Wastegate actuator mechanism of a turbocharger wastegate system
Patent Information
- Application Number
- DE202020006142
- Authority / Receiving Office
- DE · DE
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2020-10-27
- Publication Date
- 2025-09-04
- Estimated Expiration
- 2030-10-31
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a wastegate actuator mechanism configured for use in a wastegate system of a turbocharger. The present invention also relates to various components configured to be included in a wastegate actuator mechanism, in particular a connecting plate and a pin, as well as a bushing configured to be pressed into an eye of the connecting plate and a sleeve configured to be disposed on the pin. BACKGROUND OF THE INVENTION
[0002] In the field of internal combustion engines, the use of a turbocharger to increase engine efficiency and power output by creating a forced air supply to the engine is known. The turbocharger includes a turbine wheel configured to rotate under the influence of an exhaust flow from the engine. The turbocharger further includes a compressor wheel coupled to the turbine wheel for co-rotation with the turbine wheel. The compressor wheel is disposed in an air path in which air is drawn in, compressed as the compressor wheel rotates, and exhausted to the engine.
[0003] In general, the higher the exhaust flow, the higher the boost pressure in the turbocharger. To regulate the boost pressure, the turbocharger is equipped with a wastegate system that provides a bypass path for the incoming exhaust flow and includes a valve disposed in the bypass path and a wastegate actuator mechanism for controlling the position of the valve. By adjusting the position of the valve using the wastegate actuator mechanism, the extent to which exhaust gas is allowed to bypass the compressor wheel is determined, thereby adjusting the amount of exhaust gas allowed to flow to the compressor wheel. The wastegate actuator system operates based on various control signals that include signals representative of the boost pressure in the turbocharger.
[0004] The present invention relates to the wastegate actuator mechanism comprising a lever plate coupled to the valve, an actuator disposed on a compressor housing of the turbocharger, and an elongated connecting plate extending from the actuator to the lever plate, wherein the connecting plate is coupled to the lever plate by engaging a pin fixed to the lever plate. In this configuration, the pin extends partially through an eye provided in the connecting plate, and the connecting plate and the pin are rotatable relative to each other about a rotation axis extending in the longitudinal direction of the pin. Therefore, the connecting plate and the pin are wear partners because they slide relative to each other at the position where the pin extends through the eye of the connecting plate.
[0005] Today's engine designs involve elevated exhaust temperatures, which increases the use of the wastegate actuator mechanism. Also, especially in cases where the turbocharger is mounted on a three-cylinder or four-cylinder engine, the influence of engine pulsations on the wastegate actuator mechanism is increased, which can induce micro-movements in the wastegate actuator mechanism. All in all, these factors contribute to wear at the sliding contact position between the pin and the connecting plate. SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to alleviate the situation of increased wear of the connecting plate and the pin in a practical manner without resorting to costly measures such as simply manufacturing the connecting plate and the pin from a more durable material.
[0007] Aspects of the present invention are set out in the appended independent and dependent claims. Features from the dependent claims may be combined with features from the respective independent claims as required, and not only as expressly set out in the claims and explained in the following description.
[0008] In view of the foregoing, the present invention provides a wastegate actuator mechanism configured to be used in a wastegate system of a turbocharger, wherein the wastegate actuator mechanism comprises an elongated connecting plate and a pin attached to a lever plate, wherein the pin extends partially through an eye provided in the connecting plate, and wherein the connecting plate and the pin are rotatable relative to each other about a rotation axis extending in the longitudinal direction of the pin, wherein the wastegate actuator mechanism further comprises a sliding assembly arranged between the connecting plate and the pin at the position of the eye of the connecting plate, wherein the sliding assembly comprises a bushing fixedly connected to the connecting plate and a sleeve fixedly connected to the pin,and wherein an inner surface of the bushing and an outer surface of the sleeve are in sliding contact, and wherein at an interface of the bushing and the connecting plate, the bushing is provided with recessed portions and bulges of material of the connecting plate are received in the recessed portions and / or at an interface of the sleeve and the pin, the sleeve is provided with recessed portions and bulges of material of the pin are received in the recessed portions.,
[0009] It follows from the above general definition of the wastegate actuator mechanism according to the present invention that the invention is functional at the position where the pin extends through the eye of the connecting plate. According to the present invention, intermediate components are provided at this position, namely a bushing and a sleeve, which form a sliding arrangement in which an inner surface of the bushing and an outer surface of the sleeve are in sliding contact, the bushing being received in the eye of the connecting plate and the sleeve being arranged on the pin. The present invention relates to the manner in which the bushing is fixedly connected to the connecting plate and / or the manner in which the sleeve is fixedly connected to the pin.In this regard, the present invention provides at least one of the following configurations: i) at an interface of the socket and the connecting plate, the socket is provided with depressed portions and protrusions of material of the connecting plate are received in the depressed portions, and ii) at an interface of the sleeve and the pin, the sleeve is provided with depressed portions and protrusions of material of the pin are received in the depressed portions.Therefore, the present invention provides a positive-locking configuration at the interface position of the bushing and the connecting plate and / or the interface position of the sleeve and the pin, while the sliding action that takes place between the connecting plate and the pin during operation of the wastegate system is shifted entirely to the interface of the bushing and the sleeve. An improvement in wear behavior can be achieved by selecting a suitable material with respect to the bushing and the sleeve, or at least their sliding contact surfaces. Due to the application of the invention, the firm connection of the bushing to the connecting plate and / or the sleeve to the pin is ensured and cannot be deteriorated under the influence of forces associated with the normal operation of the wastegate actuator mechanism, thus maintaining the advantage of improved wear behavior.
