System for controlling a wastegate of a turbocharger

Abstract

The present invention relates to a system for controlling a wastegate of a turbocharger of an internal combustion engine, the system comprising: a lever plate adapted to communicate with the wastegate of the turbocharger for controlling the wastegate; a linking arm adapted communicate with an actuator of the system and adapted to releasably connect to the lever plate via a joint defined by a portion of the lever plate and a portion of the linking arm; wherein the joint is dimensioned to connect the linking arm and the lever plate in a first orientation of the linking arm with respect to the lever plate and to disconnect the linking arm and the lever plate in a second orientation of the linking arm with respect to the lever plate.

Description

SYSTEM FOR CONTROLLING A WASTEGATE OF A TURBOCHARGER

[0001] The present disclosure relates to a system and method for controlling a wastegate of a turbocharger in an internal combustion engine. Specifically, the present disclosure pertains to a mechanism involving a lever plate and a linking arm for efficient control of components in a turbocharger such as wastegate, variable geometry or the like. Further the present disclosure pertains to related turbocharger and motor vehicle applications.

[0002] In the field of internal combustion engines, turbochargers are commonly employed to enhance engine performance by increasing the amount of air entering the combustion chamber. Turbochargers typically include a wastegate, which is a valve that controls the flow of exhaust gases to the turbine, thereby regulating the boost pressure generated by the turbocharger. Known systems for controlling the wastegate often involve mechanical linkages with actuators or (purely) electronic actuators that adjust the position of the wastegate based on various engine parameters. These systems are designed to optimize engine efficiency and performance while preventing excessive boost pressure that could damage the engine.

[0003] Despite the substantial advances in the field of turbocharger wastegate control, there remain several challenges and limitations associated with existing systems. Known systems typically involve complex mechanical linkages that can be prone to wear and tear, leading to reliability issues over time. Additionally, the precision of wastegate control can be compromised by factors such as thermal expansion, vibration, and mechanical play within the linkage components. Electronic actuator systems, while offering improved precision, can be costly and may require sophisticated control algorithms and sensors to function effectively. Furthermore, the integration of these systems into existing engine architectures can be cumbersome and may necessitate significant modifications to the engine layout.

[0004] Further known wastegate control systems employ a multibody kinematics system to rotate the wastegate valve, typically utilizing a planar 4-bar linkage mechanism. These systems comprise multiple parts, including pivots and joints, which aim at providing various functions such as noise control and enduring high loads.

[0005] However, such conventional linkage mechanisms, while widely industrialized and well-known, present several challenges. For instance, the joints in these systems usually employ a pin-in-hole architecture, where the rods containing holes are assembled in a stacked manner and secured with axial fixators. Over time, the sliding friction in these joints leads to gradual wear, resulting in performance degradation. Additionally, modern kinematics systems have evolved to include noise reduction devices and more powerful actuators to handle higher loads and rotational speeds, further increasing the complexity, wear, noise, assembly difficulties, and cost of the systems.

[0006] The existing technology faces several challenges:

[0007] Traditional systems become complex assemblies due to the inclusion of multiple components for various functions, leading to a high number of parts and complicated assembly processes. Sliding friction in joints causes excessive wear, necessitating additional components like hard metal inserts to control wear. Noise control requires extra components such as spring washers or clip springs, adding to the system's complexity. The high number of components and the need for precise alignment complicate the assembly process, making automation difficult. High-performance systems for controlling wastegates are expensive due to the need for multiple components and complex manufacturing processes. Generally, the durability of the components used in these systems is a concern, as they must withstand harsh operating conditions, including high temperatures, pressures, and corrosive environments.

[0008] It is therefore a technical problem underlying the present invention to provide a system for controlling a wastegate of a turbocharger that at least partially overcomes the disadvantages of known systems.

[0009] The above-mentioned objects are at least partially achieved by the subject-matter of the independent claims. Preferred embodiments are subject of the dependent claims, and the skilled person finds hints for other suitable aspects of the present invention through the overall disclosure of the present application.

[0010] A first aspect of the invention provides a system for controlling a wastegate of a turbocharger of an internal combustion engine, the system comprising: a lever plate adapted to communicate with the wastegate of the turbocharger for controlling the wastegate; a linking arm adapted communicate with an actuator of the system and adapted to releasably connect to the lever plate via a joint defined by a portion of the lever plate and a portion of the linking arm; wherein the joint is dimensioned to connect the linking arm and the lever plate in a first orientation of the linking arm with respect to the lever plate and to disconnect the linking arm and the lever plate in a second orientation of the linking arm with respect to the lever plate.

[0011] It is noted that the system is not limited to the particular application of a wastegate, but may also be used to control other components, in particular components of a turbocharger, such as variable geometry or the like.

[0012] In this manner, the present disclosure provides an improved system for controlling a wastegate of a turbocharger. Specifically, the joint may facilitate easier assembly, disassembly, maintenance and / or replacement of the system’s components, as the releasable connection allows for quick tool-free actions. Further, the system allows to overcome the challenges of precise wastegate control and mechanical reliability, thereby enhancing performance and durability of the turbocharger and the internal combustion engine as a whole. The joint's ability to connect and disconnect based on orientation may provide a more accurate and reliable mechanism for wastegate actuation, potentially reducing the risk of mechanical failure and improving overall engine efficiency. By way of the joint, misalignment may be prevented, and a consistent performance may be ensured.

[0013] The number of parts necessary for controlling the wastegate can be reduced, thereby also fabrication time of the system can be improved. Further, the system provides a cost-effective solution that maintains high performance and durability.

[0014] Specifically, the present disclosure allows that existing complex designs comprising eye-and-pin architectures can be dispensed with.

[0015] The lever plate is designed to communicate with the wastegate, thereby controlling its operation. This arrangement may help in extending the operational life of the turbocharger by ensuring precise control over the wastegate, which is helpful for maintaining optimal engine performance. The lever plate may be mechanically linked to the wastegate, allowing it to modulate the opening and closing of the wastegate based on the position of the lever plate. The lever plate may be an elongate plate but is not limited thereto.

[0016] The linking arm is adapted to communicate with an actuator of the system and adapted to releasably connect to the lever plate via a joint defined by a portion of the lever plate and a portion of the linking arm. The linking arm may serve as a conduit for transmitting the actuator's movements to the lever plate. The linking arm may be an elongate element but is not limited thereto.

