Turbocharger turbine assembly

Abstract

The invention relates to a turbocharger turbine assembly. A turbocharger may include: a center housing; a bearing disposed in the through bore of the central housing, where the through bore of the central housing defines a longitudinal axis; a shaft rotatably supported by the bearing; a compressor wheel operably coupled to the shaft; a turbine wheel operably coupled to the shaft; and a turbine housing assembly operably coupled to the central housing, where the turbine housing assembly includes: a turbine housing; and a chuck comprising a nozzle wall member and a plate member axially spaced apart by a spacer, where the nozzle wall member comprises a spacer aperture for the spacer, and where the nozzle wall member has a non-circular outer periphery defined at least in part by arcs, where adjacent arcs intersect at an intersection point, and where the nozzle wall member has a non-circular outer periphery defined at least in part by the arcs. Each intersection point is located radially outward from a respective one of the spacer apertures.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a divisional application of the patent application with application number "201910911971.4" (invention name: turbocharger turbine assembly) filed on September 25, 2019. The application is based on and claims priority to the U.S. provisional application US16 / 140668 filed on September 25, 2018, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] The subject matter disclosed herein relates generally to turbochargers for internal combustion engines. Background Art

[0003] An exhaust-driven turbocharger includes a rotating group including a turbine wheel and a compressor wheel connected to each other by a shaft. The shaft is usually rotatably supported in a center housing by one or more bearings. During operation, exhaust gas from an internal combustion engine drives the turbine wheel of the turbocharger, which in turn drives the compressor wheel to pressurize the intake air to the internal combustion engine. Summary of the invention

[0004] The present invention provides a turbocharger, which includes: a center housing; a bearing disposed in a through hole of the center housing, wherein the through hole of the center housing defines a longitudinal axis; a shaft rotatably supported by the bearing; a compressor impeller operably coupled to the shaft; a turbine impeller operably coupled to the shaft; and a turbine housing assembly operably coupled to the center housing. The turbine housing assembly includes: a turbine housing; and a chuck including a nozzle wall component and a plate component axially spaced apart by a plurality of spacers. The nozzle wall component includes a plurality of spacer holes, each of which is used to receive a corresponding one of the plurality of spacers. The nozzle wall component includes a non-circular outer periphery at least partially defined by arcs, wherein adjacent arcs intersect at intersection points, the non-circular outer periphery is formed by removing material between each pair of spacer holes in the plurality of spacer holes compared to a circular periphery nozzle wall component, and wherein adjacent arcs intersect along each of the radial lines from the center axis of the nozzle wall component to the axis of the corresponding one of the plurality of spacer holes. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The various methods, devices, assemblies, systems, arrangements, etc. described herein, and their equivalents, may be more fully understood by reference to the following detailed description when taken in conjunction with the examples illustrated in the accompanying drawings, in which: Figure 1 is a schematic diagram of a turbocharger, an internal combustion engine and a controller; Figure 2 is a cross-sectional view of an example of a turbocharger; Figure 3A and 3B is a perspective view of an example of a chuck for a turbocharger; Figure 4 for Figure 3A and 3B A cross-sectional view of a chuck; Figure 5 for Figure 2 A cross-sectional view of a portion of a turbocharger in a working state; Figure 6 for Figure 2 A cross-sectional view of a portion of a turbocharger in a working state; Figure 7 is a plan view of an example of a nozzle wall member having a circular outer periphery; Figure 8 for Figure 7 A series of perspective views of simulated deformation of a nozzle wall component relative to a spacer hole; Fig. 9 is a perspective view of an example of a nozzle wall component having a non-circular outer perimeter defined at least in part by intersecting arcs; Fig.10 for Fig. 9 A perspective view of a nozzle wall component having physical property profile values ​​obtained by finite element analysis; Fig.11 for Fig. 9 A plan view of a nozzle wall component; Fig.12 for Fig. 9 A cross-sectional view of a nozzle wall component; Fig.13 is an exploded view of an example of a turbine assembly including an example of a nozzle wall component; Fig.14A and Fig. 14B An approximate flow view around a nozzle wall component having a circular outer periphery and an approximate flow view around a nozzle wall component having a non-circular outer periphery are respectively shown; Fig.15 For example, regarding nozzle wall components (such as Fig. 9 A range of geometries for nozzle wall components; Fig.16 A series of geometric shapes for examples of nozzle wall components having non-circular outer perimeters; and Fig.17 A series of approximate views of an example of a turbine assembly having an example nozzle wall component including more than three spacers. DETAILED DESCRIPTION

[0006] Below, an example of a turbocharged engine system is described, followed by various examples of components, assemblies, methods, and the like.

[0007] Turbochargers are often used to increase the output of internal combustion engines. Figure 1 As an example, the system 100 may include an internal combustion engine 110 and a turbocharger 120. Figure 1 As shown, the system 100 may be part of a vehicle 101, wherein the system 100 is disposed in an engine compartment and connected to an exhaust duct 103 that directs exhaust gas to an exhaust outlet 109, such as an exhaust outlet located behind a passenger compartment 105. Figure 1 In the example of FIG. 1 , a processing unit 107 may be provided to process the exhaust gas (eg, to reduce emissions via catalytic conversion of molecules, etc.).

[0008] like Figure 1 As shown, internal combustion engine 110 includes an engine block 118 housing one or more combustion chambers that operably drive a shaft 112 (e.g., via pistons) as well as an intake port 114 that provides a flow path for air to the engine block 118 and an exhaust port 116 that provides a flow path for exhaust gas from the engine block 118.

[0009] The turbocharger 120 may be used to extract energy from the exhaust gas and provide energy to intake air, which may be combined with fuel to form combustion gases. Figure 1 As shown, the turbocharger 120 includes an air inlet 134, a shaft 122, a compressor housing assembly 124 for a compressor impeller 125, a turbine housing assembly 126 for a turbine impeller 127, another housing assembly 128, and an exhaust outlet 136. The housing assembly 128 may be referred to as a center housing assembly because it is disposed between the compressor housing assembly 124 and the turbine housing assembly 126.

[0010] exist Figure 1 , shaft 122 may be a shaft assembly including various components (e.g., consider a shaft and wheel assembly (SWA), etc., wherein turbine wheel 127 is welded to shaft 122). As an example, shaft 122 may be rotatably supported by a bearing system (e.g., journal bearing, rolling element bearing, etc.) disposed in housing assembly 128 (e.g., in a bore defined by one or more bore walls), such that rotation of turbine wheel 127 causes rotation of compressor wheel 125 (e.g., rotatably coupled via shaft 122). As an example, a center housing rotating assembly (CHRA) may include compressor wheel 125, turbine wheel 127, shaft 122, housing assembly 128, and various other components (e.g., a compressor side plate disposed at an axial position between compressor wheel 125 and housing assembly 128).

[0011] exist Figure 1 In the example of FIG. 1 , a variable geometry assembly 129 is shown as being partially disposed between the housing assembly 128 and the housing assembly 126. Such a variable geometry assembly may include vanes or other components to change the geometry of the passage to the turbine wheel space in the turbine housing assembly 126. As an example, a variable geometry compressor assembly may be provided.

[0012] exist Figure 1 In the example of , a wastegate valve (or simply wastegate) 135 is positioned adjacent to the exhaust inlet of the turbine housing assembly 126. The wastegate valve 135 can be controlled to allow at least some exhaust gas from the exhaust port 116 to bypass the turbine impeller 127. Various wastegates, wastegate components, etc. can be applied to conventional fixed nozzle turbines, fixed vane nozzle turbines, variable nozzle turbines, twin-scroll turbochargers, etc. As an example, the wastegate can be an internal wastegate (e.g., at least partially located inside the turbine housing). As an example, the wastegate can be an external wastegate (e.g., operably coupled to a conduit in fluid communication with the turbine housing).

[0013] exist Figure 1 Also shown in the example of FIG. 1 is an exhaust gas recirculation (EGR) conduit 115 , which may optionally have one or more valves 117 , for example, to allow exhaust gas to flow to a location upstream of the compressor impeller 125 .

[0014] Figure 1 Also shown are an exemplary arrangement 150 for flowing exhaust gas to an exhaust turbine housing assembly 152 and another exemplary arrangement 170 for flowing exhaust gas to an exhaust turbine housing assembly 172. In arrangement 150, cylinder head 154 includes passages 156 therein to direct exhaust gas from the cylinders to turbine housing assembly 152, while in arrangement 170, manifold 176 provides for mounting of turbine housing assembly 172, e.g., without any intermediate length of separate exhaust conduit. In exemplary arrangements 150 and 170, turbine housing assemblies 152 and 172 may be configured for use with wastegates, variable geometry assemblies, and the like.