[0010] A practical way to achieve the desired form fit by receiving bulges of material from a first component in recessed sections of a second component is to provide the second component with the recessed sections and to select the shapes and dimensions of the respective components such that the first component is deformed in a process of fitting the second component into / onto the first component, wherein, in particular, material from the first component is forced to flow to the recessed sections of the second components. This implies that it is advantageous if the second component comprises a different material than the first component, wherein the material of the second component has a higher hardness than the material of the first component.With regard to the connecting plate and the bushing, this means that it is advantageous if the bushing comprises a different material than the connecting plate, at least at the position of an outer portion thereof, wherein the material of the bushing has a higher hardness than the material of the connecting plate. With regard to the pin and the sleeve, this means that it is advantageous if the sleeve comprises a different material than the pin, at least at the position of an inner portion thereof, wherein the material of the sleeve has a higher hardness than the material of the pin.
[0011] Regarding the option of the bushing being provided with recessed sections and bulges made of material of the connecting plate being accommodated in the recessed sections, the following notable options are mentioned, which can be applied in suitable combinations if desired: - the bulges of material of the connecting plate and the recessed portions of the bushing may be configured to prevent relative movement of the connecting plate and the bushing in a circumferential direction, i.e. in a direction around the axis of rotation of the relative movement of the connecting plate and the pin or in other words in a sliding direction of the sliding arrangement, - the recessed sections of the bushing can be distributed on the bushing in a circumferential direction so that forces acting on the bushing in the circumferential direction are distributed on the bushing and peak forces are avoided, - the bushing may have at least one bevelled outer edge and the recessed portions of the bushing may comprise notches arranged in the at least one bevelled outer edge, - the bushing may have a bevelled outer edge at one axial end thereof and a bevelled outer edge at the other axial end thereof, in which case it is possible to have a configuration in which the bushing is locked in the longitudinal direction between protrusions of material of the connecting plate located at the two axial ends of the bushing, and - the recessed portions of the bushing may comprise grooves extending along an outer surface of the bushing in the longitudinal direction. Regarding the option that the sleeve is provided with recessed sections and protrusions of the pin material are received in the recessed sections, the following noteworthy options are mentioned, which can be applied in suitable combinations if desired: - the protrusions of the pin material and the recessed sections of the sleeve are configured to prevent relative movement of the pin and the sleeve in a circumferential direction, - the recessed sections of the sleeve are distributed on the sleeve in a circumferential direction, - at the interface of the sleeve and the pin, the sleeve is provided with points that penetrate into the material of the pin, which is a further measure that contributes to the fixation of the sleeve on the pin, and - at the interface of the sleeve and the pin, the pin has a conical section shaped like a truncated cone, the inner surface of the sleeve tapering at the position of a section of the sleeve that closely surrounds the conical section of the pin so that differences in thermal expansion of the sleeve and the pin can be compensated.
[0012] The present invention further relates to a wastegate system of a turbocharger including a wastegate actuator mechanism as described above, and also to a turbocharger including a wastegate system including the wastegate actuator mechanism. With reference to the above discussion of the background of the invention, it is noted that the wastegate system is configured to provide a bypass path for an incoming exhaust gas flow in the turbocharger and includes a valve disposed in the bypass path and the wastegate actuator mechanism for controlling the position of the valve.Furthermore, with reference to the above explanation of the background of the invention, it is noted that the turbocharger is configured to be used in cooperation with an internal combustion engine, and that the turbocharger comprises a turbine wheel configured to be rotated under the influence of an exhaust gas flow from the engine, and a compressor wheel coupled to the turbine wheel to be rotatable together with the turbine wheel and configured to compress air to be supplied to the engine by the turbocharger.