[0017] This joint is defined by portions of both the lever plate and the linking arm and is dimensioned to connect the linking arm and the lever plate in a first orientation while allowing for disconnection in a second orientation. Thereby, the joint may not be limited to one integral portion, but may, for instance, be understood as comprising two portions that function together as a joint.

[0018] The joint may address the challenge of ensuring a secure yet flexible connection between the actuator and the wastegate, which is helpful for responsive and accurate wastegate control.

[0019] The joint is dimensioned to connect the linking arm and the lever plate in a first orientation of the linking arm with respect to the lever plate and to disconnect the linking arm and the lever plate in a second orientation of the linking arm with respect to the lever plate. This design allows for a versatile connection mechanism.

[0020] For instance, the linking arm can be securely attached to the lever plate when in the first orientation, ensuring stable communication between the actuator and the wastegate. Conversely, in the second orientation, the linking arm can be easily disconnected from the lever plate, facilitating maintenance or adjustments without the need for complex disassembly. As understood, the first orientation needs to be different than the second orientation.

[0021] In the context of the present invention, it is noted that the connection between the linking arm and the lever plate may be achieved also in a plurality of further orientations, i.e., not necessarily limited to the “first” orientation. These various orientations are all within the scope of the present disclosure. However, by virtue of the dimension of the joint, a difference in two orientations facilitates to connect and to disconnect the linking arm and the lever plate.

[0022] The term “orientation” refers to the relative positioning and alignment of the linking arm and the lever plate with respect to each other. The invention is designed to accommodate multiple orientations, allowing for flexibility in the spatial arrangement of the components. The different orientations may include, but are not limited to one or more of the following: a parallel orientation, e.g., where the linking arm and lever plate are aligned parallel to each other, a perpendicular orientation, e.g., where the linking arm and lever plate are oriented at a right angle (90 degrees) to each other, an angular orientations, e.g., where the linking arm and lever plate are positioned at various angles, allowing for a range of angular alignments.

[0023] In the context of this invention, the term “to connect” may refer to the state in which two components, e.g., the lever plate and the linking arm, are substantially fixedly attached to each other. This may encompass a relative rotational movement of the two components, e.g., for controlling the wastegate. This may in some examples restrict translational freedom. This means that while the components can rotate with respect to one another around a specific axis, e.g., the one at the joint, or within a defined range of motion, they remain fixed in their relative positions in terms of translation. The term “to connect” may be understood such that the components are securely joined, enabling the transfer of forces and motion while maintaining their spatial relationship.

[0024] In the context of this invention, the term “to disconnect” may refer to the state in which two components, e.g., the lever plate and the linking arm, have translational freedom with respect to each other, meaning they are not fixedly attached and can move independently in terms of translation and rotation. E.g., two components that are disconnected may be regarded as released. This allows the components to shift or slide relative to one another in various directions, providing flexibility in their spatial arrangement. The disconnection implies that the components are not constrained in their relative positions, enabling them to separate or reposition as needed.

[0025] In a preferred embodiment of the system according to the first aspect, the joint is defined by a head and a socket. In a preferred example, the head is comprised by the linking arm and the socket is comprised by the lever plate. Alternatively, the head is comprised by the lever plate and the socket is comprised by the linking arm.

[0026] This head of the linking arm and the socket of the lever plate introduce a more precise, secure and / or flexible connection between the linking arm and the lever plate. The head and socket configuration ensures that the linking arm can be easily and reliably connected to and disconnected from the lever plate, which facilitates effective control of the wastegate.

[0027] The head of the linking arm may be shaped to fit snugly into the socket of the lever plate, providing a stable and robust joint that can withstand the operational stresses encountered in the turbocharger system. This design also facilitates the releasable connection feature, allowing the linking arm (or the lever plate) to be oriented in a first orientation to engage with the lever plate (or the linking arm) and in a second orientation to disengage.

[0028] The introduction of the head and socket joint brings several advantages to the system. Firstly, it enhances the ease of assembly and disassembly, making maintenance and repairs more straightforward and less time-consuming. Secondly, the head and socket joint provides a more reliable connection compared to other types of joints, reducing the likelihood of accidental disconnection during operation, which could otherwise lead to suboptimal performance or damage to the turbocharger. Additionally, this configuration allows for a more compact and streamlined design, which can be beneficial in the often-constrained engine compartments of modern vehicles.

[0029] In some examples, the joint may be understood as a knee-like joint with a ball head-and-socket design.

[0030] In a preferred embodiment of the system according to the first aspect, the head and the socket are shaped at least partially in correspondence to one another, wherein the head of the linking arm preferably has an at least partially spherical shape, and the socket of the lever plate preferably has an at least partially concave spherical shape.

[0031] This correspondence in shape facilitates a more reliable and stable joint, reducing the likelihood of unintended disconnection or misalignment during operation.

[0032] Furthermore, the head of the linking arm is preferably designed with an at least partially spherical shape. This spherical design allows for a more versatile range of motion and articulation, enabling the linking arm to pivot smoothly within the socket of the lever plate.

[0033] The spherical shape of the head contributes to a more uniform distribution of stress and load across the joint, enhancing the durability and longevity of the connection. Complementing this, the socket of the lever plate is preferably shaped with an at least partially concave spherical form. The concave spherical shape of the socket is specifically tailored to receive and / or cradle the spherical head of the linking arm, providing a secure and stable seating for the head. This concave design not only enhances the mechanical interlock between the linking arm and the lever plate but also allows for a degree of self-alignment, which can compensate for minor misalignments or variations in the positioning of the components. The combination of these features - corresponding shapes, a spherical head, and a concave spherical socket - results in a joint that is both robust and flexible, capable of maintaining a secure connection under varying operational conditions while allowing for the necessary movement and adjustment of the linking arm relative to the lever plate.

[0034] The term “at least partially spherical shape” may refer to a geometric form that includes one or more segments or portions of a sphere. This shape may not be a complete sphere but possesses some spherical characteristics, such as a curved surface that follows the contour of a sphere. The partially spherical shape can range from a small segment of a sphere to a nearly complete sphere, and it may include variations such as hemispheres, spherical caps, or other curved surfaces that exhibit spherical properties. This definition encompasses any shape that incorporates spherical elements, providing flexibility in design and application.

