Turbocharger adjustable nozzle ring assembly with improved pneumatic actuator

Abstract

The turbocharger adjustable nozzle ring assembly with improved pneumatic actuator comprises: an adjustable nozzle ring structure, wherein an adjustable vane is arranged; a pneumatic actuator, wherein a driving rod is arranged on the pneumatic actuator, the driving rod extends into the adjustable nozzle ring structure for adjusting the opening degree of the adjustable vane; the pneumatic actuator comprises a first shell and a second shell which are detachably assembled together, the first shell and the second shell form an inner cavity after being assembled; and a gas nozzle is arranged on the first shell and partially extends into the inner cavity. The turbocharger adjustable nozzle ring assembly with improved pneumatic actuator can well adjust the opening pressure and working pressure range of the pneumatic actuator, the adjusting range is wide, the minimum opening degree of the nozzle ring can be controlled, the driving rod of the pneumatic actuator and the nozzle ring slider rod are integrated, the integration degree is high, and the cost is saved.

Description

Technical Field

[0001] This invention belongs to the field of turbocharger technology, specifically relating to an adjustable nozzle ring assembly for a turbocharger with an improved pneumatic actuator. Background Technology

[0002] A turbocharger is a device used to increase the amount of air entering an engine. It increases the density of the air intake by compressing air, thereby improving engine power and efficiency. It is commonly used in mid- to high-end cars.

[0003] Turbochargers with adjustable nozzle ring assemblies, also known as VNTs, are widely used. The adjustable nozzle ring assembly has uniformly rotating, ring-shaped adjustable blades. Rotating these blades adjusts the intake cross-section to regulate exhaust pressure. Correspondingly, an actuator unit, such as a pneumatic actuator, is required to adjust the blade rotation angle.

[0004] In the existing technology, the upper and lower housings of pneumatic actuators are not detachable after being riveted, and the working pressure range is fixed. When there is a major adjustment to the design of the booster nozzle ring drive pressure, it needs to be redeveloped, which is quite troublesome. Furthermore, when the existing pneumatic actuators are used in variable cross-section nozzle boosters, the minimum opening of the nozzle ring blades cannot be adjusted.

[0005] Based on the above situation, this application has further designed and studied the relevant structures. Summary of the Invention

[0006] To address the shortcomings of the existing technology, this invention provides a turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator. It is easy to disassemble, allows for rapid adjustment of the pneumatic actuator's opening and working pressure ranges with a wide adjustment range, and can control the minimum opening degree of the nozzle ring. Furthermore, the pneumatic actuator pull rod and the nozzle ring slider pull rod are integrated, resulting in high integration and cost savings.

[0007] The present invention is solved by the following technical solution.

[0008] A turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator includes: an adjustable nozzle ring structure having adjustable blades; a pneumatic actuator with a drive rod extending into the adjustable nozzle ring structure to adjust the opening of the adjustable blades; the pneumatic actuator includes a first housing and a second housing detachably assembled together, the first housing and the second housing forming an inner cavity after assembly; it also includes a nozzle disposed on the first housing and partially extending into the inner cavity; the drive rod extends into the inner cavity from one side of the second housing, the portion of the drive rod in the inner cavity having a piston, the piston having a spring on the side facing the second housing, at least one end of the spring having an adjusting shim; the piston having a diaphragm on the side facing the first housing, the diaphragm forming a sealed air chamber with the first housing, the inner end of the nozzle communicating with the air chamber; the nozzle is adjustable in its extension length into the inner cavity, thereby acting on the drive rod to adjust the extension length of the drive rod into the inner cavity.

[0009] The adjustable nozzle ring assembly in this application allows for convenient blade rotation adjustment via its pneumatic actuator, thereby controlling the airflow. Furthermore, the pneumatic actuator in this application features a two-part detachable assembly structure for its main housing, allowing for easy disassembly and replacement of the internal structure. Specifically, increasing the thickness of the adjusting shims adjusts the initial spring compression, and adjusting the insertion length of the air nozzle adjusts the insertion length of the drive rod. This also facilitates the replacement of springs with different elastic coefficients to better match the different operating conditions of the turbocharger.