[0015] exist Figure 1, an example of a controller 190 is shown as including one or more processors 192, a memory 194, and one or more interfaces 196. Such a controller may include circuits such as circuits of an engine control unit (ECU). As described herein, various methods or techniques may be optionally implemented in conjunction with a controller, for example, by control logic. The control logic may depend on one or more engine operating conditions (e.g., turbine speed, engine speed, temperature, load, lubricant, cooling, etc.). For example, a sensor may send information to the controller 190 via one or more interfaces 196. The control logic may rely on such information, and the controller 190 may output a control signal to control the engine operation. The controller 190 may be configured to control lubricant flow, temperature, a variable geometry component (e.g., a variable geometry compressor or turbine), a wastegate (e.g., via an actuator), an electric motor, or one or more other components associated with the engine, one (or more) turbochargers, etc. As an example, the turbocharger 120 may include one or more actuators and / or one or more sensors 198, which may be connected to one or more interfaces 196 of the controller 190, for example. As an example, the wastegate 135 may be controlled by a controller that includes an actuator responsive to an electrical signal, a pressure signal, etc. As an example, the actuator for the wastegate may be a mechanical actuator that may operate without requiring electrical power (e.g., consider a mechanical actuator configured to respond to a pressure signal supplied via a conduit).

[0016] Figure 2 An example of a turbocharger assembly 200 is shown, which includes a shaft 220 supported by a bearing 230 (e.g., a journal bearing, a bearing assembly such as a rolling element bearing with an outer race, etc.), which is disposed in a bore (e.g., a through bore defined by one or more bore walls) of a housing 280 between a compressor assembly 240 defining a compressor side (left) and a turbine assembly 260 defining a turbine side (right). The compressor assembly 240 includes a compressor housing 242 that defines a volute 246 and houses a compressor impeller 244. As shown in FIG. Figure 2 As shown, turbine assembly 260 includes a turbine housing 262 defining a volute 266 and housing a turbine wheel 264. Turbine wheel 264 may be, for example, welded or otherwise attached to shaft 220 to form a shaft and wheel assembly (SWA), wherein the free end of shaft 220 allows for attachment of compressor wheel 244.

[0017] As an example, an impeller, whether a turbine impeller or a compressor impeller, may include an inducer portion and an extractor portion, for example, characterized in part by an inducer radius (ri) and an extractor radius (re). As an example, a single blade may include an inducer edge (e.g., a leading edge) and an extractor edge (e.g., a trailing edge). The impeller may be defined in part by a trim value that characterizes the relationship between the inducer portion and the extractor portion.

[0018] For a compressor impeller, the inducer portion may be characterized by a "small" diameter, while for a turbine impeller, the inducer portion may be characterized by a "large" diameter. During operation, inlet flow to the compressor impeller or turbine impeller occurs relative to its inducer portion, and outlet flow from the compressor impeller or turbine impeller occurs relative to its extractor portion.

[0019] With respect to air flow, during operation of turbocharger 200, as compressor wheel 244 rotates, air may be directed from compressor wheel 244 to volute 246 via a diffuser portion defined in part by compressor housing 242 and compressor side plate 270, and drawn into passage 248 via inlet 249, both of which may be defined by compressor housing 242. Figure 2 As shown, during operation of turbocharger 200, compressor wheel 244 is used to boost air pressure so that the air pressure in volute 246 (Pcv) is greater than the air pressure in passage 248 (Pco). The rotation of compressor wheel 244 can generate a negative pressure that is used to "draw" air into compressor assembly 240 and direct such air to volute 246 via the diffuser portion. As an example, where exhaust gas recirculation (EGR) is implemented, ambient air can be mixed with the exhaust gas (e.g., upstream and / or downstream of compressor wheel 244).

[0020] exist Figure 2 In the example of , the axial locating pin 285 is received in an opening of the bearing 230, which can be a transverse hole of the bearing 230. As an example, one or more other types of axial locating mechanisms can be included in the turbocharger, which are used to limit the axial movement of the bearing (for example, and / or movement in one or more other directions). As an example, the locating pin can allow radial movement of the bearing, which can allow effective operation of one or more lubricant films disposed around the surface of the bearing.

[0021] exist Figure 2 In the example of , the shaft 220 includes a step (eg, a shoulder) that forms an axial annular surface. Figure 2In an example of this embodiment, the thrust ring 275 (e.g., of the collar type) includes a surface that seats against an axial annular surface of the shaft 220. In such an example, the locking nut 221 may include threads that match the threads of the end of the shaft 220, so that tightening of the locking nut 221 relative to the shaft 220 loads the compressor impeller 244 and the thrust ring 275 against the annular surface of the shaft 220, which can place the shaft 220 (e.g., from the step to its end) in a tensioned state. In such an example, the shaft 220, the compressor impeller 244, and the locking nut 221 can rotate as a unit (e.g., in response to exhaust gas driving the turbine impeller 264). Figure 2 As shown in the example of , the compressor side plate 270 may include a hole (e.g., an opening) in which at least a portion of the thrust ring 275 is positioned. The thrust ring 275 (and / or the compressor side plate 270) may include one or more grooves that may seat one or more sealing elements (e.g., O-rings, piston rings, etc.).

[0022] exist Figure 2 In the example of the invention, the turbine assembly 260 includes a variable geometry assembly 250, which may be referred to as a "chuck" (e.g., chuck 250), which may be positioned using a plate member 251, which may be referred to as a flange of the chuck 250 (e.g., optionally shaped as a stepped annular disk or annular plate), the plate member 251 of the chuck 250 is clamped between the housing 280 and the turbine housing 262 using bolts 293-1 to 293-N and a heat shield 290 (e.g., optionally shaped as a stepped annular disk), the heat shield 290 is disposed between the chuck 250 and the housing 280, and may be resilient in that it may apply a biasing force. Figure 2 As shown in the example of , the chuck 250 includes a nozzle wall component 300 and a plate component 251. As an example, one or more mounting members or spacers 254 may be provided between the nozzle wall component 300 and the plate component 251 (e.g., or an annular plate component), for example, to axially space the nozzle wall component 300 and the plate component 251 (e.g., to form a nozzle space).

[0023] As an example, the vane 255 can be positioned between the nozzle wall member 300 and the plate member 251, for example, wherein a control mechanism can cause pivoting of the vane 255. As an example, the vane 255 can include a vane post 253 that extends axially to be operably coupled to the control mechanism, for example, for pivoting the vane 255 about a pivot axis defined by the vane post 253.

[0024] With respect to exhaust gas flow, during operation of the turbocharger 200, the higher pressure exhaust gas in the volute 266 passes through passages (e.g., one or more nozzles, one or more throats, etc.) of the cartridge 250 to reach the turbine wheel 264 disposed in a turbine wheel space at least partially defined by the cartridge 250 and at least partially defined by the turbine housing 262. After passing through the turbine wheel space, the exhaust gas travels axially outward along a passage 268 defined by the walls of the turbine housing 262, which also defines an opening 269 (e.g., an exhaust gas outlet). As noted, during operation of the turbocharger 200, the exhaust gas pressure (Ptv) in the volute 266 is greater than the exhaust gas pressure (Pto) in the passage 268.

[0025] As an example, exhaust pressure in turbine assembly 260 may depend on the position or location of vanes 255. For example, closing and / or opening (eg, narrowing or widening the throat) of vanes 255 may create exhaust pressure at one or more locations.

[0026] Although Figure 2 A general direction of gravity (G, Earth's gravity) is shown, but the turbocharger 200 may be oriented in an orientation suitable for the given details of operation of lubricant supply, flow, and drainage in the engine compartment.

[0027] As an example, a turbine assembly of an exhaust gas turbocharger may include vanes as part of a variable geometry turbine (VGT) or a variable nozzle turbine (VNT). The vanes may be at least partially disposed in a cartridge disposed between a turbine housing and a center housing of the turbocharger.

[0028] As an example, the cartridge may include a nozzle wall member and a plate member axially spaced apart by a mounting member (e.g., a spacer) at which the vanes are adjusted to control exhaust flow from the volute to the turbine wheel space. As an example, the vanes may include a trailing edge and a leading edge at which a pressure side airfoil and a suction side airfoil intersect. Such vanes may have a flat upper surface and a flat lower surface, wherein there is a gap between the flat upper surface and the nozzle wall member (e.g., between the lower flat surface of the annular portion of the nozzle wall member) and / or there is a gap between the flat lower surface and the plate member (e.g., between the upper flat surface of the annular portion of the plate member).

[0029] As an example, each blade may include an axis about which the blade may pivot (e.g., a pivot axis). As an example, each blade may include a post (e.g., or shaft) defining the pivot axis. As an example, the post may be integral with the blade (e.g., cast as a single piece of metal, alloy, etc.), or the post may be a separate component operably coupled to the blade.

[0030] As an example, the movement (e.g., arcuate) of the blade may be less close to the pivot axis and further away from the pivot axis. For example, the trailing edge or leading edge may be set at a certain distance from the pivot axis so that when the blade pivots, the leading edge and / or trailing edge sweeps the maximum arc of the blade for the desired amount of pivoting. If the gap between the upper surface of the blade and the lower surface of the nozzle wall component is reduced, the blade may become stuck, in which case the risk may increase depending on the arc length because the interaction area may increase relative to the arc length. In such an example, deformation of the nozzle wall component may cause one or more blades to become stuck when pivoting or even in a stationary position. Sticking may result in loss of control, stress on the control mechanism, wear, etc.