[0035] The term “at least partially concave spherical shape” may refer to a geometric form that includes one or more segments or portions of a concave surface that follows the contour of a sphere. This shape may not be a complete concave sphere but possesses some concave spherical characteristics, such as an inwardly curved surface that mimics the interior curvature of a sphere. The partially concave spherical shape can range from a small concave segment to a nearly complete concave sphere, and it may include variations such as concave hemispheres, concave spherical caps, or other inwardly curved surfaces that exhibit concave spherical properties. This definition encompasses any shape that incorporates concave spherical elements, allowing for diverse design and functional possibilities. The term “at least partially concave spherical shape” may refer to the counterpart of the term “at least partially spherical shape”.

[0036] In a preferred embodiment of the system according to the first aspect, the at least partially spherical shape covers an angle of least 90° and / or at most 350°, preferably at most 340°, preferably at most 330°, preferably at most 320° in longitude; and / or the at least partially spherical shape covers an angle of at least 10° and / or at most 80° in latitude.

[0037] Longitude refers to the angular distance of a point on the surface of a sphere from a reference meridian (usually the prime meridian), measured along the equator. It is expressed in degrees, ranging from 0° at the prime meridian to 360°.

[0038] Latitude refers to the angular distance of a point on the surface of a sphere from the equator, measured along the meridian (a line connecting the poles). It is expressed in degrees, ranging from 0° at the equator to 90° at the poles.

[0039] The earth may be used as a practical example of a sphere where latitude and longitude are used to define locations. The equator is at 0° latitude, while the North Pole is at 90° North latitude and the South Pole is at 90° South latitude. Latitude lines extend from the equator up to 80° in both directions according to the present disclosure. The prime meridian, which passes through Greenwich, England, is at 0° longitude. Longitude lines extend east and west from the prime meridian up to 360° according to the present disclosure.

[0040] To give an illustrative example: at least 90° in longitude means the shape extends over a minimum of 90 degrees of longitude. For example, if starting at the prime meridian (0° longitude), the shape will extend, e.g., eastward to at least 90° longitude.

[0041] To give an illustrative example: at most 80° in latitude means the shape extends up to a maximum of 80 degrees of latitude from the equator in both directions. For example, starting from the equator (0° latitude), the shape could extend northward and southward up to 80° latitude. This would cover an angular section of 160° as understood by the skilled person.

[0042] This coverage in the longitude and latitude direction allows for a more secure engagement, reducing the likelihood of unintentional disconnection during operation. The upper limits allow for easy and flexible assembly and disassembly.

[0043] This balance between coverage and flexibility is helpful for the proper functioning of the wastegate control system, allowing for precise control over the wastegate’s position.

[0044] In a preferred embodiment of the system according to the first aspect, when connected in the first orientation, the head is at least partially substantially flush with the socket. It is noted that flush does not mean that the respected elements, e.g., head and socket must perfectly match one another, tolerances and minor movements may be encompassed. Further, the thickness of one component may be smaller than the other.

[0045] This embodiment introduces a precise alignment mechanism between the linking arm and the lever plate, ensuring that the head of the linking arm fits snugly into the socket of the lever plate when in the first orientation.

[0046] In a preferred embodiment of the system according to the first aspect, when connected in the first orientation, relative translational movement of the linking arm and the lever plate is substantially prevented, and relative rotational movement of the linking arm and the lever plate is preferably not prevented.

[0047] This means that when the linking arm and the lever plate are connected in the first orientation, they are substantially locked in place in such a manner that they cannot move relatively with respect to each other in translational direction. This feature is particularly advantageous as it ensures that the connection between the linking arm and the lever plate remains stable and secure during operation, thereby preventing any unintended disengagement or misalignment that could adversely affect the performance of the wastegate control system.

[0048] Furthermore, this embodiment also specifies that relative rotational movement of the linking arm and the lever plate is preferably not prevented. This implies that while the system restricts translational movement to maintain a secure connection, it allows for rotational movement between the linking arm and the lever plate. The ability to permit rotational movement while preventing translational movement provides a degree of flexibility that can accommodate the dynamic forces and motions encountered during the operation of the internal combustion engine and / or its turbocharger.

[0049] In a preferred embodiment of the system according to the first aspect, the joint is dimensioned such that the first orientation and / or the second orientation can be achieved by rotating the linking arm around a main axis of the linking arm and / or by rotating the lever plate around a main axis of the linking arm. As understood, the linking arm and the lever plate may need to be rotated relative to each other.

[0050] This feature introduces a specific mechanism of communication between the linking arm and the lever plate, wherein the rotational movement of either component around its respective main axis facilitates the engagement and disengagement of the joint. The ability to achieve the first orientation, in which the linking arm and the lever plate are connected, and the second orientation, in which they are disconnected, through rotational movement adds a layer of versatility and ease of operation to the system.

[0051] This rotational mechanism allows for a more flexible and user-friendly approach to controlling the connection and disconnection process, potentially simplifying maintenance and adjustments. By enabling the linking arm to rotate around its main axis, the system can accommodate various angular positions, enhancing the precision and control over the wastegate operation. Similarly, the rotation of the lever plate around the main axis of the linking arm ensures that the system can adapt to different spatial configurations, providing a more robust and adaptable solution for wastegate control.

[0052] In the context of the present disclosure, the term “main axis” is understood - in line with the common understanding in the field of mechanical design and kinematics - to refer to the primary line or direction along which a component is shaped. This axis is visually apparent to the skilled person. For the linking arm, the main axis typically refers to the longitudinal axis, which is the primary direction along the length.

[0053] For example, the main axis of the linking arm is the longitudinal axis that runs along the length of the arm. This axis is central to the arm's geometry and is the primary direction along which the arm extends and operates.

[0054] In a preferred embodiment of the system according to the first aspect, an angle of rotation of the linking arm around the main axis of the linking arm between the first orientation and the second orientation is at least 10°, preferably at least 30°, preferably at least 50°, preferably at least 70°, preferably at least 85°, and / or at most 170°, preferably at most 150°, preferably at most 130°, preferably at most 110°, preferably at most 95° when the angle of rotation of the lever plate around the main axis of the linking arm between the first orientation and the second orientation is substantially maintained; or wherein an angle of rotation of the lever plate around the main axis of the linking arm between the first orientation and the second orientation is at least 10°, preferably at least 30°, preferably at least 50°, preferably at least 70°, preferably at least 85°, and / or at most 170°, preferably at most 150°, preferably at most 130°, preferably at most 110°, preferably at most 95° when the angle of rotation of the linking arm around the main axis of the linking arm between the first orientation and the second orientation is substantially maintained.