[0013] Still further, the present invention relates to separate components of the wastegate actuator mechanism, in particular the bushing, the sleeve, the connecting plate and the pin, it being noted that various special features of these components have already been addressed above.
[0014] For better understanding, a method of attaching a bushing to a connecting plate configured to be included in a wastegate actuator mechanism of a wastegate system of a turbocharger is further described, and that the present invention also relates to a method of attaching a sleeve to a pin configured to be included in a wastegate actuator mechanism of a wastegate system of a turbocharger.
[0015] The first method has the following features: i) the bushing is dimensioned to fit snugly into an eye of the connecting plate, ii) the bushing is provided with depressed portions at positions where the bushing is to contact the connecting plate, and iii) the connecting plate is provided with at least one edge extending at a position where the connecting plate is to contact the bushing, and the first method comprises the step of: pressing the bushing into the eye of the connecting plate and thereby causing deformation of the at least one edge of the connecting plate and inducing formation of bulges of material of the connecting plate at the position of the depressed portions of the bushing by flows of material of the connecting plate at the position of the at least one edge into the depressed portions of the bushing.
[0016] The second method has the following feature: the sleeve is provided with depressed portions at positions where an inner surface of the sleeve is to face an outer surface of the pin, and the second method comprises the following steps: i) disposing the sleeve on the pin and ii) exerting pressure on the pin for the purpose of forming an end portion of enlarged diameter on the pin and thereby causing deformation of material of the pin and inducing formation of bulges of material of the pin at the position of the depressed portions of the sleeve by flows of material of the pin into the depressed portions of the sleeve.
[0017] It will be understood that further aspects of methods may relate to suitable use of one or more of a bushing, a sleeve, a connecting plate, and a pin having any of the features or combinations of features as disclosed above. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further features and advantages of the present invention will become apparent from the description of the invention as exemplary and non-limiting embodiments of a turbocharger and components of a wastegate actuator mechanism of a wastegate system of the turbocharger.
[0019] Those skilled in the art will recognize that the described embodiments of the turbocharger and the components of the wastegate actuator mechanism according to the present invention are merely exemplary in nature and should not be construed as limiting the scope defined in the claims in any way. Those skilled in the art will recognize that alternative and equivalent embodiments of the wastegate actuator mechanism may be devised and practiced without departing from the scope of the present invention.
[0020] Reference is made to the figures in the accompanying drawings. The figures are schematic in nature and therefore not necessarily drawn to scale. Furthermore, like reference numerals designate like or similar parts. In the accompanying drawings show Fig. 1 and Fig. 2 schematically shows a turbocharger according to an embodiment of the invention; shows Fig. 3 schematically shows a portion of an embodiment of a wastegate actuator mechanism of a wastegate system of the turbocharger; shows Fig. 4 schematically shows an embodiment of a connecting plate of the wastegate actuator mechanism; shows Fig. 5 schematically illustrates an embodiment of a bushing included in the wastegate actuator mechanism; shows Fig. 6 schematically shows an alternative embodiment of the socket; shows Fig. Figure 7 schematically shows a section of an assembly of a connecting plate and a bushing, the bushing being located in an eye of the connecting plate; is Fig. 8 an enlarged view of a detail of Fig. 7; illustrated Fig. 9 a closed arrangement of the connecting plate and the bushing; shows Fig. 10 schematically illustrates an embodiment of a sleeve included in the wastegate actuator mechanism; shows Fig. 11 schematically shows an arrangement of a lever plate, a pin and a sleeve of the wastegate actuator system; and illustrated Fig. 12 a closed arrangement of the pin and the sleeve. DETAILED DESCRIPTION OF EMBODIMENTS
[0021] Fig. 1 and Fig. 2 schematically show a turbocharger 100 according to an embodiment of the invention. The general design of the turbocharger 100 is comparable to general designs of well-known turbochargers and is therefore only briefly explained in this text.
[0022] The turbocharger 100 includes a turbine wheel housed in a turbine housing 110 and a compressor wheel housed in a compressor housing 120. The turbine wheel and compressor wheel are connected to each other via a rotating shaft for integral rotation. An inlet 130 of the turbocharger 100 is connectable to an exhaust gas outlet of an internal combustion engine. During operation, an incoming exhaust gas flow causes rotation of the interconnected turbine wheel and compressor wheel. The compressor wheel acts to compress air, and the resulting compressed air is discharged through an outlet 140 of the turbocharger 100, which is connectable to an air intake of the internal combustion engine.
[0023] The turbocharger 100 includes a wastegate system 200 that provides a bypass path for the incoming exhaust gas flow and includes a valve disposed in the bypass path and a wastegate actuator mechanism 300 for controlling the position of the valve. For example, if the engine discharges an excessive amount of exhaust gas, the wastegate actuator mechanism 300 is operated to open the valve, allowing only some or all of the exhaust gas to bypass the turbine wheel. This prevents excessive turbine speed increase and keeps boost pressure contained.