[0031] As an example, forces acting on the blades and / or blade posts may cause one or more blades to jam when pivoting or even in a stationary position. Jamming may result in loss of control, stress on the control mechanism, and wear, among other things.

[0032] With respect to pressure differentials and temperatures in a variable geometry turbine assembly, as an example, the exhaust gas in the volute may have a pressure in the range of about 120 kPa to about 400 kPa, and a possible peak pressure of up to about 650 kPa (absolute), and, for example, a temperature in the range of about 150° C. to about 980° C., while at a location axially downstream of the turbine wheel, the exhaust gas may have a lower range of pressures and a lower range of temperatures. The exhaust gas temperature in a gasoline fueled internal combustion engine may exceed the exhaust gas temperature of a diesel fueled internal combustion engine. Where a variable geometry turbine assembly is used with a gasoline fueled internal combustion engine, the environment may be more severe in terms of temperature than a diesel fueled internal combustion engine.

[0033] As an example, one or more components of a variable geometry turbine assembly (e.g., a VGT assembly or a variable nozzle turbine (VNT) assembly) may include at least a portion made of a material capable of withstanding pressures and temperatures within the above ranges. For example, the material may be INCONEL® 718 alloy (Specialty Materials, New Hartford, NY). Some other examples of materials include INCONEL® 625, C263 (Aluminum-Titanium Age-Hardened Nickel), René 41 (Nickel-Based Alloy), WASPALOY® Alloy (Age-Hardened Austenitic Nickel-Based Alloy, United Technologies, Hartford, CT), and the like.

[0034] As an example, the chuck may include a blade that is at least partially disposed between two components. As an example, at least a portion of the blade may be made of a material such as HK30, which is a chromium-nickel-iron stainless steel alloy that includes approximately 30% chromium and 20% nickel, with the balance being primarily iron (by mass percentage). As an example, at least a portion of the blade may be made of an HK series stainless steel alloy that includes approximately 18-22% nickel by mass. Such an alloy may be fully austenitic. As an example, one or more components of the chuck may be made of a material such as, for example, a PL23 alloy or an SS310 alloy.

[0035] As an example, an exhaust variable geometry turbine assembly may include a plurality of pivotable vanes at least partially defining a throat within an exhaust nozzle, wherein each pivotable vane includes a corresponding post.

[0036] Figure 3A and 3B Shows Figure 2 A perspective view of an exemplary chuck 250 is provided. Figure 3A and 3B , the nozzle wall member 300 includes at least an annular plate portion 310 and may include a cylindrical tube portion 350. In the case where the nozzle wall member 300 includes the cylindrical tube portion 350, the overall shape of the nozzle wall member 300 may be referred to as a hat shape. As shown, the annular plate portion 310 includes an outer periphery defined by an outer surface 312, wherein the outer periphery is circular. The outer surface 312 may be considered a cylindrical surface that intersects with opposing annular surfaces 314 and 316, wherein the annular surface 316 includes a shroud portion 318 as a shroud for a turbine wheel space of a turbine wheel, wherein a gap exists between the shroud portion 318 and a suitable turbine wheel disposed in the turbine wheel space. As shown, the nozzle wall member 300 includes a plurality of holes 320-1, 320-2, and 320-3 (e.g., spacer holes) that receive a plurality of spacers 254-1, 254-2, and 254-3 that axially space the nozzle wall member 300 relative to the plate member 251. The holes 320-1, 320-2, and 320-3 are shown as cylindrical and extend between opposing surfaces 314 and 316 of the nozzle wall member 300, wherein the holes 320-1, 320-2, and 320-3 each have a diameter and an axial length along a hole axis, wherein the hole axis is located at a radius of an axis defined by a turbine wheel space, such as an axis defined by the shroud portion 318, which axis may be referred to as a rotational axis (e.g., an intended rotational axis of a turbine wheel disposed in the turbine wheel space). Figure 3A and 3BIn the example of FIG. 1 , a circle with a diameter centered on the axis of rotation will pass through the bore axes of holes 320-1, 320-2, and 320-3 for a manufactured nozzle wall component 300, which can be considered an assembled state prior to using chuck 250 in a turbocharger installed in an engine compartment of an internal combustion engine. As discussed further below, nozzle wall component 300 can be subjected to various conditions (e.g., forces, temperatures, pressures, etc.) that can affect nozzle wall component 300 (e.g., with respect to integrity, shape, etc.).

[0037] With respect to the cylindrical tube portion 350, it includes an inner surface 352 and an outer surface 354 and an end face 356. The cylindrical tube portion 350 can be defined at least in part by an inner diameter, an outer diameter, and an axial length (e.g., measured along the axis of rotation). In the example shown, the outer surface 354 includes one or more grooves 355, which can receive one or more sealing elements (e.g., sealing components, such as or similar to piston rings). In the example shown, the surface 314 and the surface 354 intersect and form a shoulder with an angle of about 90 degrees. With respect to the surface 316 and the surface 352, they intersect at the respective ends of the shield portion 318. For example, the surface 316 can be substantially flat, intersecting with the molded shield portion 318, and then intersecting with the surface 352, and the surface 352 extends axially to the end face 356. As shown, the end face 356 is an annular surface where the inner surface 352 intersects with the outer surface 354.

[0038] The perspective view shows one or more sealing rings 261 disposed in one or more grooves 355 of the nozzle wall member 300, a plurality of spacers 254-1, 254-2, and 254-3, a plurality of vanes 255 (e.g., 255-1 to 255-N) and corresponding vane posts 253-1 to 253-N, a plurality of vane control arms 256, a unison ring 257, a plurality of pins 258-1, 258-2, and 258-3, and a plurality of guides 259-1, 259-2, and 259-3.

[0039] exist Figure 3A and 3B In the example of FIG. 2 , the unison ring 257 can be rotated about a central axis (e.g., substantially aligned with the rotational axis of the turbine wheel) to rotate the plurality of blade control arms 256 about the respective column axes of the respective blade columns 253 of the plurality of blades 255. The plurality of pins 258-1, 258-2, and 258-3 and the plurality of guides 259-1, 259-2, and 259-3 can help align the unison ring 257 relative to the other components of the chuck 250.

[0040] exist Figure 3A and 3BIn the example of the embodiment of the present invention, one or more ends of the spacers 254-1, 254-2 and 254-3 can be fixed (e.g., riveted, capped, etc.). For example, one end of the spacer can be flattened to be larger than the radius of the opening of the hole through which the spacer extends, so that the spacer cannot move axially into the hole. As shown, each of the spacers 254-1, 254-2 and 254-3 includes a nozzle portion having a radius and / or diameter larger than the corresponding end of the opposite end, which is received by the corresponding spacer hole of the nozzle wall component 300 and the plate component 251. For example, the spacer can be defined by one or more radii and / or one or more diameters and one or more axial dimensions, such as the axial dimension of the nozzle portion.

[0041] The nozzle portion of each spacer 254-1, 254-2 and 254-3 may include opposing shoulders, wherein one shoulder abuts the nozzle wall member 300 and the other shoulder abuts the plate member 251 to define a nozzle axial dimension, which nozzle axial dimension may be slightly larger than the blade axial dimension to allow the blade to pivot in the nozzle, where the gap may be defined at least in part based on one or more thermal considerations (e.g., thermal expansion, contraction, etc.).

[0042] exist Figure 3A and 3B In the example of FIG. 1 , the chuck 250 may be fixed as a chuck unit via riveted ends of the spacers 254-1, 254-2, and 254-3, which fixes the axial distance between the nozzle wall member 300 and the plate member 251 at a given temperature (e.g., ambient temperature during assembly). This riveting process may introduce a certain amount of stress at the passages (e.g., holes) of the nozzle wall member 300 and / or the plate member 251 through which the spacers 254-1, 254-2, and 254-3 pass.

[0043] Figure 4 Shows Figure 3A and 3B A cross-sectional view of the chuck 250 is shown. Figure 4Various dimensions are shown relative to a cylindrical coordinate system (θ, r, z) having a central axis z, wherein the cutaway view is a 180 degree view showing a cross section in the r, z plane. The radial dimensions include a radius r1 from the central axis z to an inner surface 352 of a cylindrical tube portion 350 of the nozzle wall member 300, which inner surface partially defines a turbine wheel space, a radius r2 from the central axis z to an outer surface 354 of the cylindrical tube portion 350 of the nozzle wall member 300, a radius r3 from the central axis z to an axis of the spacer 254 (e.g., parallel to the central z axis), and a radius r4 from the central axis z to an outer periphery of an annular plate portion 310 of the nozzle wall member 300 at a surface 312, wherein the annular plate portion 310 of the nozzle wall member 300 includes a portion between r2 and r4, and the annular plate portion 310 may be referred to as an outer brim portion.

