Variable turbine geometry assembly and turbocharger

Abstract

A variable turbine geometry assembly for controlling exhaust gas flow to a turbine wheel of a turbocharger includes an adjustment ring extending about an axis and rotatable about the axis, at least one blade rod coupled to the adjustment ring, and at least one blade coupled to the at least one blade rod. The at least one vane is movable relative to the adjustment ring when the adjustment ring rotates about the axis. The variable turbine geometry assembly also includes a wave spring in operable contact with at least one of the at least one vane rod and the adjustment ring. The wave spring is configured to bias one of the at least one vane rod and the adjustment ring toward the other of the at least one vane rod and the adjustment ring.

Description

Technical Field

[0001] The utility model generally relates to a variable turbine geometry assembly for controlling the exhaust gas flow to a turbine wheel of a turbocharger and a turbocharger. Background Art

[0002] A turbocharger receives exhaust gas from an internal combustion engine and delivers compressed air to the internal combustion engine. A turbocharger is used to increase the power output of an internal combustion engine, reduce the fuel consumption of the internal combustion engine, and reduce the emissions produced by the internal combustion engine. Delivering compressed air to the internal combustion engine via the turbocharger allows the internal combustion engine to be smaller, yet be able to produce the same or similar amount of horsepower as a larger, naturally aspirated internal combustion engine. Using a smaller internal combustion engine in a vehicle reduces the mass and aerodynamic frontal area of ​​the vehicle, which helps reduce the fuel consumption of the internal combustion engine and improves the fuel economy of the vehicle.

[0003] A typical turbocharger includes a turbine housing defining an interior of the turbine housing, a turbine impeller arranged in the interior of the turbine housing for receiving exhaust gas from an internal combustion engine, and a shaft coupled to the turbine impeller and rotatable by the turbine impeller. A typical turbocharger also includes a compressor housing defining an interior of a compressor housing, and a compressor impeller arranged in the interior of the compressor housing and coupled to the shaft, the compressor impeller being rotatable by the shaft so as to deliver compressed air to the internal combustion engine. Specifically, energy from the exhaust gas of the internal combustion engine (which would normally be wasted energy) is used to rotatably drive the turbine impeller, which is used to rotatably drive the shaft and in turn rotatably drive the compressor impeller to compress air and deliver the compressed air to the internal combustion engine.

[0004] Typically, a turbocharger includes a variable turbine geometry assembly arranged around a turbine wheel. It is known that the variable turbine geometry assembly controls the exhaust gas flow to the turbine wheel of the turbocharger. However, variable turbine geometry assemblies known in the art fail due to repeated wear on the various components of the variable turbine geometry assembly caused by vibrations between the various components of the variable turbine geometry assembly. Wear on the components of the variable turbine geometry assembly caused by vibrations between the different components of the variable turbine geometry assembly can lead to increased noise, even further increased vibrations, and increased acoustic vibration harshness (NVH) of the turbocharger. In addition, wear on the components may also lead to functional failure of the variable turbine geometry assembly, resulting in the variable turbine geometry assembly being unable to adequately control the exhaust gas flow to the turbine wheel of the turbocharger.

[0005] Therefore, there remains a need for an improved variable turbine geometry assembly for a turbocharger. Utility Model Content

[0006] A variable turbine geometry assembly for controlling exhaust flow to a turbine wheel of a turbocharger includes an adjustment ring extending about an axis and rotatable about the axis. The variable turbine geometry assembly also includes at least one blade rod coupled to the adjustment ring and at least one blade coupled to the at least one blade rod. The at least one blade is movable relative to the adjustment ring, wherein the adjustment ring rotates about the axis. The variable turbine geometry assembly also includes a wave spring operably contacting at least one of the at least one blade rod and the adjustment ring. The wave spring is configured to bias one of the at least one blade rod and the adjustment ring toward the other of the at least one blade rod and the adjustment ring.