[0024] In the embodiment shown, the wastegate actuator mechanism 300 includes a lever plate 330 coupled to the valve, an actuator 340 disposed on the compressor housing 120, and an elongated connecting plate 310 extending from the actuator 340 to the lever plate 330. The connecting plate 310 is coupled to the lever plate 330 by engaging a pin 320 attached to the lever plate 330. The actuator 340 may also include a lever plate, as in the embodiment shown. The pin 320 extends partially through an eye 311 provided in the connecting plate 310, and the connecting plate 310 and the pin 320 are rotatable relative to each other about a rotation axis R extending in the longitudinal direction of the pin 320. During operation, the connecting plate 310 serves to transmit a driving force from the actuator 340 to the valve.
[0025] With reference to Fig. 3, it should be noted that the wastegate actuator mechanism 300 further includes a sliding assembly 400 disposed between the connecting plate 310 and the pin 320 at the position of the eye 311 of the connecting plate 310. The sliding assembly 400 includes a bushing 410 fixedly connected to the connecting plate 310 and a sleeve 420 fixedly connected to the pin 320, with an inner surface 413 of the bushing 410 and an outer surface 424 of the sleeve 420 in sliding contact. Advantageously, the bushing 410 and the sleeve 420 are made of a hard / durable material such as tungsten carbide, whereas the connecting plate 310 and the pin 320 may be made of another, less durable material such as stainless steel.
[0026] Fig. Figure 4 illustrates the option of providing the connecting plate 310 with a bushing 410 in each of two eyes 311 thereof. This implies that a sliding assembly 400 comprising a bushing 410 and a sleeve 420 can also be applied at the position of the actuator 340.
[0027] Fig. 5 schematically shows an embodiment of the bushing 410. The bushing 410 is generally annular and has a generally circular inner circumference and a generally circular outer circumference. First, it is emphasized that the bushing 410 has a smooth inner surface 413 configured to serve as one of two cooperating sliding contact surfaces of the sliding assembly 400. Second, it is noted that the bushing 410 is provided with chamfered outer edges 412 at each of its two axial ends and recessed portions 411 arranged in the respective chamfered outer edges 412. In each of the respective chamfered outer edges 412, the recessed portions 411 are distributed on the bushing 410 in a circumferential direction in a regular pattern, according to which a circumferential distance between two adjacent recessed portions 411 is the same for any two adjacent recessed portions 411. In the Fig. In the embodiment of the bushing 410 shown in Figure 5, the recessed portions 411 comprise notches. Fig. 6 schematically shows an alternative embodiment of the bushing 410 to illustrate the fact that the recessed portions 411 may further comprise grooves extending along an outer surface 414 of the bushing 410 in the longitudinal direction.
[0028] As mentioned above, in the wastegate actuator mechanism 300, the bushing 410 is fixedly connected to the connecting plate 310. Referring to the Fig. 7, Fig. 8 and Fig. 9 and with reference to the above description of the Fig. A practical manner in which the fixed connection can be realized will now be explained with reference to the embodiment of the bushing 410 shown in Figure 5. It should be noted that it is important to have the fixed connection to avoid (micro)movements between the bushing 410 and the connecting plate 310 in both the circumferential and longitudinal directions.
[0029] According to the invention, the bushing 410 is pressed into an eye 311 of the connecting plate 310 during an assembly process of the wastegate actuator mechanism 300. The bushing 410 is dimensioned to fit tightly into the eye 311 of the connecting plate 310. An outer diameter of the bushing 410 can be selected to be equal to or only slightly larger than an inner diameter of the eye 311. Furthermore, the connecting plate 310 is designed with special circumferential deformation regions A, B, wherein an entry deformation region A is located at a transition position of one of the main body surfaces 312, 313 of the connecting plate 310 to the inner surface 314 of the eye 311, and wherein a stop deformation region B is located at a transition position of the other of the main body surfaces 312, 313 of the connecting plate 310 to the inner surface 314 of the eye 311. The stop deformation area B includes a machined circumferential stop edge 315.