[0010] In a preferred embodiment, the second housing is provided with a base, through which the pneumatic actuator is mounted to the housing of the adjustable nozzle ring structure, which is convenient to install and has a compact and robust structure.

[0011] In a preferred embodiment, the portion of the drive rod that extends into the adjustable nozzle ring structure is provided with an adjusting block. When the drive rod moves, the adjusting block drives the actuating disk to rotate, thereby realizing the rotation of the adjustable blade.

[0012] In a preferred embodiment, the first housing and the second housing are threaded together, making disassembly and assembly convenient.

[0013] In a preferred embodiment, the first housing is provided with an air nozzle nut, the air nozzle is threaded onto the air nozzle nut and partially extends into the inner cavity, and the length of extension can be easily adjusted by rotation.

[0014] In a preferred embodiment, the second housing is provided with a through hole through which the drive rod passes, and the inside of the through hole is provided with a guide shim and an adjusting shim.

[0015] In a preferred embodiment, a diaphragm gasket is provided on the side of the diaphragm facing the first housing to provide protection.

[0016] In a preferred embodiment, the diaphragm has a central structure covering part or all of the outer surface of the piston and a pleated peripheral structure.

[0017] In a preferred embodiment, the outer peripheral structure includes a first bent portion, a second bent portion, and an outer peripheral end. The first bent portion is located in the gap between the piston and the inner cavity wall to provide deformation allowance. The second bent portion is matched with a protruding structure on the second housing, making it difficult to detach. The outer peripheral end is placed in a recessed structure on the second housing to improve the firmness after assembly.

[0018] In a preferred embodiment, a sealing gasket is provided at the outer peripheral end structure to provide sealing performance.

[0019] Compared with the prior art, the present invention has the following advantages: it provides a turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator, wherein the pneumatic actuator can adjust the spring compression by adjusting the number of shims, and it is also convenient to replace springs with different elastic coefficients, thereby adjusting the opening pressure and working pressure range of the pneumatic actuator, with a wide adjustment range; and the position of the nozzle ring pull rod can be controlled by adjusting the screw depth of the air nozzle, thereby controlling the minimum opening of the nozzle ring; at the same time, the pneumatic actuator pull rod and the nozzle ring slider pull rod are integrated, with high integration and cost savings. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the adjustable nozzle ring assembly for a turbocharger in this invention.

[0021] Figure 2 This is a cross-sectional view of the adjustable nozzle ring assembly of the turbocharger in this invention.

[0022] Figure 3 The three-dimensional pneumatic actuator of the present invention Figure 1 .

[0023] Figure 4 The three-dimensional pneumatic actuator of the present invention Figure 2 .

[0024] Figure 5 This is a cross-sectional view of the pneumatic actuator in this invention.

[0025] Figure 6 for Figure 5 Enlarged view of region A in the middle.

[0026] Figure 7 Three-dimensional view of the internal structure of pneumatic actuators Figure 1 .

[0027] Figure 8 Three-dimensional view of the internal structure of pneumatic actuators Figure 2 .

[0028] Figure 9 This is a three-dimensional view of the nozzle structure in a pneumatic actuator.

[0029] Figure 10 This is a 3D view of the air nozzle in a pneumatic actuator.

[0030] Figure 11 This is a three-dimensional view of the diaphragm in a pneumatic actuator.

[0031] Figure 12 The difference in actuator characteristic curves for different initial pressure springs with the same K value.