[0044] As described above, the nozzle wall member 300 may be substantially formed as a cap-shaped member in which the cylindrical tube portion 350 extends axially away from the annular plate portion 310 or the outer flange portion of the nozzle wall member 300. With respect to the cross-sectional profile, the nozzle wall member 300 has a substantially L-shaped cross-sectional profile formed by the cylindrical tube portion 350 and the annular plate portion 310. Figure 4 As shown in the example of FIG. 3 , the nozzle wall component 300 is a single piece, which may be formed from a single piece of billet, cast as a single piece, etc.

[0045] As an example, the nozzle wall component 300 may be machined to form one or more features. For example, the nozzle wall component 300 may be drilled to form holes (see, e.g., holes 320) for axially supporting and / or positioning a plurality of spacers (see, e.g., spacers 254). Figure 4 As shown, the nozzle wall member 300 may be defined by an axial dimension Δzinsert, which may be the sum of an axial outer flange dimension Δzbrim and an axial pipe dimension Δzpipe.

[0046] like Figure 4 As shown, vanes 255 are at least partially disposed between plate member 251 and nozzle wall member 300 , wherein an axial distance between members 251 and 300 may be at least partially defined by spacers 254 .

[0047] like Figure 4As shown, the spacer 254 may include a portion having an axial dimension and a diameter, wherein the diameter is greater than the diameter of an axial extension of the spacer 254, wherein one axial extension passes through the opening of a passage (e.g., a hole) in the plate member 251 where the axial extension is expanded or capped, and wherein the other axial extension passes through the opening of a hole 320 in the nozzle wall member 300 where the axial extension is expanded or capped. In such an example, the axial spacing between the plate member 251 and the nozzle wall member 300 may be fixed to define an axial nozzle dimension, which may be referred to as a throat dimension (see, e.g., Δzthroat).

[0048] As described above, exhaust turbine components may be exposed to high temperatures. For example, consider a relatively small turbocharger with a variable nozzle cartridge (VNT cartridge) that is specified for use in internal combustion engine applications, where the maximum temperature of the VNT cartridge may exceed about 700 degrees Celsius and, for example, is less than about 1000 degrees Celsius. Temperature changes may cause one or more materials to expand (e.g., depending on geometry, size, structural materials, forces, etc.). Depending on the type of material used, the shape of the components, gaps, tolerances, etc., stresses may occur, particularly relative to the plate component 251, the nozzle wall component 300, and the spacer 254, which in turn may affect one or more gaps of the blade 255. In the event that the blade is stuck (e.g., contacting a surface with high friction), control of the VNT cartridge (or VGT cartridge) may be achieved. In addition, the blade may increase the stress or multiple stresses of the cartridge.

[0049] Reference again Figure 2 As described above, the heat shield 290 can be resilient in that it can act as a spring. For example, the heat shield 290 can contact the housing 280 and the plate member 251 so that the chuck 250 is biased against the housing 262. For example, the housing 262 may include an annular step that includes a stop surface that limits the axial movement of the plate member 251 and, therefore, the chuck 250. Figure 2 , 3 and 4, the plate member 251 includes an annular step or annular shoulder at a position radially outward from the spacer 254, which includes a portion extending through the opening of the passage through the plate member 251 and a portion extending through the opening of the hole 320 through the nozzle wall member 300. Figure 4 In the example of FIG. 2 , the annular shoulder of the plate member 251 is shown to include an axial dimension Δzshoulder and a radial dimension Δrshoulder.

[0050] Figure 5A portion of the cartridge 250 is shown in spatial relationship to the turbine housing 262 and the center housing 280, and various operating parameters representing examples of operating conditions. For example, the turbine volute (TV) includes a volute pressure (Ptv) and a volute temperature (Ttv), the throat or nozzle includes a nozzle pressure (PN), the center housing (CH) 280 includes a center housing temperature (TCH), and the space existing between the center housing 280, the turbine housing 262, and the plate member 251 includes a space temperature (Ts).

[0051] like Figure 5 As shown, the exhaust gas flows in a volute having various rotating cross-sectional flow profiles, wherein the exhaust gas flows from the volute to a nozzle (e.g., throat) defined by adjacent vanes 255, nozzle wall member 300, and plate member 251. The volute shape can affect vortex formation, vortex size, pressure loss, etc. Figure 5 In the example of , the volute may include a main vortex and one or more small vortices. Such vortices may be referred to as secondary flows or secondary flow patterns, which may depend on the type of flow to the volute (e.g., pulsating, steady, etc.).

[0052] like Figure 5 As shown, the pressure in the volute (Ptv) is greater than the pressure in the nozzle (PN), wherein a pressure difference can be defined between the two pressures. Figure 5 As shown, the pressure differential is accompanied by a velocity differential (e.g., via Bernoulli's principle), wherein the nozzle wall member 300 has a higher average velocity on its nozzle-facing surface than its volute-facing surface, causing a "lift" force axially downward in a direction from the nozzle wall member 300 toward the plate member 251. Figure 5In the method, when the spacers 254 (e.g., spacers 254-1, 254-2, and 254-3) fix the axial distance between the nozzle wall member 300 and the plate member 251, the "lift" force does not cause any change in the axial distance. Ignoring the temperature effects during operation or non-operation, the axial distance remains unchanged; noting that temperature changes may cause some changes in the axial distance due to the coefficient of thermal expansion (or contraction), which may be complicated by the fact that the plate member 251 and the nozzle wall member 300 are connected and fixed by the spacers 254-1, 254-2, and 254-3 (e.g., riveted at the ends, etc.). For example, thermal stresses may be generated, wherein such stresses may cause deformation of the nozzle wall member 300, in part because the spacers 254-1, 254-2, and 254-3 are coupled to the plate member 251. In such an example, the nozzle wall member 300 may cause the spacers 254-1, 254-2, and 254-3 to expand, which may hinder such expansion, causing stresses to build up and deform the nozzle wall member 300. Deformation of the nozzle wall component 300 may affect the clearance relative to the turbine wheel (e.g., considering the rotation profile of the turbine wheel), for example, along the contour of the shroud portion. In the event of a change in clearance, performance may change, which may change in an unfavorable manner. In the event of a reduction in clearance, there is a risk of contact between the nozzle wall component and the turbine wheel, which may lead to catastrophic failure of the turbine wheel and / or the turbine housing (e.g., one or more other components of the turbocharger).

[0053] Figure 5 The example of also shows various force arrows (e.g., approximate force and / or reaction force vectors). As shown, the shoulder of the plate component 251 contacts the mating shoulder of the turbine housing 262 such that there is zero clearance and there are forces and reaction forces. The force can be applied through the heat shield 290, which can apply a biasing force axially upward away from the center housing 280. The force relative to the spacer 254 is also shown, where various interfaces can exist, where the plate component 251 and the nozzle wall component 300 are at least partially clamped by the spacer 254.

[0054] Figure 6 Shows Figure 5 The assembly, wherein the chuck 250 and Figure 5 As shown, the shoulder of the plate member 251 is axially displaced relative to the mating shoulder of the turbine housing 262 by a distance Δz, so that the plate member 251 is not in direct contact with the turbine housing 262. In such an example, the heat shield 290 can apply an increased force that acts to push the chuck 250 axially upward away from the center housing 280. As shown, with the chuck 250 axially moved, one or more sealing rings 261 can slide against the surface of the turbine housing 262.

[0055] Figure 5 and Figure 6 It is shown that the chuck 250 can be moved axially while the axial distance between the plate member 251 and the nozzle wall member 300 remains constant (eg, ignoring temperature effects).

[0056] Figure 7 A plan view of a nozzle wall member 300 is shown, wherein holes 320-1, 320-2, and 320-3 are shown as being angularly spaced about an axis of rotation for which a circle having a diameter may be defined. As shown, each hole 320-1, 320-2, and 320-3 may be defined by a hole diameter (eg, dB).

[0057] The nozzle wall member 300 can be formed to include holes 320-1, 320-2, and 320-3 for spacers, wherein each hole can include a hole wall thickness defined from a wall of the hole (e.g., hole wall) along a radial line from an axis of the nozzle wall member to a periphery of the nozzle wall member, wherein the axis can be defined as a z-axis in a cylindrical coordinate system (e.g., r, z, and Θ) that can be positioned in the assembled turbine assembly to coincide with an axis of rotation of the turbine impeller about an axis that is operably coupled to the compressor impeller. The nozzle wall member 300 can be defined in part by an outer diameter (Douter) of its circular periphery. Further, the axis of the hole can coincide with a diameter of another circle, which can be referred to as a hole axis diameter (Daxes). As Figure 7 As shown, azimuth spans R1, R2 and R3 exist between the bore axes of bores 320-1, 320-2 and 320-3, wherein azimuth span R1 corresponds to bores 320-1 and 320-2, azimuth span R2 corresponds to bores 320-2 and 320-3, and azimuth span R3 corresponds to bores 320-3 and 320-1. Figure 7 Also shown is a minimum diameter (Dmin), which may correspond to a minimum shroud diameter or a minimum diameter of the cylindrical tube portion 350 .