[0030] When the bushing 410 is pressed into the eye 311, this occurs from the side of the connecting plate 310 where the entry deformation area A is present. The movement of the bushing 410 is stopped when the beveled outer edge 412 of the bushing 410, which is located at the front in the direction of movement of the bushing 410, reaches the stop edge 315. Under the influence of the pressure exerted on the bushing 410, the stop edge 315 is deformed and a formation of bulges of material 316 of the connecting plate 310 is induced at the position of the depressed portions 411 of the bushing 410 by flows of material of the connecting plate 310 at the position of the stop edge 315 into the depressed portions 411 of the bushing 410.Furthermore, at the position of the deformation region A, a formation of bulges of material 316 of the connecting plate 310 is also induced by exerting pressure on the deformation region A using a suitable pressing tool, thereby displacing material of the connecting plate 310 in a radially inward direction. As a result of the displacement of the material, a circumferential recess 317 is formed in the deformation region A. Due to the bulges of material 316 of the connecting plate 310, which are received in the recessed sections 411 of the bushing 410, a relative movement of the connecting plate 310 and the bushing 410 is prevented at both axial ends of the bushing 410, both in a circumferential direction and in the longitudinal direction.
[0031] Fig. 10 schematically shows an embodiment of the sleeve 420. The sleeve 420 is generally annular and has a generally circular inner periphery and a generally circular outer periphery. First, it should be noted that the sleeve 420 has a smooth outer surface 424 configured to serve as one of two cooperating sliding contact surfaces of the sliding assembly 400. Advantageously, the outer surface 424 has a slightly convexly curved outline in the longitudinal direction, so that sliding contact between the sleeve 420 and the bushing 410 occurs along defined, more or less central portions of the outer surface 424 of the sleeve 420 and the inner surface 413 of the bushing 410. Secondly, it is noted that the inner surface 425 of the sleeve 420 tapers at the position of a widened portion 423 of the sleeve 420 intended to surround a conical portion 321 of the pin 320 shaped like a truncated cone, as shown in Fig. 11 and Fig. 12. Thirdly, it is noted that the sleeve 420 is provided with recessed portions 421 in the inner surface 425 thereof. The recessed portions 421 are distributed on the sleeve 420 in a circumferential direction in a regular pattern, according to which a circumferential distance between two adjacent recessed portions 421 is the same for any two adjacent recessed portions 421. In the Fig. In the embodiment of the sleeve 420 shown in Figure 10, the recessed portions 421 comprise notches extending along a substantial portion of the sleeve 420, as seen in the longitudinal direction. Furthermore, the sleeve 420 is provided with points 422 arranged to protrude inwardly from the inner surface 425 of the sleeve 420.
[0032] As mentioned above, in the wastegate actuator mechanism 300, the sleeve 420 is fixedly connected to the pin 320. A practical way in which the fixed connection can be realized will now be explained. It should be noted that it is important to have the fixed connection to avoid (micro)movements between the sleeve 420 and the pin 320 in both the circumferential and longitudinal directions.
[0033] According to the invention, the sleeve 420 is arranged on the pin 320 during an assembly process of the wastegate actuator mechanism 300 while the pin 320 is in a manufacturing state in which the pin 320 is not yet provided without the end portion 322 with an enlarged diameter, as shown in Fig. 11 and Fig. 12. As suggested above, a correct position of the sleeve 410 on the pin 320 includes the widened portion 423 of the sleeve 420 surrounding the conical portion 321 of the pin 320. Subsequently, the combination of the pin 320 and the sleeve 420 arranged on the pin 320 is placed relative to the lever plate 330, with a portion of the pin 320 being inserted through an eye of the lever plate 330. A fixed configuration of the pin 320, the sleeve 420, and the lever plate 330 is realized in a process for forming the enlarged diameter end portion 322 under the influence of pressure, i.e., in a riveting process of the pin 320. As a result of the riveting process, a configuration is obtained in which the lever plate 330 and the sleeve 420 are clamped between the end portion 322 of the pin 320 on one side and the conical portion 321 of the pin 320 on the other side.During the riveting process, the material of the pin 320 is deformed, and the formation of bulges of the material 323 of the pin 320 is induced at the position of the recessed portions 421 of the sleeve 420 by flows of the material of the pin 320 into the recessed portions 421 of the sleeve 420. Furthermore, the tips 422 of the sleeve 420 penetrate the material of the pin 320.
[0034] Due to the bulges of material 323 of the pin 320, which are received in the recessed sections 421 of the sleeve 420, relative movement of the pin 320 and the sleeve 420 in a circumferential direction is prevented. Due to the fact that the tips 422 of the sleeve 420 penetrate into the material of the pin 320, further fixation results are achieved. Due to the widened section 423 of the sleeve 420, which surrounds the conical section 321 of the pin 320, a configuration is achieved that is adapted to compensate for differences in thermal expansion of the sleeve 420 and the pin 320. During operation, the pin 320 expands both in the longitudinal direction and in a radial direction. At the position of the conical outer surface 324the expansion causes a force transfer from the pin 320 to the sleeve 420. The cone angle of the conical portion 321 of the pin 320 and the widened portion 423 of the sleeve 420 can be selected so that in situations involving a temperature increase, the pin 320 is not overstressed, thus preventing deformation of the material of the pin 320 under the influence of contact with the sleeve 420.