[0032] Figure 13 The difference in spring K value for the same initial pressure is reflected in the actuator characteristic curve. Detailed Implementation

[0033] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0034] In the following embodiments, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0035] In the description of this invention, it should be understood that terms such as center, longitudinal, transverse, length, width, thickness, upper, lower, front, rear, left, right, vertical, horizontal, top, bottom, inner, outer, clockwise, counterclockwise, etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing and simplifying the description of this invention; therefore, they should not be construed as limiting this invention. Furthermore, terms such as first, second, etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features shown. In the description of this invention, unless otherwise expressly specified and limited, terms such as installation, connection, linking, etc., should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0036] See Figures 1 to 13This application relates to a turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator, comprising: an adjustable nozzle ring structure 1, wherein the adjustable nozzle ring structure 1 is provided with an adjustable blade 11; a pneumatic actuator 2, wherein the pneumatic actuator 2 is provided with a drive rod 4, the drive rod 4 extending into the adjustable nozzle ring structure 1 for adjusting the opening degree of the adjustable blade 11; the pneumatic actuator 2 includes a first housing 21 and a second housing 22 that are detachably assembled together, the first housing 21 and the second housing 22 forming an inner cavity after assembly, specifically, the first housing 21 and the second housing 22 are threaded together, making disassembly and assembly convenient. It also includes an air nozzle 3, which is disposed on the first housing 21 and partially extends into the inner cavity; a drive rod 4 extends into the inner cavity from one side of the second housing 22, and the portion of the drive rod 4 located in the inner cavity is provided with a piston 38 and is positioned by a axial retaining ring 32. A spring 44 is provided on the side of the piston 38 facing the second housing 22, and at least one end of the spring 44 is provided on an adjusting shim 43; a diaphragm 36 is provided on the side of the piston 38 facing the first housing 21, and a sealed air cavity is formed between the diaphragm 36 and the first housing 21, and the inner end 31 of the air nozzle 3 communicates with the air cavity; the length of the air nozzle 3 extending into the inner cavity can be adjusted, thereby acting on the drive rod 4 to adjust the length of the drive rod 4 extending into the inner cavity.

[0037] As can be seen from the accompanying drawings, in this application, the second housing 22 is provided with a base 221, through which the pneumatic actuator 2 is mounted to the housing of the adjustable nozzle ring structure 1. This installation is convenient, and the structure is compact and robust. The portion of the drive rod 4 that extends into the adjustable nozzle ring structure 1 is provided with an adjusting block 41. When the drive rod 4 moves, the adjusting block 41 drives the actuating disk to rotate, thereby realizing the rotation of the adjustable blade 11.

[0038] Furthermore, in this application, the first housing 21 is provided with a valve nut 312, and the valve 3 is threaded onto the valve nut 312 and partially extends into the inner cavity. The length of the extension can be easily adjusted by rotation. The second housing 22 is provided with a through hole for the drive rod 4 to pass through. The inner side of the through hole is provided with a guide washer 42 and an adjusting washer 43.

[0039] From the appendix Figure 5 and attached Figure 6 As can be seen from the above, in this application, the diaphragm 36 has a diaphragm gasket 35 on the side facing the first housing 21, which serves a protective function. The diaphragm 36 has a central structure 367 covering part or all of the outer surface of the piston 38 and a pleated outer peripheral structure.

[0040] Specifically, from the appendix Figure 6As can be seen, the outer peripheral structure includes a first bend 361, a second bend 362, and an outer peripheral end 363. The first bend 361 is located in the gap between the piston 38 and the inner cavity wall to provide deformation allowance. The second bend 362 fits onto the protruding structure 226 on the second housing 22, making it difficult to detach. The outer peripheral end 363 is placed in the recessed structure on the second housing 22, improving the firmness after assembly. A sealing gasket 37 is provided at the outer peripheral end 363 to provide sealing performance.

[0041] The technical solution in this application designs the traditional pneumatic actuator as a detachable type. The first housing 21 and the second housing 22 are fixed by threads, forming a sealed cavity with the diaphragm gasket 35, the sealing gasket 37, and the diaphragm 36. When an external air source enters this area through the air nozzle 3, air pressure is generated. After the gas pressure acts on the diaphragm 36, it begins to interact with the spring force. When the gas force is greater than the spring force, the spring is compressed; otherwise, the spring rebounds, thereby moving the drive rod 4. The drive rod 4 is integrated with the traditional nozzle ring pull rod into the same rod, with no connecting structure in the middle, resulting in a compact structure.