[0007] By configuring the wave spring to bias one of the at least one blade rod and the adjustment ring toward the other of the at least one blade rod and the adjustment ring, vibrations between the adjustment ring and the at least one blade rod are reduced. The reduced vibrations between the adjustment ring and the at least one blade rod reduce wear between different components of the variable turbine geometry assembly. More specifically, the reduced vibrations between the adjustment ring and the at least one blade rod reduce wear on the adjustment ring and the at least one blade rod. The reduced wear on the adjustment ring and the at least one blade rod further reduces noise, vibration and harshness (NVH) of the turbocharger and reduces the likelihood of functional failure of the variable turbine geometry assembly, thereby properly controlling the exhaust gas flow to the turbine wheel of the turbocharger. In addition, the wave spring provides a simple, cost-effective and durable solution while achieving the above advantages. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present invention will be readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:

[0009] Figure 1 is a cross-sectional view of a turbocharger including a turbine housing defining a turbine housing interior, a turbine wheel disposed in the turbine housing interior, a variable turbine geometry assembly disposed about the turbine wheel, a shaft rotatably coupled to the turbine wheel, a compressor housing defining a compressor housing interior, and a compressor wheel disposed in the compressor housing interior and rotatably coupled to the shaft;

[0010] Figure 2is a perspective view of a variable turbine geometry assembly according to one embodiment, wherein the variable turbine geometry assembly includes an adjustment ring, at least one blade rod, at least one blade, a first blade ring, a second blade ring, and a wave spring disposed between the adjustment ring and the first blade ring;

[0011] Figure 3 is a perspective view of a variable turbine geometry assembly according to another embodiment, wherein the wave spring is a single turn wave spring;

[0012] Figure 4 is a perspective view of a variable turbine geometry assembly according to another embodiment, the variable turbine geometry assembly including a wave spring, the wave spring being a single turn wave spring, and the single turn wave spring extending between a first circumferential end and a second circumferential end and having a gap circumferentially defined between the first circumferential end and the second circumferential end;

[0013] Figure 5 is a perspective view of a variable turbine geometry assembly according to another embodiment, the variable turbine geometry assembly including a wave spring, the wave spring being a single-turn wave spring, and a first circumferential end of the single-turn wave spring overlapping a second circumferential end of the single-turn wave spring;

[0014] Figure 6 is a perspective view of a variable turbine geometry assembly according to another embodiment, the variable turbine geometry assembly including a wave spring that is a nested wave spring;

[0015] Figure 7 is a perspective view of a variable turbine geometry assembly according to another embodiment, the variable turbine geometry assembly including a wave spring, the wave spring being a multi-turn wave spring;

[0016] Figure 8 is a perspective view of a variable turbine geometry assembly according to another embodiment, the variable turbine geometry assembly including a wave spring including a shim in operative contact with the at least one vane rod;

[0017] Fig. 9 yes Figure 2 a cross-sectional view of an adjustment ring, at least one blade rod, at least one blade, a first blade ring, and a wave spring;

[0018] Fig.10 is a cross-sectional view of an adjustment ring, at least one blade rod, at least one blade, and a wave spring, wherein the at least one blade rod includes an axial stop; and

[0019] Fig.11is a cross-sectional view of the adjustment ring, at least one blade rod, at least one blade, and a wave spring, wherein the at least one blade rod has a contact surface that is axially retracted to seat the wave spring. DETAILED DESCRIPTION

[0020] Referring to the drawings, wherein like reference numerals represent like parts throughout the several views, Figure 1-11 1 shows a variable turbine geometry assembly 10 for controlling the exhaust gas flow to the turbine wheel 12 of the turbocharger 14. The variable turbine geometry assembly 10 includes an adjustment ring 16 extending about an axis A1 and rotatable about the axis A1. The variable turbine geometry assembly 10 also includes at least one vane rod 18 coupled to the adjustment ring 16, and the variable turbine geometry assembly 10 includes at least one vane 20 coupled to the at least one vane rod 18. When the adjustment ring 16 rotates about the axis A1, the at least one vane 20 is movable relative to the adjustment ring 16. The variable turbine geometry assembly 10 also includes a wave spring 22, which is operably in contact with at least one of the at least one vane rod 18 and the adjustment ring 16. In other words, the wave spring 22 is operably in contact with at least one vane rod 18, the adjustment ring 16, or both of the at least one vane rod 18 and the adjustment ring 16. The wave spring 22 is configured to bias one of the at least one vane rod 18 and the adjustment ring 16 toward the other of the at least one vane rod 18 and the adjustment ring 16. In other words, the wave spring 22 is configured to bias the at least one blade rod 18 toward the adjustment ring 16 , or configured to bias the adjustment ring 16 toward the at least one blade rod 18 .