[0035] For the sake of clarity, it should be noted that in the above-described process of inserting the bushing 410 into the eye 311 of the connecting plate 310, the relatively soft material of the connecting plate 310 is locally displaced and deformed while the relatively hard material of the bushing 410 maintains its original shape, and that in the above-described process of inserting the sleeve 420 onto the pin 320, the relatively soft material of the pin 320 is locally displaced and deformed while the relatively hard material of the sleeve 420 maintains its original shape.
[0036] It is a practical possibility to apply a washer 426 between the sleeve 420 and the lever plate 330, as shown in the Fig. 11 and Fig.12. In such a case, a stack of the lever plate 330, the washer 426, and the sleeve 420 is clamped between the end portion 322 of the pin 320 on one side and the tapered portion 321 of the pin 320 on the other side. Advantages associated with the use of a washer 426 include a reduction in thermal expansion differences in the longitudinal direction and an opportunity to save the relatively expensive material of the sleeve 420 by reducing the dimension of the sleeve 420 in the longitudinal direction.
[0037] From the foregoing, it follows that according to the invention, the combination of the bushing 410 and the connecting plate 310 and the combination of the sleeve 420 and the pin 320 can be designed such that during assembly of the respective combinations, a firm connection is achieved on the basis that material of one component is deformed in a predetermined manner when the other component is placed in / onto the one component, wherein the other component is provided with recessed portions 411, 421 for receiving bulges of material 316, 323 from the one component, and wherein it is further possible for the one component to be provided with specific deformation features such as the above-mentioned stop edge 315 of the connecting plate 310.Although good fixation results can be achieved based on the closed configuration including the recessed portions 411, 421 and the material protrusions 316, 323, the invention does not preclude the use of additional fixation measures, such as the use of a locking pin arranged to extend through both of the components to be firmly connected. Furthermore, it may be advantageous if both the combination of the bushing 410 and the connecting plate 310 and the combination of the sleeve 420 and the pin 320 include the closed configuration based on the material protrusions 316, 323 being accommodated in the recessed portions 411, 421. However, this does not change the fact that the invention also covers the option of applying such a closed configuration to only one of the respective combinations.
[0038] It will be apparent to a person skilled in the art that the scope of the present invention is not limited to the examples discussed above, but that various changes and modifications thereof are possible without departing from the scope of the present invention as defined by the appended claims. In particular, combinations of specific features of different aspects of the invention can be made. One aspect of the invention may be further advantageously enhanced by adding a feature described with respect to another aspect of the invention. While the present invention has been illustrated and described in detail in the figures and specification, such illustration and description are to be considered as illustrative or exemplary only and not restrictive.
[0039] The present invention is not limited to the disclosed embodiments. Variations to the disclosed embodiments may be understood and effected by one skilled in the art in practicing the claimed invention from an examination of the figures, the description, and the appended claims. In the claims, the word "comprising" does not exclude other steps or elements, and the indefinite article "a" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of those measures cannot be advantageously used. Reference signs in the claims should not be construed as limiting the scope of the present invention.
[0040] Notable aspects of the invention are summarized as follows. The invention relates to a wastegate actuator mechanism 300 comprising an elongated connecting plate 310 and a pin 320 attached to a lever plate 330. The pin 320 extends partially through an eye 311 provided in the connecting plate 310, and the connecting plate 310 and the pin 320 are rotatable relative to each other about a rotation axis R extending in the longitudinal direction of the pin 320. The wastegate actuator mechanism 300 further includes a sliding assembly 400 disposed between the connecting plate 310 and the pin 320 at the position of the eye 311 of the connecting plate 310, and including a bushing 410 fixedly connected to the connecting plate 310 and a sleeve 420 fixedly connected to the pin 320, wherein an inner surface 413 of the bushing 410 and an outer surface 424 of the sleeve 420 are in sliding contact.At an interface of the bushing 410 and the connecting plate 310, the bushing 410 is provided with depressed portions 411, and protrusions of material 316 of the connecting plate 310, which were formed under pressure during assembly of the bushing 410 and the connecting plate 310, are received in the depressed portions 411. Additionally or alternatively, the sleeve 420 is provided with depressed portions 421 at an interface of the