[0058] Figure 8 A view of an annular plate portion 310 of a nozzle wall member 300 is shown simulated via a numerical simulation framework (ANSYS simulation software, Ansys, Inc., Canonsburg, Pennsylvania, USA) for various conditions that may occur during actual operation of a turbocharger including the nozzle wall member 300 as part of a turbine assembly. As shown, deformation may occur, which may be plastic such that the nozzle wall member 300 does not recover. As described above, deformation of the nozzle wall member 300 may result in adverse consequences (e.g., with respect to blades, blade clearances, integrity, etc.). In particular, one or more hole walls defining the respective one or more holes 320-1, 320-2, and 320-3 may deform and, for example, crack. Figure 8A single hole of the plurality of holes is shown, labeled hole 320. Contour lines of various values ​​are shown, along with general markings for low and high deformations.

[0059] Figure 8 The simulation view of FIG. 1 involves the influence of a temperature exceeding 900° C., where cracking may occur in actual operation of the nozzle wall member 300, which is an integrity problem and a deformation problem. Specifically, the cause of the cracking may be associated with the force and deformation occurring at the wall between the hole 320 of the nozzle wall member 300 and the surface 312 at the outer periphery. Figure 8 The view of shows the accumulated plastic strain, which deforms the annular plate portion 310 of the nozzle wall component 300 in a manner that deforms the hole 320, which may affect the forces about the corresponding spacer, which may further affect one or more other components.

[0060] As an example, a nozzle wall component may be formed that includes holes for spacers, wherein each hole may include a hole wall thickness defined from a wall of the hole (e.g., a hole wall) along a radial line from an axis of the nozzle wall component to a periphery of the nozzle wall component, wherein the axis may be defined as a z-axis in a cylindrical coordinate system (e.g., r, z, and θ) that may be positioned in an assembled turbine assembly to coincide with an axis of rotation of a turbine impeller about an axis that is operably coupled to a compressor impeller. In such an example, the nozzle wall component may be inscribed by a circle having a diameter (e.g., an outer diameter) and inscribed by another circle having a different diameter (e.g., an inner diameter). In addition, the axis of the hole may coincide with a diameter of another circle, which may be referred to as a hole axis diameter, which may be, for example, a diameter that is less than or equal to the inner diameter and thus less than the outer diameter. As an example, the axis of the hole may coincide with a diameter that is greater than the inner diameter but less than the outer diameter. In a plan view located in the r, θ plane, the nozzle wall component may have an outer periphery having one or more maxima at the outer diameter and one or more minima at the inner diameter. Thus, the area of ​​the nozzle wall member in plan view can be determined in part by the area existing between the inner diameter and the outer diameter, which area can be larger in the area near the hole. As an example, the nozzle wall member can include an outer perimeter that can be defined by intersecting curves, which can be intersecting arcs, where the intersection points define or approximately define the outer diameter and the corresponding intermediate points on each curve can collectively define the inner diameter; noting that, for the centroid, one or more such diameters can be slightly offset from the central axis of the nozzle wall member, or can be exactly on the central axis of the nozzle wall member. As an example, given an inner diameter and an outer diameter, the area located therein can be shaped to have a convex outer perimeter side defined by the corresponding curves and a concave side defined by the inner diameter. As an example, the area between the inner diameter and the outer diameter can include multiple areas corresponding to multiple spacer holes. For example, for three spacer holes, the area can be composed of three sub-areas (e.g., spacer hole areas).

[0061] As an example, where a first nozzle wall component has an outer perimeter defined in part by an outer diameter and an inner diameter, and where a second, different nozzle wall component has an outer perimeter defined by the same outer diameter as the first nozzle wall component, the area in a plan view of the first nozzle wall component is less than the area of ​​the second nozzle wall component. Further, where the thickness (e.g., axial thickness) of the first and second nozzle wall components are the same and they are made of the same material, the mass of the first nozzle wall component is less than the mass of the second nozzle wall component. With respect to response to thermal cycles, the deformation of the bore wall region caused by the shape of the first nozzle wall component is less than the deformation of the bore wall region caused by the shape of the second nozzle wall component. Thus, as an example, the first nozzle wall component may have less mass (e.g., less material) and perform better in its response to thermal cycles. Such improved response to thermal cycles may improve the integrity of the nozzle wall component, particularly for the bore of the spacer (e.g., the spacer bore). Depending on one or more factors, the lesser mass may be optional; noting that the lesser mass may result in a lesser mass turbocharger, which may help reduce vehicle weight in the case where the turbocharger is mounted in a vehicle operably coupled to an internal combustion engine.

[0062] As explained, a nozzle wall component having an outer perimeter defined by intersecting curves (which may be arcs) may be limited to have thermal expansion less than a corresponding nozzle wall component having an outer perimeter defined by a circle.

[0063] For nozzle wall components having an outer perimeter defined by a circle, it has been observed and simulated that the effect of thermal expansion becomes more pronounced as the outer diameter increases, since the larger the outer diameter, the greater the compressive stresses in the outer perimeter to cause undesirable "clogging" of material in the area of ​​the wall comprising the spacer hole (see e.g. Figure 8 of simulation results).

[0064] By shaping the outer perimeter of the nozzle wall component with a cross-curve (which may be an arc), material is "effectively" removed between each pair of spacer holes compared to a circular perimeter nozzle wall component, thereby reducing thermal expansion and subsequently limiting strain in the material. As an example, at the same time, the wall thickness at the spacer holes can remain the same as the wall thickness of the circular perimeter nozzle wall component (e.g., depending on one or more factors, etc.). As an example, the outer diameter of the nozzle wall component can be determined in part by one or more gaps during assembly and / or during assembly of the components. As an example, with the outer diameter set to a maximum value, the nozzle wall component with a cross-curve outer perimeter will exhibit less thermal expansion with respect to the walls of the spacer holes compared to the nozzle wall component with a circular outer perimeter. In this approach, removing and / or reducing material of the nozzle wall component can help reduce thermal expansion of its outer perimeter, thereby helping to limit thermally induced strains in the walls of the spacer holes (e.g., where the nozzle wall component may include multiple spacer holes, each with a corresponding wall).

[0065] Although Figure 7 The exemplary nozzle wall component 300 shows a plurality of holes 320-1, 320-2, and 320-3 (e.g., spacer holes) with R1~144 degrees, R2~108 degrees, and R3~108 degrees, but such azimuthal spans may be substantially equal according to the formula R=360 degrees / Nsb, where Nsb is the number of spacer holes. For example, three spacer holes may be positioned R1~R2~R2~120 degrees.

[0066] Fig. 9 An example of a nozzle wall component 900 is shown that includes a plate portion 910 having a shape that is different from the shape of the annular plate portion 310 of the nozzle wall component 300 . Fig. 9 The nozzle wall component 900 may be included in a turbocharger, such as Figure 1 Turbocharger 120, Figure 2 The turbocharger 200 etc. (see also e.g. Fig.13 Exploded view of the ).

[0067] exist Fig. 9In the example of the nozzle wall component 900, the plate portion 910 includes a plate portion 910 and a cylindrical portion 950, wherein the plate portion 910 includes an outer surface 912, opposing surfaces 914 and 916, a shroud surface 918 intersecting with the surface 916, and holes 920-1, 920-2, and 920-3 (e.g., spacer holes), and wherein the cylindrical portion 950 includes an inner surface 952, an outer surface 954 having a groove 955, and an end surface 956, wherein the surfaces 952 and 954 meet at the end surface 956 and the surface 952 meets the shroud surface 918. The groove 955 may be optional and may be sized to receive one or more sealing elements (e.g., a sealing ring, etc.). As an example, the nozzle wall component 900 may be without the cylindrical portion 950 (see, e.g., Fig.13 ).

[0068] exist Fig. 9 In the example of FIG. 1 , various axial dimensions are shown, including an outer flange dimension (Δzbrim), a tube dimension (Δzpipe), and an insert dimension (Δzinsert), wherein the insert dimension may be the total axial height of the nozzle wall component 900, the total axial height including the axial height of the plate portion 910 (e.g., outer flange) and the portion 950 (e.g., cylindrical tube portion or “tube”). The term “insert” may be used when the nozzle wall component is at least partially inserted into the space defined by the turbine housing.

[0069] exist Fig. 9 In the embodiment of the present invention, the nozzle wall component 900 can have an outer perimeter that can be defined by the intersection of curves. For example, consider the intersection of three circles or the confluence of arcs. Fig. 9 In the example of , nozzle wall component 900 includes three arcs, wherein adjacent arcs intersect along each of three radial lines from the central axis to the axis of a corresponding one of holes 920 - 1 , 920 - 2 , and 920 - 3 (eg, spacer holes).

[0070] As an example, the outer perimeter of the nozzle wall component may include features of a curvilinear polygon, which may be a curvilinear polygon formed by arcs of a circle or other arcs (e.g., an ellipse, etc.). As an example, the outer perimeter of the nozzle wall component may be a Lurox polygon. For example, consider a Lurox triangle.