[0055] The above-mentioned angles may also be applicable considering a rotation in the opposite direction. The angles in the opposite direction would be 360° minus the above-mentioned angles. Hence, e.g., an angle of 90° mentioned above would correspond to an angle of 360° minus 90°, i.e., 270° in the opposite direction.

[0056] In general, within the present disclosure, a rotation of about 90° may encompass a rotation of about 90° + 360° times x, wherein x is an integer excluding zero.

[0057] This angular rotation ensures that the joint between the linking arm and the lever plate can be reliably connected and disconnected, enhancing the operational flexibility and reliability of the wastegate control system. The specified range of angles allows for a controlled and predictable interaction between the components, reducing the risk of mechanical failure or misalignment.

[0058] In a preferred embodiment of the system according to the first aspect, the joint, preferably the socket of the lever plate comprises an interface portion configured to contact the head of the linking arm in the first orientation, the interface portion comprising a first material and the lever plate comprising a second material. In some examples, a first material and a second material may be provided during manufacturing so as to provide a substantially seamless material composition.

[0059] This interface portion ensures a precise and secure connection between the lever plate and the linking arm, facilitating effective control of the wastegate of the turbocharger. The interface portion's configuration to contact the head of the linking arm in the first orientation enhances the stability and reliability of the joint, ensuring that the components remain connected under operational conditions.

[0060] Furthermore, the interface portion comprises a first material, which may optimize durability and performance of the joint. The selection of the first material for the interface portion can be tailored to provide specific mechanical properties, such as wear resistance, thermal stability, or reduced friction, thereby enhancing the overall functionality and longevity of the system.

[0061] Additionally, the lever plate comprises a second material, distinct from the first material of the interface portion. This differentiation in material composition between the lever plate and the interface portion introduces another layer of functionality. By utilizing a second material for the lever plate, the system can benefit from the unique properties of this material, which may include improved structural integrity, weight reduction, or cost efficiency.

[0062] The combination of different materials for the interface portion and the lever plate allows for a more tailored approach to material selection, optimizing the performance characteristics of each component according to their specific roles within the system. This strategic use of materials not only enhances the mechanical interaction between the lever plate and the linking arm but also contributes to the overall robustness and efficiency of the wastegate control system. By incorporating these features, the system achieves a more refined and effective mechanism for controlling the wastegate of a turbocharger, addressing both the functional and durability aspects critical to the operation of internal combustion engines.

[0063] In a preferred embodiment of the system according to the first aspect, the socket comprises a through hole.

[0064] In a preferred embodiment of the system according to the first aspect, the socket is configured so as to substantially limit movement of the linking arm, preferably the head of the linking arm in an axial direction within the socket, movement to at most 50% of an axial length of the socket, preferably at most 40%, preferably at most 30%, preferably at most 20%, preferably at most 10% of an axial length of the socket. Preferably, the socket is configured so as to substantially secure the linking arm, preferably the head of the linking arm in an axial alignment within the socket. This makes usage of the system for prolonged time failsafe. For instance, movement of the linking arm within the socket over time, e.g., due to worn portions of the components, may be balanced.

[0065] In one example, the socket may comprise a bottom, e.g., the socket has the shape of a cup. This may improve precise positioning and may entail a failsafe operation. In one example, the socket may comprise a ridge than can be adjusted, e.g., crimped, preferably the socket comprises two ridges than can be adjusted, e.g., crimped, wherein the one or two ridges are configured to be crimped. In some examples, the ridge-to-crimp solution may be even advantageous compared to the solution using a bottom.

[0066] In a preferred embodiment of the system according to the first aspect, the system further comprises an actuator lever plate configured to communicate with an actuator, the actuator lever plate adapted to releasably connect to the linking arm.

[0067] This actuator lever plate’s communication with the actuator facilitates precise control of the wastegate, as it ensures that the actuator can effectively transmit its movements to the actuator lever plate. The actuator lever plate, in turn, is adapted to connect, preferably releasably connect, to the linking arm.

[0068] The inclusion of the actuator lever plate introduces an additional layer of control and flexibility to the system. Specifically, it allows for the actuator to engage and disengage the lever plate as needed, thereby providing a mechanism for more precise and controlled manipulation of the wastegate. This feature is particularly advantageous in scenarios where variable control of the wastegate is required to optimize engine performance and efficiency.

[0069] By enabling the actuator lever plate to releasably connect to the lever plate, the system can accommodate different operational states, such as varying levels of turbocharger boost pressure, without necessitating a complete disassembly or reconfiguration of the system. This adaptability not only enhances the overall functionality of the wastegate control system but also contributes to its durability and ease of maintenance. Furthermore, the releasable connection between the actuator lever plate and the lever plate ensures that the system can quickly respond to changes in engine conditions, thereby improving the responsiveness and reliability of the turbocharger control.

[0070] In a preferred embodiment of the system according to the first aspect, the linking arm is substantially flat, preferably planar and / or elongate, wherein the linking arm is preferably substantially straight.

[0071] The flat nature of the linking arm ensures that it can maintain a consistent and reliable connection with the lever plate, thereby facilitating precise control over the wastegate. This flat configuration minimizes the risk of misalignment or slippage that could occur with more complex geometries, thereby ensuring that the actuator's movements are accurately translated to the lever plate. Furthermore, the flat linking arm can be manufactured with greater ease and consistency, reducing production costs and improving the overall reliability of the system.

[0072] The linking arm is preferably planar and / or elongate, which further contributes to the system's robustness and precision. A planar linking arm offers a uniform surface that can effectively interface with the actuator and lever plate, reducing the likelihood of mechanical play or variability in the joint. An elongate design provides the necessary length to bridge the actuator and lever plate while maintaining a low profile, which is advantageous for fitting within the constrained spaces typically found in engine compartments. This elongate nature also allows for a more gradual and controlled transfer of force from the actuator to the lever plate, enhancing the system's responsiveness and reducing wear on the components.