sleeve 420 and the pin 320, and protrusions of material 323 of the pin 320, which were formed under pressure during assembly of the sleeve 420 and the pin 320, are received in the depressed portions 421.With regard to the assembly of the wastegate actuator mechanism 300, this implies a process of firmly connecting the bushing 410 to the connecting plate 310 by pressing the bushing 410 into the eye 311 of the connecting plate 310 and allowing material of the connecting plate 310 to deform and be received in recessed portions 411 of the bushing 410, and / or a process of firmly connecting the sleeve 420 to the pin 320 by disposing the sleeve 420 on the pin 320 and allowing material of the pin 320 to deform and be received in recessed portions 421 of the sleeve 420, in a process of forming an enlarged diameter end portion 322 on the pin 320. List of reference symbols 100 turbochargers 110 Turbine housing 120 compressor housing 130 Turbocharger inlet 140 Turbocharger outlet 200 Wastegate system 300 wastegate actuator mechanism 310 connecting plate 311 Eye of the connecting plate 312, 313 Main body surfaces of the connecting plate 314 Inner surface of the eye 315 stop edge 316 bulges made of connecting plate material 317 circumferential deepening 320 pen 321 conical section of the pin 322 End section of the pin 323 bulges made of pin material 324 Outer surface of the pin 330 lever plate 340 Actuator 400 sliding arrangement 410 socket 411 recessed sections of the socket 412 bevelled outer edge 413 Inner surface of the socket 414 Outer surface of the socket 420 case 421 recessed sections of the sleeve 422 peaks 423 widened section of the sleeve 424 Outer surface of the sleeve 425 inner surface of the sleeve 426 washer A Entry deformation area B Stop deformation range R axis of rotation
Claims
[1] Wastegate actuator mechanism (300) configured to be used in a wastegate system (200) of a turbocharger (100), wherein the wastegate actuator mechanism (300) comprises an elongated connecting plate (310) and a pin (320) fixed to a lever plate (330), wherein the pin (320) extends partially through an eye (311) provided in the connecting plate (310), and wherein the connecting plate (310) and the pin (320) are rotatable relative to each other about a rotation axis (R) extending in the longitudinal direction of the pin (320), wherein the wastegate actuator mechanism (300) further comprises a sliding assembly (400) arranged between the connecting plate (310) and the pin (320) at the position of the eye (311) of the connecting plate (310), wherein the sliding assembly (400) comprises a bushing (410) fixedly connected to the connecting plate (310) and a sleeve (420) fixedly connected to the pin (320), and wherein an inner surface (413) of the bushing (410) and an outer surface (424) of the sleeve (420) are in sliding contact, and wherein at an interface of the bushing (410) and the connecting plate (310), the bushing (410) is provided with recessed sections (411) and bulges made of material (316) of the connecting plate (310) are received in the recessed sections (411), wherein the bulges of material (316) of the connecting plate (310) and the recessed portions (411) of the bushing (410) are configured to prevent relative movement of the connecting plate (310) and the bushing (410) in a circumferential direction. [2] The wastegate actuator mechanism (300) of claim 1, wherein the bushing is pressed into an eye (311) of the connecting plate (310). [3] Wastegate actuator mechanism (300) according to claim 1 or 2, wherein the bulges of material (316) are formed by applying pressure to the connecting plate (310). [4] A wastegate actuator mechanism (300) according to any one of claims 1-3, wherein the bulges of material (316) were formed by applying pressure to the connecting plate (310) after the bushing was received in the eye of the connecting plate (310). [5] Wastegate actuator mechanism (300) according to any one of claims 1-4, wherein at the interface of the bushing (410) and the connecting plate (310), the bushing (410) is provided with depressed portions (411) and bulges of material (316) of the connecting plate (310) are received in the depressed portions (411), and wherein the bushing (410) comprises a different material than the connecting plate (310), the material of the bushing (410) having a higher hardness than the material of the connecting plate (310). [6] The wastegate actuator mechanism (300) according to any one of claims 1-5, wherein the recessed portions (411) of the bushing (410) are distributed on the bushing (410) in a circumferential direction. [7] The wastegate actuator mechanism (300) of any one of claims 1-6, wherein the recessed portions (411) of the sleeve (410) comprise notches. [8] The wastegate actuator mechanism (300) of claim 7, wherein the notches are disposed in a beveled outer edge (412) of the bushing (410). [9] The wastegate actuator mechanism (300) of claim 8, wherein the beveled outer edge (412) of the bushing (410) is present at each of two axial ends of the bushing (410). [10] Wastegate actuator mechanism (300) according to any one of claims 1-9, wherein the bushing (410) is locked in the longitudinal direction between bulges of material (316) of the connecting plate (310) located at the two axial ends of the bushing (410). [11] The wastegate actuator mechanism (300) of any one of claims 1-10, wherein the recessed portions (411) of the bushing (410) comprise