[0021] The wave spring 22 is configured to bias one of the at least one vane rod 18 and the adjustment ring 16 toward the other of the at least one vane rod 18 and the adjustment ring 16, thereby reducing vibrations between the adjustment ring 16 and the at least one vane rod 18. In other words, the wave spring 22 may be configured to reduce vibrations between the adjustment ring 16 and the at least one vane rod 18. Thus, the reduced vibrations between the adjustment ring 16 and the at least one vane rod 18 reduce wear between different components of the variable turbine geometry assembly 10. More specifically, the reduced vibrations between the adjustment ring 16 and the at least one vane rod 18 reduce wear on the adjustment ring 16 and the at least one vane rod 18. The reduced wear on the adjustment ring 16 and the at least one vane rod 18 further reduces noise, vibration and harshness (NVH) of the turbocharger 14, and reduces the likelihood of functional failure of the variable turbine geometry assembly 10, which properly controls the exhaust gas flow to the turbine wheel 12 of the turbocharger 14. Furthermore, the wave spring 22 provides a simple, cost-effective, and durable solution while achieving the above-mentioned advantages.

[0022] The variable turbine geometry assembly 10 may further include a first blade ring 82 extending about the axis A1, and the variable turbine geometry assembly 10 may further include a second blade ring 84 extending about the axis A1. The second blade ring 84 may be spaced apart from the first blade ring 82 such that at least one blade 20 is disposed between the first blade ring 82 and the second blade ring 84. When the adjustment ring 16 rotates about the axis A1, the first blade ring 82 and the second blade ring 84 support movement of the at least one blade 20.

[0023] In one embodiment, Figure 2 and Fig. 9 As shown, the wave spring 22 is arranged between the adjustment ring 16 and at least one blade 20. In addition, the wave spring 22 can be arranged between the adjustment ring 16 and the first blade ring 82. The wave spring 22 can be in direct contact with the first blade ring 82. However, it should be understood that the wave spring 22 does not need to be in direct contact with the first blade ring 82. The wave spring 22 can only be in operative contact with the first blade ring 82. As such, additional components arranged between the wave spring 22 and the first blade ring 82 can be included. In addition, the wave spring 22 can be in direct contact with the adjustment ring 16. However, it should be understood that the wave spring 22 does not need to be in direct contact with the adjustment ring 16. The wave spring 22 can only be in operative contact with the adjustment ring 16. In this way, additional components arranged between the wave spring 22 and the adjustment ring 16 can be included.

[0024] The wave spring 22 may be in direct contact with at least one blade rod 18, such as Figure 3-8 , 10 and 11. However, it should be understood that the wave spring 22 need not be in direct contact with the at least one blade rod 18. The wave spring 22 may only be in operable contact with the at least one blade rod 18. As such, additional components disposed between the wave spring 22 and the at least one blade rod 18 may be included. Even for these embodiments having additional components disposed between the wave spring 22 and the at least one blade rod 18, vibrations between the adjustment ring 16 and the at least one blade rod 18 are reduced.

[0025] The wave spring 22 may include at least one peak 24 extending away from the adjustment ring 16. The wave spring 22 may also include at least one valley 26 extending toward the adjustment ring 16. It is understood that the wave spring 22 may include at least two peaks 24 extending away from the adjustment ring 16 and at least two valleys 26 extending toward the adjustment ring 16. In addition, the wave spring 22 may include at least three peaks 24 extending away from the adjustment ring 16 and at least three valleys 26 extending toward the adjustment ring 16.