[0073] In a preferred embodiment of the system according to the first aspect, the lever plate is substantially flat, and the lever plate preferably comprises a connecting element for connecting to the lever plate to a wastegate shaft, the connecting element being spaced apart from the socket of the lever plate.

[0074] The flatness of the lever plate ensures that it can be manufactured with ease and precision, reducing the likelihood of mechanical failure due to complex geometries. This feature enhances the overall reliability and durability of the system by minimizing stress concentrations and potential weak points that could arise from more intricate designs.

[0075] Additionally, the lever plate comprises a connecting element for connecting the lever plate to a wastegate shaft. The connecting element may comprise for instance a recess, a hole or a through hole. This connecting element serves as a critical interface between the lever plate and the wastegate shaft, ensuring secure and effective communication between these components. The presence of a dedicated connecting element facilitates a more straightforward and reliable connection, which is beneficial for the accurate control of the wastegate.

[0076] Furthermore, the connecting element is spaced apart from the socket of the lever plate. This spatial arrangement between the connecting element and the socket is significant as it allows for greater flexibility in the design and operation of the system.

[0077] In a preferred embodiment of the system according to the first aspect, a plane projecting through a center of the connecting element and a center of the socket is substantially parallel to the flat lever plate.

[0078] This embodiment may be referred to as an aligned design, e.g., the centers of working surfaces are on a common plane, which improves load distribution. Such an aligned design is not possible for the traditional system designs because of the length of the pin assembly, which would protrude from the lever plate. Aligned Linking can result into intrinsic robustness against misalignment (as any turbocharger rotation (e.g., in degrees) is converted to a lower misalignment magnitude which is attributable to the joint and the absence of traditional pin designs).

[0079] This embodiment introduces a precise geometrical alignment between the connecting element and the socket, ensuring that the plane defined by these two centers maintains a parallel relationship with the flat surface of the lever plate. The mechanism of communication between the components in this embodiment is characterized by the spatial configuration of the connecting element and the socket relative to the lever plate. This alignment facilitates a more stable and predictable interaction between the linking arm and the lever plate, enhancing the reliability and efficiency of the wastegate control system. By ensuring that the plane through the centers of the connecting element and socket is parallel to the lever plate, the system minimizes potential misalignments that could arise during operation, thereby reducing wear and tear on the joint and extending the lifespan of the components.

[0080] A further aspect of the invention refers to a turbocharger comprising: a turbine comprising a wastegate for bypassing flow around an impeller of the turbine; a compressor preferably provided in an intake flow path through which intake air is configured to be supplied to the engine, wherein the compressor is configured to be driven by the turbine to compress intake air; and a system for controlling a wastegate as described in the present disclosure.

[0081] The turbocharger comprises all advantages of the system for controlling a wastegate described herein.

[0082] A further aspect of the invention refers to a motor vehicle comprising: the turbocharger as described in the present disclosure; a control unit adapted to control the system.

[0083] As understood by the skilled person, the motor vehicle comprises all advantages of the turbocharger described herein.

[0084] The motor vehicle may be a self-propelled machine for the transportation of people, goods, or the like. The motor vehicle may be powered by an internal combustion engine. The motor vehicle referred to herein may be in an exemplary and non-exhaustive list: a car, a truck, a motorcycle, a bus, maritime and aeronautical vehicles, and other a similar vehicle.

[0085] A further aspect of the invention provides a system for controlling a wastegate of a turbocharger of an internal combustion engine, the system comprising: a lever plate adapted to communicate with the wastegate of the turbocharger for controlling the wastegate; a linking arm adapted communicate with an actuator of the system and adapted to releasably connect to the lever plate via a joint defined by a portion of the lever plate and a portion of the linking arm; the system further comprising a biasing means disposed on the lever plate and adapted to bias movement imposed on the lever plate by means of the wastegate.

[0086] This has the advantage of cushioning movement of the wastegate and to push the head of the linking arm substantially into the socket of the lever plate. Thereby noise and jitter may be reduced.

[0087] The biasing means may be implemented by means of a spring. The biasing means may comprise a joint bias portion and / or a wastegate axial lift portion. This may provide for a dual function. This may be applicable to any kind of turbocharger applications.

[0088] In an alternative example, the biasing means may be specifically dimensioned for the lever plate, which may be flat. The biasing means may comprise an axial push portion and a wastegate axial list portion.

[0089] In a preferred embodiment, the biasing means is adapted to push the linking arm and the lever plate closer to one another.

[0090] In a preferred embodiment, the wherein the biasing means is adapted to communicate with a shaft of the wastegate.

[0091] The system according to any one of the preceding claims, wherein the system comprises a plurality of further orientations of the linking arm with respect to the lever plate, such as a plurality of intermediate orientations between the first orientation and the second orientation.

[0092] A further aspect of the invention refers to a method for assembling a system for controlling a wastegate, the system as described in the present disclosure, the method comprising: bringing the lever plate and the linking arm in communication to one another via the joint in the second orientation; bringing, preferably rotating, the linking arm and the lever plate from the second orientation into the first orientation to connect the linking arm and the lever plate.

[0093] The method comprises all advantages of the system and / or the turbocharger described herein. Particularly, it is noted that the method as described herein may include all aspects and / or embodiments described herein, even if not expressly described as a method but rather with reference to the system and / or the turbocharger. It is also to be understood that the features and advantages described with reference to the system and / or the turbocharger may equally be applicable to the method as described herein.

[0094] In the following, preferred embodiments of the disclosure are disclosed by reference to the accompanying figure.Figure 1: shows an embodiment of a linking arm and lever plate in different orientations, illustrating the connection and disconnection of the joint.Figure 2: shows an embodiment of a turbocharger system with various components including a wastegate, actuator, and connecting elements.Figure 2A: shows an embodiment of a turbocharger system with various components including a wastegate, actuator, and connecting elements.Figure 2B: shows an embodiment of a turbocharger system with various components including a wastegate, actuator, and connecting elements.Figure 3: shows an embodiment of a lever plate with a socket and a connecting element in two different orientations.Figure 4: shows an embodiment of a linking arm connected to the lever plate via a joint and a separate lever plate.Figure 5: shows another embodiment of a lever plate with a socket.Figure 6: shows a linking arm connected to a lever plate via a joint.Figure 7: shows an embodiment of a linking arm and lever plate with a biasing means.Figure 8: shows an embodiment of a linking arm and lever plate connected to a turbocharger system with a biasing means.

