the first support structure while bringing the first inner surface into abutment against the first side surface and bringing the second side surface into abutment against the opposite surface.

3. The method according to claim 2, wherein, Fixedly attaching the spacer includes frictionally fixing the spacer to the first support structure.

4. The method according to claim 2, wherein Fixedly attaching the spacer includes welding the spacer to the first support structure.

5. The method according to claim 1, the method further comprising: Fixedly attaching the spacer to the second support structure.

6. The method according to claim 5, wherein Fixedly attaching the spacer to the second support structure includes riveting the spacer to the second support structure.

7. The method according to claim 1, wherein The first support structure includes an aperture; The method further comprises: pressing the tool member towards the first support structure to set the spacer within the aperture to a predetermined depth; and Wherein fixedly attaching the spacer to the first support structure includes fixedly attaching the spacer to the first support structure within the aperture to the predetermined depth.

8. A method of manufacturing a variable vane mechanism, the method comprising: Selecting a thickness of a shim according to a predetermined vane gap dimension of the variable vane mechanism; Arranging a vane and a spacer between a first support structure and a tool member of a tool, the tool member including a base and the selected shim; Bringing a first inner surface of the first support structure into abutment against a first side surface of the vane, bringing a second side surface of the vane into abutment against the shim, and bringing a control surface of the spacer into abutment against the base, such that the control surface of the spacer projects from the first support structure by a predetermined distance; With the control surface of the spacer protruding from the first support structure by the predetermined distance, the spacer is fixedly attached to the first support structure when the first inner surface is brought into abutment against the first side surface and the second side surface is brought into abutment against the gasket; And After the spacer is fixedly attached to the first support structure, the second support structure is brought into abutment against the control surface of the spacer to define a gap between the first support structure and the second support structure, and the blade is disposed in the gap with the predetermined blade clearance dimension.

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