[0026] like Figure 2 and Fig. 9As shown, at least one valley 26 can be in direct contact with the adjustment ring 16. However, it should be understood that at least one valley 26 does not need to be in direct contact with the adjustment ring 16. At least one valley 26 can only be in operative contact with the adjustment ring 16. In this way, additional components arranged between at least one valley 22 and the adjustment ring 16 can be included. In addition, at least one valley 22 can extend toward the first blade ring 82, and at least one valley 22 can be in direct contact with the first blade ring 82. It can be understood that at least one valley 26 does not need to be in direct contact with the first blade ring 82. At least one valley 26 can only be in operative contact with the first blade ring 82. As such, additional components arranged between at least one valley 22 and the first blade ring 82 can be included.

[0027] Although not required, Figure 3-8 , Fig.10 and Fig.11 As shown, at least one valley 26 can extend toward at least one blade rod 18 and can be operably contacted with at least one blade rod 18. At least one valley 26 can be in direct contact with at least one blade rod 18. However, at least one valley 26 need not be in direct contact with at least one blade rod 18. At least one valley 26 only needs to be in operably contact with at least one blade rod 18. As such, additional components disposed between at least one valley 26 and at least one blade rod 18 can be included. Figure 8 As shown, the wave spring 22 may include a shim 28 coupled to at least one valley 26, and the shim 28 may be in operative contact with at least one blade rod 18. The shim 28 may be in direct contact with the at least one blade rod 18. However, the shim 28 need not be in direct contact with the at least one blade rod 18. The shim 28 only needs to be in operative contact with the at least one blade rod 18. As such, additional components disposed between the shim 28 and the at least one blade rod 18 may be included.

[0028] The at least one blade rod 18 may be further defined as a plurality of blade rods 18. Furthermore, the at least one blade 20 may be further defined as a plurality of blades 20. It should be understood that the wave spring 22 may be operably in contact with at least two of the plurality of blade rods 18. In other words, the wave spring 22 may be operably in contact with two of the blade rods 18, three of the blade rods 18, four of the blade rods 18, five of the blade rods 18, six of the blade rods 18, seven of the blade rods 18, eight of the blade rods 18, up to all of the blade rods 18 included in the variable turbine geometry assembly 10. Furthermore, the wave spring 22 may be operably in contact with at least three blade rods 18. In other words, the wave spring 22 may be operably in contact with three of the blade rods 18, four of the blade rods 18, five of the blade rods 18, six of the blade rods 18, seven of the blade rods 18, eight of the blade rods 18, up to all of the blade rods 18 included in the variable turbine geometry assembly 10.

[0029] Although not required, Figure 2-8 As shown, the wave spring 22 can extend around most of the circumference of the adjustment ring 16. The wave spring 22 extending around most of the circumference of the adjustment ring 16 increases the stability of the wave spring 22 and allows the wave spring 22 to operably contact more than one blade rod 18. In a non-limiting example, the wave spring 22 can operably contact two, three, four, five, six, seven, eight or more blade rods 18.

[0030] The wave spring 22 may be in operable contact with the blade rods 18 that are circumferentially adjacent to each other around the axis A1. Alternatively, the wave spring 22 may not be in operable contact with one or more blade rods 18 that are circumferentially arranged between the blade rods 18, and the wave spring 22 is in operable contact with the blade rod 18. As a non-limiting example, when the wave spring 22 extends circumferentially around the axis A1, the wave spring 22 may alternate between being in operable contact with the blade rod 18 and not being in operable contact with the blade rod 18.