[0095] In the following only some possible embodiments of the invention are described in detail. However, the present invention is not limited to these, and a multitude of other embodiments are applicable without departing from the scope of the invention. The presented embodiments can be modified in a number of ways and combined with each other whenever compatible and certain features may be omitted in so far as they appear dispensable. In particular, the disclosed embodiments may be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0096] It is to be understood that not all features of the described aspects / embodiments have to be present for realizing the technical advantages provided by the present disclosure, which is defined by the subject-matter of the claims. The disclosed aspects / embodiments may be modified by combining certain features of one aspect / embodiment with one or more features of another aspect / embodiment. Specifically, the skilled person will understand that features, and / or functional elements of one aspect / embodiment can be combined with technically compatible features, and / or functional elements of any other aspect / embodiment of the present disclosure given that the resulting combination falls within the definition of the present disclosure.

[0097] Throughout the present figures and specification, the same reference numerals refer to the same elements. For the sake of clarity and conciseness, certain aspects of components or steps of certain embodiments are presented without undue detail where such detail would be apparent to those skilled in the art in light of the teachings herein and / or where such detail would obfuscate an understanding of more pertinent aspects of the embodiments.

[0098] As understood by the skilled person and / or in order to avoid redundancies, reference is also made to the explanations in the preceding sections, which also apply to the following detailed description. Further, not all features, parts, elements, aspects, components and / or steps are expressly indicated by reference signs for the sake of brevity and clarity. This particularly applies, where the skilled person recognizes that such features, parts, elements, aspects, components and / or steps are present in a plurality.

[0099] Fig. 1 illustrates an embodiment of a system for controlling a wastegate of a turbocharger of an internal combustion engine. The system 1 comprises a lever plate 50 and a linking arm 40, which are designed to communicate with a wastegate and an actuator 80 (shown in Fig. 2), respectively. The linking arm 40 is adapted to releasably connect to the lever plate 50 via a joint defined by a head 41 of the linking arm 40 and a socket 51 of the lever plate 50.

[0100] The first image (corresponding to a second orientation referenced as P2) shows the linking arm 40 and the lever plate 50 that are about to be assembled. Both components can be freely moved by means of translational and rotational movements.

[0101] In the second image, the linking arm 40 has been moved into the socket 51 of the lever plate 50 and is shown to be slightly rotated relative to the lever plate 50. This rotation is around the main axis MA of the linking arm 40. The rotation is, however, not performed to such an extent that the first orientation (P1) has been reached.

[0102] As can be seen, the joint 60 is designed such that the first orientation and the second orientation can be achieved by rotating the linking arm 40 around its main axis MA and / or by rotating the lever plate 50 around the main axis of the linking arm 40. The angle α of rotation around the main axis MA of the linking arm 40 between the first orientation and the second orientation may be specified to be within a range, for example, at least 10° and at most 170° (Fig. 3 shows a preferred angle α of 90°).

[0103] In the third image (corresponding to a first orientation referenced as P1), the linking arm 40 is shown in a position where the head 41 is aligned with the socket 51 of the lever plate 50. The head 41 of the linking arm 40 has an at least partially spherical shape, and the socket 51 of the lever plate 50 has an at least partially concave spherical shape. This configuration allows the head 41 to fit snugly into the socket 51, forming a secure joint. The head 41 is securely seated in the socket 51. The joint 60 is dimensioned to connect the linking arm 40 and the lever plate 50 in this first orientation P1 and to disconnect them in a second orientation P2.

[0104] It is noted that in traditional designs with pin, especially when either the lever plate or the linking arm is non-planar, there can be a risk of jamming due to misalignment (e.g., in assembly process and / or in operation). Therefore, additional clearance needs to be provided in traditional designs. The proposed system, by virtue of a substantially aligned configuration can reduce this risk of the jamming. Thereby, it facilitates minimizing the necessary clearance, e.g., between head 41 and socket 51. Thereby, chattering noise may be mitigated.

[0105] As best seen in Fig. 4, the lever plate 50 is shown to have a connecting element 53 for connecting to a wastegate shaft, which is spaced apart from the socket 51.

[0106] As best seen in Fig. 6, a plane (indicated by a dashed line) projecting through the center of the connecting element 53 and the center of the socket 51 is substantially parallel to the flat lever plate 50. The linking arm 40 is depicted as being substantially flat and elongate, which is preferable for the intended mechanical interaction with the lever plate 50.

[0107] As best seen in Fig. 4, the system 1 also includes an interface portion 52 within the socket 51 of the lever plate 50, configured to contact the head 41 of the linking arm 40 in the first orientation P1. This interface portion comprises a first material, while the lever plate 50 comprises a second material, ensuring durability and optimal mechanical performance.

[0108] This embodiment demonstrates the practical application of the system for controlling a wastegate, highlighting the mechanical interaction between the linking arm 40 and the lever plate 50, and the specific design features that facilitate their connection and disconnection through rotational movement.

[0109] Fig. 2 illustrates an embodiment of a system 1 for controlling a wastegate of a turbocharger 10 having a turbine 30 and a compressor 20, the turbocharger 10 being of an internal combustion engine.

[0110] The actuator 80 is connected to an actuator lever plate 70, the actuator lever plate 70 adapted to releasably connect to the linking arm 40. The actuator 20 is configured to provide the necessary force to move the linking arm 60, which in turn moves the lever plate 50 and controls the position of the wastegate. The actuator 80 is connected to the linking arm 60 via the actuator lever plate 70. The actuator lever plate 70 ensures that the movement from the actuator 80 is accurately transmitted to the linking arm 40 and subsequently to the lever plate 50.

[0111] Fig. 2A illustrates an embodiment in which the joint 60 is provided on the other side of the linking arm 40. Fig. 2B illustrates an embodiment in which the joint 60 is provided both sides. These illustrates the broad applicability of the joint as described in here. Further, as stated elsewhere herein, the system may also be used to control variable guide vanes or the like.