[0071] Reference again Figure 7 As shown in the figure, the nozzle wall member may include holes at unequal intervals. For example, Figure 7, the nozzle wall component 300 includes an angular span of about 144 degrees between the hole 320-1 and the hole 320-2 and an angular span of about 108 degrees between the holes 320-2 and 320-3. For example, the nozzle wall component can be defined in a cylindrical coordinate system with coordinates r, z and θ, where r is a radial dimension, z is an axial dimension, and θ is an azimuthal dimension (e.g., in radians, degrees, etc.). In such an example, the angular spans of about 144 degrees (R1) and 108 degrees (R2 and R3) can be azimuthal spans. With respect to the angular span between the hole 320-1 and the hole 320-3 (e.g., measured from their respective hole axes), it can be approximately equal to 360 degrees - 144 degrees - 108 degrees, i.e., 108 degrees. Fig. 9 The nozzle wall component 900 includes an angular span (eg, an azimuthal span) between the apertures 920 - 1 , 920 - 2 , and 920 - 3 , wherein one of the angular spans may be different than one or more other angular spans.

[0072] A variable nozzle turbine (VNT) or variable geometry turbine (VGT) cartridge may include a nozzle wall member that does not have a circular outer diameter. As explained, the nozzle wall member and the plate member may define a nozzle, wherein vanes disposed in the nozzle may define a throat, the vanes may be adjustable vanes that pivot about respective axes to adjust how exhaust gas flows from a scroll or volute to a turbine wheel space.

[0073] As explained, spacers can be used to axially space the nozzle wall member and the plate member. The spacers are in the exhaust flow area and can therefore interfere with the exhaust flow. As shown, the spacers can be obstacles to the exhaust flow, wherein the exhaust must flow around the spacers to generate flow disturbances. Since each spacer may generate flow disturbances, the number of spacers can be kept to a minimum. As shown in various examples, three spacers are used, noting that more spacers can be used, but with increased flow disturbances. For example, the number of spacers can be between 3 and 6, again noting that three spacers tend to have less flow disturbances than four, five, or six spacers. In addition, the number of spacers may affect the expansion and contraction of the nozzle wall member. For example, for three spacers, the nozzle wall member can be constrained at three points, while for four spacers, the nozzle wall member can be constrained at four points. The increased number of spacers may complicate one or more of the expansion, contraction, and deformation of the nozzle wall member.

[0074] As an example, consider a nozzle wall component that is spaced apart from a plate component by three spacers that are orbitally cold riveted on the nozzle wall component and the plate component. In such an example, each of the nozzle wall component and the plate component is considered to include three axial holes of approximately 6 mm in diameter, and each of the three axial holes of the nozzle wall component may have an associated wall thickness dimension (e.g., wall thickness to the outer periphery) along a line from the inner wall of the axial hole to the outer surface of the nozzle wall component.

[0075] The effects of thermal cycling that may be encountered during operation and non-operation of a turbocharger turbine assembly are detrimental to the nozzle wall components relative to their axial bore for the spacer. For example, the thinnest portion of the bore wall may crack, which can be demonstrated via digital computer simulation using finite element analysis.

[0076] Fig. 9 The exemplary nozzle wall component 900 can help reduce the risk of cracking of the thinnest portion of the hole wall of the spacer hole (see, for example, holes 920-1, 920-2, and 920-3) by utilizing a shape of the nozzle wall component 900 that locally increases the hole wall thickness by utilizing an outer peripheral contour, which can be a Lurox triangle or other type of curved polygon. As an example, Fig. 9 The outer perimeter in the example may be referred to as a trilobite shape or trilobite perimeter, which may provide a local increase in hole wall thickness while minimally increasing flow disturbances to the exhaust flow in the operating turbine assembly of the turbocharger. This approach may reduce the risk of cracking and thus serve to increase the life of the turbine assembly of the turbocharger while minimizing the impact on performance related to the exhaust flow. In addition, since cracking is a deformation or distortion that may change the shape of the nozzle wall component, which may have adverse consequences for the controllability of the blade (e.g., sticking, etc.), the arcuate perimeter approach of local hole wall thickening may reduce the risk of deformation or distortion issues in the operating turbine assembly of the turbocharger.

[0077] As an example, the nozzle wall component can be machined from a piece of material (e.g., a forged billet, etc.), wherein such machining can form a precise shroud profile. Such machining can also be implemented to form the perimeter of the nozzle wall component into a plurality of intersecting arcs, which can be at least three intersecting arcs, wherein the intersection point is close to the corresponding spacer hole, thereby providing a desired amount of local hole wall thickness, which can reduce the risk of such local hole wall cracking. As an example, a machine that can form a circular perimeter can be used to form multiple intersecting arcs. As an example, an edge formed by two intersecting arcs can be machined so that the edge is smooth. Such smoothing can round the edge so that flow disturbances during operation are reduced compared to sharp edges. In addition, such smoothing can help reduce stresses that may be caused by sharp edges and / or physical and / or chemical effects (e.g., action sites, penetration sites, etc.).

[0078] As an example, the nozzle wall component may include one or more chamfers and / or one or more rounded corners along the outer periphery. For example, during machining of the nozzle wall component, intersecting arcs may be formed that meet at an edge, which may be referred to as a sharp edge. In such an example, a chamfer may be machined at the edge to create two edges, and / or one or more rounded corners may be machined at the edge and / or at the chamfered edge.

[0079] As an example, chamfers and / or radii can give a component better flow and less drag. Using one or more radii can reduce and / or eliminate one or more sharp edges that may be more easily damaged when in contact with an object than a radii, for example, using one or more radii can help reduce the risk of injury during handling of the part. As for reducing the risk of damage, this approach can translate into higher production throughput, and inspection can also be more effective. Radii can help reduce one or more stress concentration factors because the radii can help distribute stress over a wider area. As an example, a nozzle wall component having one or more chamfers and / or one or more radii can be more durable and able to withstand greater loads than the same component having sharp edges.

[0080] As an example, the outer periphery of the nozzle wall component can be formed via forging, wherein the outer profile is determined by forging rather than machining. In such an example, machining can be utilized, for example, to form and / or grind spacer holes, reduce the sharpness of one or more edges, improve the shroud profile, etc.

[0081] Fig.10 Shows Fig. 9 The physical parameter contour values ​​of the nozzle wall component 900 correspond to the accumulated plastic strain determined by a finite element analysis (FEA) simulation of the nozzle wall component 900 with respect to temperature. Fig.10Holes 920-1, 920-2 and 920-3 are shown, and holes 920-1, 920-2 and 920-3 are referred to as spacer holes 1, 2 and 3 for "arc" or cross-curve outer peripheries in Table 1 below, compared to holes 320-1, 320-2 and 320-3, which are also referred to as spacer holes 1, 2 and 3 for "circular" outer peripheries.

[0082] Table 1. FEA results (ANSYS simulation software results)

[0083] As shown in Table 1, the accumulated plastic strain at each of the three spacer holes is reduced by at least 50% for the nozzle wall component having an arc (e.g., a cross curve) formed at the periphery compared to the nozzle wall component having a circular periphery. Note that the percentage values ​​are scaled, wherein the spacer hole 1 of the circular outer periphery nozzle wall component 900 has the highest accumulated plastic strain value of 9.24, which is scaled as 100% in the percentage column.

[0084] Fig.11 A plan view of the nozzle wall component 900 is shown, along with various examples of dimensions, including an inscribed outer diameter (Douter), an inscribed inner diameter (Dinner), and a bore axis diameter (Daxes). As an example, the nozzle wall component 900 is considered to be inscribed in a circle having a diameter of approximately 76 mm (Douter), wherein the inscription is defined by three intersection points formed by the intersection of three arcs, which at least partially define the outer perimeter of the nozzle wall component 900. In such an example, each of the holes 920-1, 920-2, and 920-3 (e.g., spacer holes) can define a circle having a diameter of approximately 66 mm (Daxes). Thus, there is a radial distance of approximately 5 mm (e.g., 0.5 (76 mm-66 mm)) from the spacer hole axis to the intersection of the two arcs. If a circle is inscribed at the radially outermost point of each spacer hole, such a circle has a diameter of approximately 69 mm, which generally corresponds to the inner diameter (e.g., Dinner). In such an example, the thinnest spacer hole wall thickness to the outer periphery of the nozzle wall component 900 is approximately 3.5 mm (e.g., 0.5 (76 mm-69 mm)). The same spacer hole wall thickness can be achieved using a circular outer periphery with a diameter of 76 mm, however, as described above, this approach will result in an increase in detrimental thermal effects and, for example, may result in more mass.

[0085] exist Fig.11 In the example of FIG. 1 , the arc may include two 45 mm radius arcs and one 40 mm radius arc, wherein the 40 mm radius arc is Fig.11The left side of the image is shown in Figure 1 (see e.g. R1) and the 45mm radius arc is on the right side, upper right side and lower right side (see e.g. R2 and R3).