grooves extending along an outer surface (414) of the bushing (410) in the longitudinal direction. [12] Wastegate actuator mechanism (300) according to any one of claims 1-11, wherein at the interface of the sleeve (420) and the pin (320), the sleeve (420) is provided with recessed portions (421) and bulges of material (323) of the pin (320) are received in the recessed portions (421), and wherein the sleeve (420) comprises a different material than the pin (320), the material of the sleeve (420) having a higher hardness than the material of the pin (320). [13] The wastegate actuator mechanism (300) of claim 12, wherein the bulges of material (323) of the pin (320) and the recessed portions (421) of the sleeve (420) are configured to prevent relative movement of the pin (320) and the sleeve (420) in a circumferential direction. [14] The wastegate actuator mechanism (300) according to claim 12 or 13, wherein the recessed portions (421) of the sleeve (420) are distributed on the sleeve (420) in a circumferential direction. [15] Wastegate actuator mechanism (300) according to any one of claims 12-14, wherein at the interface of the sleeve (420) and the pin (320), the sleeve (420) is provided with tips (422) that penetrate into the material of the pin (320). [16] Wastegate actuator mechanism (300) according to any one of claims 12-15, wherein at the interface of the sleeve (420) and the pin (320), the pin (320) has a conical portion (321) shaped like a truncated cone, and wherein the inner surface (425) of the sleeve (420) tapers at the position of a portion (423) of the sleeve (420) that closely surrounds the conical portion (321) of the pin (320). [17] Wastegate system (200) of a turbocharger (100) including a wastegate actuator mechanism (300) according to any one of claims 1-16. [18] A turbocharger (100) comprising a wastegate system (200) including a wastegate actuator mechanism (300) according to any one of claims 1-16. [19] A bushing (410) configured to be included in a wastegate actuator mechanism (300) of a wastegate system (200) of a turbocharger (100), wherein the bushing (410) is provided with recessed portions (411) on its outer surface (414), and wherein the recessed portions (411) of the bushing (410) are configured to prevent relative movement of a connecting plate (310) of the wastegate actuator mechanism (300) and the bushing (410) in a circumferential direction. [20] Bushing (410) according to claim 19, wherein the bushing is included in the wastegate actuator mechanism (300) of the wastegate system (200) of the turbocharger (100) to be pressed into an eye (311) of a connecting plate (310) of the wastegate actuator mechanism (300). [21] Bushing (410) according to claim 19 or 20, wherein the bulges of material (316) are formed by exerting pressure on the connecting plate (310). [22] A bushing (410) according to any one of claims 19-21, wherein the bulges of material (316) were formed by exerting pressure on the connecting plate (310) after the bushing was received in the eye of the connecting plate (310). [23] Bushing (410) according to any one of claims 19-22, wherein the recessed portions (411) are distributed on the bushing (410) in a circumferential direction. [24] A bushing (410) according to any one of claims 19-23, wherein the recessed portions (411) of the bushing (410) comprise notches. [25] Bushing (410) according to claim 24, wherein the notches are arranged in a bevelled outer edge (412) of the bushing (410). [26] Bushing (410) according to claim 25, wherein the beveled outer edge (412) is present at each of two axial ends of the bushing (410). [27] A bushing (410) according to any one of claims 19-26, wherein the recessed portions (411) of the bushing (410) comprise grooves extending along its outer surface (414) in the longitudinal direction. [28] Bushing (410) according to any one of claims 19-27, comprising a material that is significantly harder than stainless steel. [29] Wastegate actuator mechanism (300) configured to be used in a wastegate system (200) of a turbocharger (100), wherein the wastegate actuator mechanism (300) comprises an elongated connecting plate (310) and a pin (320) fixed to a lever plate (330), wherein the pin (320) extends partially through an eye (311) provided in the connecting plate (310), and wherein the connecting plate (310) and the pin (320) are rotatable relative to each other about a rotation axis (R) extending in the longitudinal direction of the pin (320), wherein the wastegate actuator mechanism (300) further comprises a sliding assembly (400) arranged between the connecting plate (310) and the pin (320) at the position of the eye (311) of the connecting plate (310), wherein the sliding assembly (400) comprises a bushing (410) fixedly connected to the connecting plate (310) and a sleeve (420) fixedly connected to the pin (320), and wherein an inner surface (413) of the bushing (410) and an outer surface (424) of the sleeve (420) are in sliding contact, and wherein at an interface of the bushing (410) and the connecting plate (310), the bushing (410) is provided with recessed sections (411) and bulges made of material (316) of the connecting plate (310) are received in the recessed sections (411), and at an interface of the sleeve (420) and the pin (320), the sleeve (420) is provided with recessed sections (421) and bulges made of material (323) of the pin (320) are received in the recessed sections (421).