[0112] As shown in Fig. 4, the lever plate 50 is substantially flat and comprises a connecting element 53 for connecting to the wastegate shaft. The connecting element 53 is spaced apart from the socket 51 of the lever plate 50, ensuring that the lever plate 50 can effectively control the movement of the wastegate. The linking arm 40 is also substantially flat and elongate and is preferably substantially straight to facilitate efficient transmission of force from the actuator 20 to the lever plate 50.

[0113] As seen in Figs. 3 and 4, the joint 60 is dimensioned to connect the linking arm 40 and the lever plate 50 in a first orientation P1 of the linking arm 40 with respect to the lever plate 50 and to disconnect the linking arm 40 and the lever plate 50 in a second orientation P2 of the linking arm 40 with respect to the lever plate 50. The joint 60 is defined by a head 41 of the linking arm 40 and a socket 51 of the lever plate 50. The head 41 and the socket 51 are shaped at least partially in correspondence to one another, wherein the head 41 of the linking arm 40 preferably has an at least partially spherical shape, and the socket 51 of the lever plate 50 preferably has an at least partially concave spherical shape.

[0114] The at least partially spherical shape covers an angle γ of at least 90° and / or at most 320° in longitude (Fig. 4); and / or the at least partially spherical shape covers an angle β of at least 10° and / or at most 80° in latitude. The angle β in latitude is shown on one side of the equator only. As understood in here, an angle β of 80° in latitude means that that the angle can go upwards (e.g., north) from the equator by 80° and downwards (e.g., south) from the equator by 80°.

[0115] When connected in the first orientation, relative translational movement of the linking arm 40 and the lever plate 50 is substantially prevented, and relative rotational movement of the linking arm 40 and the lever plate 50 is preferably not prevented.

[0116] An angle of rotation α of the linking arm 40 around the main axis of the linking arm 40 between the first orientation P1 and the second orientation P2 is at least 10°, preferably at least 30°, preferably at least 50°, preferably at least 70°, preferably at least 85°, and / or at most 170°, preferably at most 150°, preferably at most 130°, preferably at most 110°, preferably at most 95° when the angle of rotation of the lever plate 50 around the main axis of the linking arm 40 between the first orientation and the second orientation is substantially maintained; or an angle of rotation of the lever plate 50 around the main axis of the linking arm 40 between the first orientation and the second orientation is at least 10°, preferably at least 30°, preferably at least 50°, preferably at least 70°, preferably at least 85°, and / or at most 170°, preferably at most 150°, preferably at most 130°, preferably at most 110°, preferably at most 95° when the angle of rotation α of the linking arm 40 around the main axis of the linking arm 40 between the first orientation and the second orientation is substantially maintained.

[0117] This means that either the linking arm 40 or the lever plate 50 can be rotated by the angle α around the main axis MA of the linking arm 40. As understood, the linking arm 40 and the lever plate 50 could also both rotate, e.g., both by about 45° around the main axis MA of the linking arm 40.

[0118] Fig. 5 illustrates a lever plate 50 designed to communicate with the wastegate of the turbocharger. The lever plate 50 comprises a socket 51, which is configured to interface with a head of a linking arm (not shown in this figure). The socket 51 is partially concave, providing a secure fit for the head of the linking arm. The lever plate 50 also includes a connecting element 53, which is spaced apart from the socket 51 and is used to connect the lever plate 50 to a wastegate shaft. Additionally, the lever plate 50 features a base portion 54, which provides structural support and stability to the lever plate. Thereby, the socket 51 has the shape of a cup. As stated above, the present disclosure is not limited to the example of a base portion 54 and further solutions are possible that substantially limit movement of the linking arm 40, preferably the head of the linking arm in an axial direction within the socket 41, e.g., one or more, such as two ridges may be provided.

[0119] Fig. 6 shows a view of the system 1, highlighting the interaction between the lever plate 50 and the linking arm 40. The linking arm 40 is substantially flat and elongate, and it is designed to communicate with an actuator 80 of the system. The linking arm 40 includes a head 41, which is dimensioned to fit into the socket 51 of the lever plate 50. The head 41 of the linking arm 40 has an at least partially spherical shape, allowing it to be securely received by the concave socket 51 of the lever plate 50.

[0120] In the illustrated embodiment, the linking arm 40 and the lever plate 50 are shown in the first orientation P1 with respect to one another, where the head 41 is securely connected within the socket 51. This connection prevents relative translational movement between the linking arm 40 and the lever plate 50, while allowing relative rotational movement. E.g., the lever plate 50 can pivotally rotate around the joint 60. The lever plate 50 is further shown with its connecting element 53 aligned for attachment to a wastegate shaft.

[0121] Overall, the figures illustrate the detailed construction and interaction of the lever plate 50 and the linking arm 40 within the system for controlling a wastegate of a turbocharger. The specific shapes and dimensions of the components, as well as their materials, are designed to ensure a secure and efficient connection, allowing for precise control of the wastegate.

[0122] It is noted that the head and socket described in here can have various configurations. For instance, it can have cylindrical shapes, e.g., on both sides.

[0123] Alternative configurations may comprise that the head is spherical, and the socket is cylindrical or elliptical or a segmented polygon. The socket should have smaller (or equal) curvature, i.e., the radius of the head should be smaller than that of the socket.

[0124] As a non-exhaustive list, the following configurations are encompassed by the present disclosure:

[0125]

[0126] Fig. 7 illustrates an embodiment of the system 1 for controlling a wastegate of a turbocharger of an internal combustion engine. The system 1 comprises a linking arm 40 and a lever plate 50. The linking arm 40 is depicted as substantially flat and elongate, with a head 41 at one end. The head 41 is designed to engage with a socket 51 on the lever plate 50. The lever plate 50 is shown with a connecting element 53, which is configured to connect to a wastegate shaft.

[0127] The linking arm 40 is adapted to communicate with an actuator of the system, enabling it to control the wastegate. The head 41 of the linking arm 40 and the socket 51 of the lever plate 50 form a joint, which is dimensioned to connect the linking arm 40 and the lever plate 50 in a first orientation and to disconnect them in a second orientation. The head 41 is preferably spherical, and the socket 51 is concave, allowing for a secure connection that permits rotational movement while preventing translational movement when in the first orientation.