[0031] In one embodiment, Figure 3-5 As shown, the wave spring 22 is further defined as a single-turn wave spring 30. Although not required, the single-turn wave spring 30 can extend between a first circumferential end 32 and a second circumferential end 34. Figure 4 As shown, a gap 36 may be circumferentially defined between a first circumferential end 32 of the single-turn wave spring 30 and a second circumferential end 34 of the single-turn wave spring 30. Alternatively, as shown in FIG. Figure 5As shown, the first circumferential end 32 of the single-turn wave spring 22 can overlap with the second circumferential end 34 of the single-turn wave spring 22. However, it should also be understood that the single-turn wave spring 30 can extend completely around the axis A1 and thus have no circumferential ends, such as Figure 3 In another embodiment, as shown. Figure 7 and Figure 8 As shown, the wave spring 22 is further defined as a multi-turn wave spring 38. In another embodiment, as shown in FIG. Figure 6 As shown, the wave spring 22 is further defined as a nested wave spring 40 .

[0032] The at least one blade rod 18 may have a contact surface 42 facing away from the adjustment ring 16. The wave spring 22 may be operably in contact with the contact surface 42 of the at least one blade rod 18 to reduce vibration between the adjustment ring 16 and the at least one blade rod 18. Although not required, the contact surface 42 of the at least one blade rod 18 may be axially recessed into the at least one blade rod 18 to seat the wave spring 22. Seating the wave spring 22 further increases the stability of the wave spring 22 relative to the adjustment ring 16. Additionally, seating the wave spring 22 prevents the wave spring 22 from rotating relative to the at least one blade rod 18 about the axis A1, thereby ensuring that a desired portion of the wave spring 22 (e.g., the valley 26) is in operably contact with the at least one blade rod 18.

[0033] The at least one blade rod 18 may have a first rod end 44 coupled to the adjustment ring 16 and a second rod end 46 defining a pin hole 48. The variable turbine geometry assembly 10 may further include a pin 50 disposed in the pin hole 48 defined by the second rod end 46 of the at least one blade rod 18. The at least one blade 20 may be coupled to the pin 50. When the adjustment ring 16 rotates about the axis A1, the at least one blade 20 may be movable relative to the adjustment ring 16. The at least one blade rod 18 may also have an inner rod surface 52 that faces the adjustment ring 16 and extends parallel to the adjustment ring 16, and the at least one blade rod 18 may have an axial stop 54 that extends axially away from the inner rod surface 52 toward the adjustment ring 16 and is configured to limit axial movement of the at least one blade rod 18. Although not required, the first rod end 44 may be fixed to the adjustment ring 16, and the second rod end 46 may be fixed to the pin 50.

[0034] At least one blade rod 18, including an axial stopper 54, which extends axially away from the inner rod surface 52 toward the adjustment ring 16 and is configured to limit the axial movement of the at least one blade rod 18, reduces the relative distance between the at least one blade rod 18 and the adjustment ring 16, thereby allowing the wave spring 22 to more easily reduce vibration between the at least one blade rod 18 and the adjustment ring 16 and thus reduce wear. Although not required, the axial stopper 54 may have a first stopper surface 56 facing the adjustment ring 16, a second stopper surface 58 facing the axis A1, and a third stopper surface 60 opposite the first stopper surface 56 and away from the axis A1.

[0035] like Figure 3-8 As shown, the variable turbine geometry assembly 10 may further include an adjustment protrusion 80 connected to and extending axially away from the adjustment ring 16. The adjustment protrusion 80 may be coupled to an actuator configured to move the adjustment protrusion 80 to rotate the adjustment ring 16 about the axis A1 and move at least one vane 20.

[0036] In addition, if Figure 1 As shown, the turbocharger 14 includes Figure 2-11 Variable turbine geometry assembly 10 is shown. The turbocharger 14 generally includes a shaft 62 extending along an axis A1 between a first shaft end 64 and a second shaft end 66, the second shaft end 66 being spaced apart from the first shaft end 64 along the axis A1. The turbocharger 14 also includes a turbine wheel 12 coupled to the first shaft end 64 of the shaft 62 and a compressor wheel 68 coupled to the second shaft end 66 of the shaft 62. The turbocharger 14 also includes a turbine housing 70 defining a turbine housing interior 72, wherein the turbine wheel 12 is disposed in the turbine housing interior 72, and a compressor housing 74 defining a compressor housing interior 76, wherein the compressor wheel 68 is disposed in the compressor housing interior 76. The turbine housing 70 may be further defined as a double volute turbine housing 78.