[0042] When the booster requires an increase in the opening pressure of the pneumatic actuator, since the length of the drive rod is fixed, the shaft retaining ring 32 fixes the maximum position of the diaphragm gasket 35, diaphragm 36 and piston 38. Increasing the number of adjusting shims 43 can shorten the spring installation space distance and increase the spring compression. At this time, the pre-compression force of the spring increases, which requires the gas pressure at which the spring begins to compress to also increase, that is, the opening pressure of the pneumatic actuator increases.

[0043] Similarly, when the number of adjusting shims 43 is reduced, the opening pressure decreases, and the overall working pressure range of the actuator shifts to the left (the overall working pressure decreases). The working pressure range of the pneumatic actuator can be adjusted by replacing the spring with a different spring coefficient (k). If the working pressure range of the pneumatic actuator needs to be increased, replace it with a spring with a larger spring coefficient; otherwise, the operation is reversed.

[0044] In this application, by integrating the nozzle ring pull rod with the drive rod, when it is necessary to adjust the minimum opening range of the nozzle ring blades, the nozzle can be moved by changing the screw depth of the nozzle to push the drive rod, and the drive rod can push the nozzle ring fork to change the blade angle and adjust the flow range of the nozzle ring.

[0045] The specific principle is as follows.

[0046] The working characteristic curve of a pneumatic actuator is essentially a curve relating spring compression to force, with the slope of the curve being the spring force coefficient k. The force generated by the zero-position gas pressure of the pneumatic actuator is equal to the pre-compression pressure of the spring, and the force generated by the maximum gas pressure of the pneumatic actuator corresponds to the spring force when the spring is at its maximum effective compression (the spring force coefficient k is fixed when the spring is effectively compressed).

[0047] By changing the number of adjusting shims, the pre-compression of the spring is changed, thereby adjusting the initial spring force. At this time, the air pressure value required to balance the pre-compression force of the spring changes. Since the blade opening range is fixed, that is, the actuator working stroke is fixed, the size of the actuator working pressure area is fixed. By adjusting the spring pre-compression, the position of the working pressure area on the actuator characteristic curve is changed.

[0048] When the existing pneumatic actuator characteristic curve cannot meet the requirements, the characteristic curve parameters of the actuator can be changed by replacing the spring with a different spring force coefficient (k). When the spring force coefficient changes, the spring force corresponding to the same compression amount also changes (spring force = spring force coefficient k * deformation). The corresponding manifestation in the pneumatic actuator air pressure is as follows: when the spring force coefficient increases, because the nozzle ring stroke is fixed, that is, the spring deformation is fixed, the spring force increases after the k value increases, and the corresponding actuator working pressure range increases.

[0049] When adjusting the minimum flow of the nozzle ring, the nozzle insertion depth is adjusted. At this point, the nozzle, pressing against the gasket, pushes the piston, causing the drive rod to move to the left, increasing the blade opening angle and thus expanding the nozzle ring flow range. Similarly, when the nozzle retracts, the spring causes the drive rod to move to the right, decreasing the blade opening and reducing flow. Simultaneously, a notch is cut into the nozzle thread to avoid excessive gas flow resistance due to insufficient gas flow cross-section after the nozzle end face contacts the gasket, which would affect the actuator's working pressure. After adjusting the nozzle insertion depth, the nozzle nut is tightened to prevent loosening and subsequent changes in the minimum flow of the nozzle ring.

[0050] Specifically, Figure 12 The figure shows the difference in actuator characteristic curves when the spring K value is the same for different initial pressures. That is, the same spring can be used to obtain different initial pressures by adjusting the number of shims 43, resulting in different pressure-stroke ranges. Figure 13 The figure shows the difference in actuator characteristic curves for springs with the same initial pressure but different K values. In other words, springs with different K values ​​can achieve different pressure-stroke ranges.