[0128] The system 1 further comprising a biasing means 90 disposed on the lever plate 50 and adapted to bias movement imposed on the lever plate 50 by means of the wastegate. The biasing means 90 may be implemented by means of a spring. The biasing means 90 may comprise a joint bias portion and / or a wastegate axial lift portion. This may provide for a dual function.

[0129] Fig. 8 provides a detailed view of the connection between the linking arm 40 and the lever plate 50 within the turbocharger assembly. The lever plate 50 is connected to the wastegate shaft via the connecting element 53. The socket 51 of the lever plate 50 is shown in engagement with the head 41 of the linking arm 40.

[0130] The system 1 comprises a biasing means 90, which is specifically dimensioned for the lever plate 50, which may be flat. The biasing means 90 may comprise an axial push portion and a wastegate axial lift portion. The biasing means 90 of Fig. 7 and Fig. 8 is adapted to push the linking arm and the lever plate closer to one another.

[0131] It is to be noted that the scope of protection is determined by the claims and is not limited by the embodiments disclosed in the above figures.

[0132] 1　system 10　turbocharger 20　compressor 30　turbine 40　linking arm 41　head 50　lever plate 51　socket 52　interface portion 53　connecting element 54　base portion 60　joint 70　actuator lever plate 80　actuator 90　biasing means α　angle in orientation β　angle of latitude γ　angle of longitude P1　first orientation P2 　　second orientation MA　main axis of the linking arm

Claims

1. A system (1) for controlling a wastegate of a turbocharger (10) of an internal combustion engine, the system (1) comprising: a lever plate (50) adapted to communicate with the wastegate of the turbocharger (10) for controlling the wastegate; a linking arm (40) adapted communicate with an actuator (80) of the system (1) and adapted to releasably connect to the lever plate (50) via a joint (60) defined by a portion of the lever plate (50) and a portion of the linking arm (40); wherein the joint (60) is dimensioned to connect the linking arm (40) and the lever plate (50) in a first orientation (P1) of the linking arm (40) with respect to the lever plate (50) and to disconnect the linking arm (40) and the lever plate (50) in a second orientation (P2) of the linking arm (40) with respect to the lever plate (50).

2. The system according to claim 1, wherein the joint (60) is defined by a head (41) of the linking arm (40) and a socket (51) of the lever plate (50).

3. The system according to claim 2, wherein the head (41) and the socket (51) are shaped at least partially in correspondence to one another, wherein the head (41) of the linking arm (40) preferably has an at least partially spherical shape, and the socket (51) of the lever plate (50) preferably has an at least partially concave spherical shape.

4. The system according to claim 3, wherein the at least partially spherical shape covers an angle (γ) of least 90° and / or at most 320° in longitude; and / or wherein the at least partially spherical shape covers an angle (β) of at least 10° and / or at most 80° in latitude.

5. The system according to any one of the preceding claims, wherein, when connected in the first orientation (P1), relative translational movement of the linking arm (40) and the lever plate (50) is substantially prevented and relative rotational movement of the linking arm (40) and the lever plate (50) is preferably not prevented.

6. The system according to any one of the preceding claims, wherein the joint (60) is dimensioned such that the first orientation (P1) and / or the second orientation (P2) can be achieved by rotating the linking arm (40) around a main axis (MA) of the linking arm (40) and / or by rotating the lever plate (50) around a main axis (MA) of the linking arm (40).

7. The system according to claim 6, wherein an angle (α) of rotation of the linking arm (40) around the main axis (MA) of the linking arm (40) between the first orientation (P1) and the second orientation (P2) is at least 10°, preferably at least 30°, preferably at least 50°, preferably at least 70°, preferably at least 85°, and / or at most 170°, preferably at most 150°, preferably at most 130°, preferably at most 110°, preferably at most 95° when the angle of rotation of the lever plate (50) around the main axis (MA) of the linking arm (40) between the first orientation (P1) and the second orientation (P2) is substantially maintained; or wherein an angle (α) of rotation of the lever plate (50) around the main axis (MA) the linking arm (40) between the first orientation (P1) and the second orientation (P2) is at least 10°, preferably at least 30°, preferably at least 50°, preferably at least 70°, preferably at least 85°, and / or at most 170°, preferably at most 150°, preferably at most 130°, preferably at most 110°, preferably at most 95° when the angle of rotation of the linking arm (40) around the main axis (MA) of the linking arm (40) between the first orientation (P1) and the second orientation (P2) is substantially maintained.

8. The system according to any one of the preceding claims, wherein the joint (60), preferably the socket (51) of the lever plate (50) comprises an interface portion (52) configured to contact the head (41) of the linking arm (40) in the first orientation (P1), the interface portion (52) comprising a first material and the lever plate (50) comprising a second material.

9. The system according to any one of the preceding claims, further comprising an actuator lever plate (70) configured to communicate with an actuator (80), the actuator lever plate (70) preferably being adapted to releasably connect to the linking arm (40).

10. The system according to any one of the preceding claims, wherein the linking arm (40) is substantially flat, preferably planar and / or elongate, wherein the linking arm (40) is preferably substantially straight.

11. The system according to any one of the preceding claims, wherein the lever plate (50) is substantially flat, and the lever plate (50) comprises a connecting element (53) for connecting to the lever plate (50) to a wastegate shaft, the connecting element (53) being spaced apart from the socket (51) of the lever plate (50).

12. The system according to claim 11, wherein a plane projecting through a center of the connecting element (53) and a center of the socket (51) is substantially parallel to the flat lever plate.

13. A turbocharger (10) comprising: a turbine (30) comprising a wastegate for bypassing flow around an impeller of the turbine (30); a compressor (20) preferably provided in an intake flow path through which intake air is configured to be supplied to the engine, wherein the compressor (20) is configured to be driven by the turbine (30) to compress intake air; and a system (1) for controlling a wastegate according to any one of the preceding claims.

14. A motor vehicle comprising: the turbocharger (10) of claim 13; a control unit adapted to control the system (1).

15. A method for assembling a system (1) for controlling a wastegate, the system according to of any one of claims 1 to 12, the method (100) comprising: bringing the lever plate (50) and the linking arm (40) in communication to one another via the joint (60) in the second orientation (P2); bringing, preferably rotating, the linking arm (40) and the lever plate (50) from the second orientation (P2) into the first orientation (P1) to connect the linking arm (40) and the lever plate (50).

Images