[0037] The utility model has been described in an exemplary manner, and it should be understood that the terms used are intended to have the nature of description rather than limitation. According to the above teachings, many modifications and variations of the utility model are possible, and the utility model can be implemented in a manner different from that specifically described.

Claims

1. A variable turbine geometry assembly for controlling the exhaust gas flow to a turbine wheel of a turbocharger, characterized in that: The variable turbine geometry assembly comprises: an adjustment ring extending about an axis, the adjustment ring being rotatable about the axis; at least one blade rod coupled to the adjustment ring; at least one blade coupled to the at least one blade rod, wherein the at least one blade is movable relative to the adjustment ring when the adjustment ring is rotated about the axis; and A wave spring is operably contacted with at least one of the at least one blade rod and the adjustment ring, wherein the wave spring is configured to bias one of the at least one blade rod and the adjustment ring toward the other of the at least one blade rod and the adjustment ring.

2. The variable turbine geometry assembly of claim 1, wherein: The wave spring is disposed between the adjustment ring and the at least one blade.

3. The variable turbine geometry assembly of claim 1, wherein: The variable turbine geometry assembly also includes a first blade ring extending about the axis and a second blade ring extending about the axis, wherein the second blade ring is spaced apart from the first blade ring such that the at least one blade is disposed between the first blade ring and the second blade ring.

4. The variable turbine geometry assembly of claim 3, wherein: The wave spring is arranged between the adjustment ring and the first blade ring.

5. The variable turbine geometry assembly of claim 3, wherein: The wave spring is in direct contact with the first blade ring.

6. The variable turbine geometry assembly of claim 5, wherein: The wave spring is in direct contact with the adjustment ring.

7. The variable turbine geometry assembly of claim 1, wherein: The wave spring is in direct contact with the adjustment ring.

8. The variable turbine geometry assembly of claim 1, wherein: The wave spring is configured to reduce vibrations between the adjustment ring and the at least one blade stem.

9. The variable turbine geometry assembly of claim 1, wherein: The wave spring includes at least one peak extending away from the adjustment ring and at least one valley extending toward the adjustment ring.

10. The variable turbine geometry assembly of claim 9, wherein: The wave spring includes at least three peaks extending away from the adjustment ring and at least three valleys extending toward the adjustment ring.

11. The variable turbine geometry assembly of claim 9, wherein: The at least one valley is in direct contact with the adjustment ring.

12. The variable turbine geometry assembly of claim 9, wherein: The variable turbine geometry assembly also includes a first blade ring extending about the axis and a second blade ring extending about the axis, wherein the second blade ring is spaced apart from the first blade ring such that the at least one blade is arranged between the first blade ring and the second blade ring, wherein the at least one valley extends toward the first blade ring and is in direct contact with the first blade ring.

13. The variable turbine geometry assembly of claim 1, wherein: The wave spring is selected from a single-turn wave spring, a multi-turn wave spring and a nested wave spring.

14. The variable turbine geometry assembly of claim 1, wherein: The wave spring is in direct contact with the at least one blade rod.

15. The variable turbine geometry assembly of claim 1, wherein: The at least one blade rod is further defined as a plurality of blade rods, wherein the at least one blade is further defined as a plurality of blades, and wherein the wave spring is in operative contact with at least three of the plurality of blade rods.

16. A turbocharger comprising the variable turbine geometry assembly of claim 1 and further comprising, a shaft extending along the axis between a first shaft end and a second shaft end, the second shaft end being spaced apart from the first shaft end along the axis; a turbine wheel coupled to the first shaft end of the shaft; a compressor impeller coupled to the second shaft end of the shaft; as well as A turbine housing defines a turbine housing interior, wherein the turbine wheel is disposed in the turbine housing interior.

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