[0086] Fig.12 A cross-sectional view of a nozzle wall component 900 is shown, along with various examples of dimensions, including radial and axial dimensions (see also, e.g. Figure 4 radial and axial dimensions). Fig.12 As shown, the nozzle wall member 900 may be defined by an axial dimension Δzinsert, which may be the sum of an axial outer flange dimension Δzbrim and an axial tube dimension Δzpipe. Fig.12 The radial dimensions in the example include a radius r1 from the central axis z (z-axis) to an inner surface 952 of a cylindrical portion 950 of the nozzle wall member 900 that partially defines a turbine wheel space, a radius r2 from the central axis z to an outer surface 954 of the cylindrical portion 950 of the nozzle wall member 900, a radius r3 from the central axis z to an axis of the bore 920 (e.g., parallel to the central z-axis), and a radius r4 from the central axis z to an outer periphery of a plate portion 910 of the nozzle wall member 900 at a surface 912, wherein the plate portion 910 of the nozzle wall member 900 includes a portion between r2 and r4, and wherein the plate portion may be referred to as an outer flange portion, which is shown as including a shroud surface 918 that partially defines a turbine wheel space for a turbine that may be aligned on a shaft supported by a bearing in a bore of a center housing, wherein the axis of rotation of the turbine wheel and the shaft are substantially aligned. Fig.12 The z-axis shown in (eg, the central axis of nozzle wall member 900 ) is aligned.

[0087] Fig.13An exploded cross-sectional view of assembly 1300 is shown, which includes seal 1362, chuck 1000, turbine housing 1360, center housing 1380, component 1382, component 1390, and component 1392. A common axis (z-axis) is shown, which is the longitudinal axis of the bore of center housing 1380 and the center axis of chuck 1000. As an example, component 1390 can contact chuck 1000, wherein component 1390 can have a spring constant (e.g., be elastically deformable). As an example, when assembled, chuck 1000 can be axially biased between center housing 1380 and turbine housing 1360 via component 1390 (e.g., heat shield) and seal 1362. As an example, turbine housing 1360 can be clamped to center housing 1380 so that a gap-free interface is formed therebetween. For example, turbine housing 1360 can be coupled and axially fixed to center housing 1380. As an example, component 1390 can apply a force (e.g., a load) to chuck 1000 that is reacted by turbine housing 1360. As an example, seal 1362 can be more flexible than component 1390, such that seal 1362 compresses (e.g., achieves a compressed state) when subjected to a load (e.g., at least in part by a force applied by component 1390) in an assembled state of assembly 1300. As an example, seal 1362 can be elastically deformable, e.g., compressed to a compressed state in an assembly and returned to an uncompressed state when the assembly is disassembled (e.g., seal 1362 is removed from the assembly).

[0088] exist Fig.13 In the example of , the chuck 1000 includes a nozzle wall component 1090 that does not include a cylindrical portion. As shown, the nozzle wall component 1090 includes an outer periphery formed by a plurality of arcs that intersect to locally increase the wall thickness at each of the plurality of spacer holes. Fig.13 As shown, the chuck 1000 includes a plate member 1051 and a spacer 1054 that defines the axial dimension of the nozzle space between the nozzle wall member 1090 and the plate member 1051 , such as between facing surfaces thereof (eg, a lower surface of the nozzle wall member 1090 and an upper surface of the plate member 1051 ).

[0089] As can be appreciated, the outer periphery of nozzle wall member 1090 is received in turbine housing 1360 such that the outer periphery is disposed in a volute for exhaust gas flow. Thus, the shape of the outer periphery may affect the exhaust gas flow.

[0090] Fig.14A and Fig. 14B An example of a turbine assembly 1410 having a nozzle wall member 1419 with a circular outer perimeter and an example of a turbine assembly 1430 having a nozzle wall member 1439 with an outer perimeter formed by intersecting arcs are shown, respectively. Fig.14A and 14B In the example of , a turbine assembly 1410 includes a turbine housing having an exhaust inlet 1411 and a tongue 1413, the tongue 1413 being at a transition from an inlet portion to a volute portion, and a turbine assembly 1430 includes a turbine housing having an exhaust inlet 1431 and a tongue 1433 being at a transition from an inlet portion to a volute portion. As shown, the flow in the volute may be disturbed to some extent at the location where the arcs intersect, and as described above, the arcs may be smoothed via one or more fillets and chamfers. For example, the exhaust flow may deviate slightly along the streamline near the intersection or intersection area. In terms of performance impact, computational fluid dynamics simulations indicate that the amount of impact from the outer periphery of the intersection arc versus the circular outer periphery is minimal. For an exhaust velocity of approximately 240 m / s in the volute, the impact on mass velocity is approximately 9 g / s.

[0091] As mentioned above, one type of curved polygon is the Lurox triangle. With respect to the Lurox triangle, it can be defined as a curve of constant width constructed by drawing arcs from each polygon vertex of an equilateral triangle between the other two vertices. For any curve of constant width of given width, the Lurox triangle has the minimum area. Let the arc radius be , and since the area of ​​each meniscus of the Lurox triangle is and area The area of ​​the central equilateral triangle can be obtained by Defined as , considered for the total area The following equation:

[0092]

[0093] .

[0094] According to the above equation, equal areas The triple and center of an equilateral triangle The area limits the total area The total area of ​​a nozzle wall component having a curved perimeter segment may be compared to the total area of ​​a nozzle wall component having a circular perimeter.

[0095] Fig.15An example of a nozzle wall component 1510 and a triangle (T) and three curves (C1, C2, and C3) are shown, wherein a portion of each curve (C1, C2, and C3) defines an outer perimeter of the nozzle wall component 1510. As shown, the outer perimeter is formed by three arcs, which are circular arcs, two of which have the same diameter (i.e., the same radius) and the other has a smaller diameter (i.e., a smaller radius). As shown, the spacer holes may form the vertices of the triangle (T), however, in Fig.15 In the example of , the triangle is not an equilateral triangle, although it is an isosceles triangle because it has two equal (e.g., substantially equal) lengths. As shown, the arcs intersect at points that can define a larger triangle, where the vertices between the triangles can define the hole axis to perimeter difference, which includes the spacer hole wall thickness.

[0096] Fig.16 An example of a nozzle wall component 1610 is shown, where a composite view shows that arcs of three ellipses (E1, E2, and E3) can form an outer perimeter of the nozzle wall component. As described above, the nozzle wall component can be at least partially formed or defined by intersecting arcs. Fig.16 In the example, the intersection arcs are arcs of portions of ellipses (E1, E2, and E3) that have the same loci, major and minor axes as the ellipses. Note that in Fig.16 In the example shown, the shape of the outer perimeter of the nozzle wall component 1610 is not defined by the area formed by the intersection of all three ellipses, which means that the example shown is different from the area formed in, for example, a Lurox triangle.

[0097] Fig.17 A plan view of an example of a turbine assembly 1710 is shown that includes a nozzle wall member 1719 having four spacers and therefore four spacer holes, wherein the outer perimeter of the nozzle wall member includes four arcs, wherein adjacent arcs intersect and the arcs may be circular arcs.

[0098] Fig.13 The nozzle wall component 1090 of FIG. 14, 1439 of FIG. 14, Fig.15 1510 Fig.16 1610 or Fig.17 One or more features of 1719 may be included in a nozzle wall component in a turbocharger, such as, for example Figure 1 Turbocharger 120, Figure 2 Turbocharger 200, Fig.13As explained, a non-circular outer perimeter that may be defined in part by intersecting curves may reduce thermal effects associated with deformation, which may improve the integrity of a nozzle wall component in a turbine assembly of a turbocharger, for example, with respect to one or more forces that may be experienced during operation or during non-operation (e.g., considering temperature cycling between operation and non-operation, where temperatures may vary from less than 0 degrees Celsius to hundreds of degrees Celsius or more).

[0099] As an example, the minimum axial distance between the plate member and the nozzle wall member defined by the at least one spacer can be greater than the maximum blade height of the blade. In such an example, the risk of blade contact (e.g., and damage, binding, etc.) can be reduced by using the outer periphery of the nozzle wall member, which can be at least partially defined via a crossover arc for locally increasing the thickness of the spacer hole wall.

[0100] As an example, a Figure 2 The turbocharger 200 of the turbocharger may include a center housing (see, e.g., center housing 280); a bearing (see, e.g., bearing 230) disposed in a through hole of the center housing, wherein the through hole of the center housing defines a longitudinal axis; a shaft (see, e.g., shaft 220) rotatably supported by the bearing; a compressor impeller (see, e.g., compressor impeller 244) operably coupled to the shaft; a turbine impeller (see, e.g., turbine impeller 264) operably coupled to the shaft; and a turbine housing assembly (see, e.g., turbine housing assembly 260) operably coupled to the center housing, wherein the turbine housing assembly includes a turbine housing (see, e.g., turbine housing 262); and a nozzle wall member (see A chuck (see, e.g., chuck 250) having a nozzle wall component (e.g., nozzle wall component 900, nozzle wall component 1090, nozzle wall component 1439, nozzle wall component 1510, nozzle wall component 1610, nozzle wall component 1719, etc.) and a plate component (see, e.g., plate component 251, plate component 1051, etc.), wherein the nozzle wall component and the plate component are axially spaced apart by spacers (see, e.g., spacer 254, spacer 1054, etc.), wherein the nozzle wall component includes a spacer hole for the spacer (see, e.g., spacer hole 920), and wherein the nozzle wall component includes a non-circular outer periphery at least partially defined by arcs, adjacent arcs intersecting at intersections and each intersection being located radially outward from a corresponding one of the spacer holes.