[0051] As described above, this invention provides a turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator. The pneumatic actuator can adjust the spring compression by adjusting the number of shims, and it is also convenient to replace springs with different elastic coefficients, thereby adjusting the opening pressure and working pressure range of the pneumatic actuator, with a wide adjustment range. Furthermore, the position of the nozzle ring pull rod can be controlled by adjusting the screw depth of the air nozzle, thereby controlling the minimum opening of the nozzle ring. At the same time, the pneumatic actuator pull rod and the nozzle ring slider pull rod are integrated, resulting in high integration and cost savings.

[0052] The scope of protection of this invention includes, but is not limited to, the above embodiments. The scope of protection of this invention is defined by the claims. Any substitutions, modifications, or improvements to this technology that are easily conceived by those skilled in the art fall within the scope of protection of this invention.

Claims

1. A turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator, comprising: An adjustable nozzle ring structure (1) is provided with an adjustable blade (11). A pneumatic actuator (2) is provided with a drive rod (4), which extends into an adjustable nozzle ring structure (1) to adjust the opening of the adjustable blade (11); Its features are: The pneumatic actuator (2) includes a first housing (21) and a second housing (22) that are detachably assembled together, and the first housing (21) and the second housing (22) form an inner cavity after assembly; It also includes an air nozzle (3), which is disposed on the first housing (21) and partially extends into the inner cavity; The drive rod (4) extends into the inner cavity from one side of the second housing (22). The portion of the drive rod (4) located in the inner cavity is provided with a piston (38). The piston (38) is provided with a spring (44) on the side facing the second housing (22). At least one end of the spring (44) is provided on the adjusting shim (43). The piston (38) has a diaphragm (36) on the side facing the first housing (21), and a sealed air chamber is formed between the diaphragm (36) and the first housing (21), and the inner end (31) of the air nozzle (3) is connected to the air chamber; The air nozzle (3) can be adjusted to extend into the inner cavity, thereby acting on the drive rod (4) to adjust the length of the drive rod (4) extending into the inner cavity.

2. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 1, characterized in that, The second housing (22) is provided with a base (221), through which the pneumatic actuator (2) is mounted to the housing of the adjustable nozzle ring structure (1).

3. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 1, characterized in that, The part of the drive rod (4) that extends into the adjustable nozzle ring structure (1) is provided with an adjustment block (41). When the drive rod (4) moves, the adjustment block (41) drives the dial to rotate, thereby realizing the rotation of the adjustable blade (11).

4. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 1, characterized in that, The first housing (21) and the second housing (22) are threaded together.

5. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 1, characterized in that, The first housing (21) is provided with a nozzle nut (312), and the nozzle (3) is threaded onto the nozzle nut (312) and partially extends into the inner cavity.

6. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 1, characterized in that, The second housing (22) is provided with a through hole through which the drive rod (4) passes, and a guide pad (42) and an adjusting pad (43) are provided on the inner side of the through hole.

7. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 1, characterized in that, The diaphragm (36) has a diaphragm gasket (35) on the side facing the first housing (21).

8. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to any one of claims 1 to 7, characterized in that, The diaphragm (36) has a central structure (367) covering part or all of the outer surface of the piston (38) and a peripheral structure with pleats.

9. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 8, characterized in that, The outer peripheral structure includes a first bend (361), a second bend (362), and an outer peripheral end (363). The first bend (361) is located in the gap between the piston (38) and the inner cavity wall to provide deformation allowance. The second bend (362) is matched on the protrusion (226) on the second housing (22), and the outer peripheral end (363) is placed in the recessed structure on the second housing (22).

10. The turbocharger adjustable nozzle ring assembly with an improved pneumatic actuator according to claim 9, characterized in that, A sealing gasket (37) is provided at the outer peripheral end (363) structure.

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