[0101] As an example, a turbocharger may include a center housing; a bearing disposed in a through hole of the center housing, wherein the through hole of the center housing defines a longitudinal axis; a shaft rotatably supported by the bearing; a compressor impeller operably coupled to the shaft; a turbine impeller operably coupled to the shaft; and a turbine housing assembly operably coupled to the center housing, wherein the turbine housing assembly includes a turbine housing; and a cartridge including a nozzle wall member and a plate member axially spaced apart by a spacer, wherein the nozzle wall member includes a spacer hole for the spacer, and wherein the nozzle wall member has a non-circular outer perimeter at least partially defined by arcs, wherein adjacent arcs intersect at intersections, and wherein each intersection is located radially outward from a corresponding one of the spacer holes. In such an example, the plate member may include a corresponding number of spacer holes, wherein the spacer extends axially between the plate member and the nozzle wall member.

[0102] As an example, the spacers may be fixed by deforming one or more ends of one or more opposing ends of each spacer. Each spacer may include a nozzle portion that may include opposing shoulders that define an axial dimension of the nozzle. For example, Figure 4 , 5 , 6 and 13 show spacers comprising opposing shoulders, wherein one shoulder abuts a nozzle wall member and the other shoulder abuts a plate member, which may be an annular plate member.

[0103] As an example, the chuck may include three spacers. As an example, the nozzle wall component may include three spacer holes. As an example, the nozzle wall component may be formed by forging, wherein, for example, the nozzle wall component includes a shroud profile formed at least in part by machining, wherein the shroud profile may be a turbine wheel shroud profile of a turbine wheel at least partially defined by a portion of the nozzle wall component. As an example, the nozzle wall component may partially define a nozzle space and may partially define a turbine wheel space. As an example, the nozzle wall component may partially extend into a volute space of an exhaust volute partially defined by a turbine housing. As an example, the spacer holes of the nozzle wall component may be formed at least in part by machining.

[0104] As an example, each of the plurality of spacer holes of the nozzle wall component can include an axis, wherein the axis of the spacer hole defines a triangle. In such an example, the triangle can be an isosceles triangle or another type of triangle, for example. As an example, the triangle can be an equilateral triangle.

[0105] As an example, the chuck may include a vane disposed between the plate member and the nozzle wall member. As an example, such a vane may be static (non-pivoting or non-adjustable) or may be dynamic (eg, pivoting or adjustable).

[0106] As an example, the outer periphery of the nozzle wall component may include at least one chamfer and / or at least one rounded corner. In such an example, the chamfer and / or rounded corner may be disposed in a volute space defined in part by a turbine housing. In such an example, the chamfer and / or rounded corner may help reduce disturbances regarding the flow of exhaust gas from the volute space to the nozzle (e.g., or a throat between adjacent blades) and to the turbine wheel space.

[0107] As an example, the nozzle wall member can be at least partially disposed in the turbine housing to define at least a portion of an exhaust volute (e.g., an exhaust volute). During operation, the exhaust gas can include thermal energy that can be partially absorbed by the nozzle wall member, wherein the nozzle wall member can increase in temperature and expand according to the coefficient of thermal expansion of the material of the nozzle wall member. Thermal expansion refers to the tendency of a substance to change in shape, area, and volume in response to changes in temperature. Temperature tends to be a monotonic function of the average molecular kinetic energy of a substance. When a substance is heated, the kinetic energy of its molecules increases. As a result, the molecules begin to vibrate / move more and generally maintain a greater average separation. Materials that contract as temperature increases may be considered unusual, where such effects tend to be size-limited and occur over a limited temperature range. The relative expansion (e.g., strain) divided by the change in temperature can be referred to as the coefficient of thermal expansion of the material, which can vary with temperature.

[0108] As an example, a material such as INCONEL® 718 alloy may have a coefficient of thermal expansion ranging from about 12.8×10-6 / °C (e.g., 25°C to about 93°C) to about 16×10-6 / °C (25°C to 760°C). The melting temperature of such a material is in the range of about 1210°C to about 1344°C. The density of such a material is about 8220 kg / m3.

[0109] refer to Figure 8 and 10 , such material properties can be considered for one or more of material selection, material processing to form the component, material weight, material deformation, material integrity used in turbine components, etc. As for mass, the volume can be calculated to determine the mass using a specified density. As an example, the volume and / or mass of a nozzle wall component having a circular perimeter and a nozzle wall component having a non-circular perimeter can be determined. As an example, constrained and non-constrained considerations can be considered when determining thermal effects. For example, a physically constrained component can deform differently than a component that is not physically constrained. As an example, where a nozzle wall component is constrained via one or more spacers (e.g., radially, axially, and / or azimuthally), such constraint can be considered with respect to the shape of the outer perimeter of the nozzle wall component, where the shape can advantageously be non-circular, where features of the shape can correspond to the location of such constraint.

[0110] As an example, a turbine housing may include a wall at least partially defining a volute, wherein the wall includes a tongue. In such an example, one of the spacers may be positioned adjacent to the tongue. In such an example, an azimuthal span from a spacer positioned adjacent to the tongue to one spacer that is an adjacent spacer in a counterclockwise or clockwise direction may be different from an azimuthal span from a spacer positioned adjacent to the tongue to another spacer that is an adjacent spacer in a clockwise or counterclockwise direction, respectively (i.e., counterclockwise is paired with clockwise or clockwise is paired with counterclockwise). In such an example, the sum of the azimuthal spans is greater than about 240 degrees.

[0111] Although some examples of methods, apparatus, systems, arrangements, etc. are shown in the drawings and described in the foregoing detailed description, it should be understood that the disclosed example embodiments are not limiting but are capable of numerous rearrangements, modifications, and substitutions.

Claims

1. A turbocharger, comprising: center housing; a bearing disposed in a throughbore of the center housing, wherein the throughbore of the center housing defines a longitudinal axis; a shaft rotatably supported by the bearing; a compressor impeller operably coupled to the shaft; a turbine wheel operably coupled to the shaft; and a turbine housing assembly operably coupled to the center housing, wherein the turbine housing assembly comprises: a turbine housing; and a chuck including a nozzle wall member and a plate member axially spaced apart by a plurality of spacers, wherein the nozzle wall component comprises a plurality of spacer holes, each of the plurality of spacer holes being used to receive a corresponding one of the plurality of spacers, wherein the nozzle wall component includes a non-circular outer perimeter defined at least in part by arcs, wherein adjacent arcs intersect at intersection points, the non-circular outer perimeter being formed by removing material between each pair of spacer holes in the plurality of spacer holes as compared to a circular perimeter nozzle wall component, and wherein adjacent arcs intersect along each of radial lines from a central axis of the nozzle wall member to an axis of a corresponding one of the plurality of spacer holes.

2. The turbocharger according to claim 1, wherein: The arc is a circular arc.

3. The turbocharger according to claim 1, wherein: The arc is an elliptical arc.

4. The turbocharger according to claim 1, wherein: The plurality of spacers includes three spacers.

5. The turbocharger according to claim 1, wherein: The plurality of spacer holes includes three spacer holes.

6. The turbocharger according to claim 1, wherein: The nozzle wall member is formed by forging.

7. The turbocharger according to claim 6, wherein: The nozzle wall component includes a shroud profile formed at least in part by machining.

8. The turbocharger according to claim 6, wherein: The plurality of spacer holes are at least partially formed by machining.

9. The turbocharger according to claim 6, wherein: The intersecting arcs are formed at least in part by machining.

10. The turbocharger according to claim 1, wherein: The axes of the plurality of spacer holes define a triangle.

11. The turbocharger according to claim 10, wherein: The triangle is an isosceles triangle.

12. The turbocharger according to claim 11, wherein: The triangle is an equilateral triangle.

13. The turbocharger according to claim 1, wherein: The non-circular outer periphery is a Lurox polygon.

14. The turbocharger according to claim 1, wherein: The chuck includes a vane disposed between the plate member and the nozzle wall member.

15. The turbocharger according to claim 1, wherein: The nozzle wall member is at least partially disposed within the turbine housing to define at least a portion of an exhaust volute.

16. The turbocharger according to claim 1, wherein: The turbine housing includes a wall at least partially defining a volute, wherein the wall includes a tongue.

17. The turbocharger according to claim 16, wherein: One of the plurality of spacers is positioned adjacent to the tongue.

18. The turbocharger according to claim 17, wherein: An azimuthal span from one of the spacers located adjacent to the tongue and an adjacent spacer in a counterclockwise or clockwise direction is different from an azimuthal span from the spacer located adjacent to the tongue and another adjacent spacer in a clockwise or counterclockwise direction.

19. The turbocharger according to claim 18, wherein: The sum of the azimuth angle spans is greater than 240 degrees.

Images