Turbocharger Compressor Bellows Absorption Element
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Solution Overview
Problem
Existing exhaust gas turbochargers face challenges in containing compressor wheel fragments during bursting, leading to unforeseen consequences for adjacent housing components, and existing solutions require large construction volumes and high production accuracy, increasing costs and structural mass.
Innovation Solution
A rotationally symmetrical peripheral bellows absorption element is designed to absorb axial forces in the event of a compressor wheel bursting, allowing for elastic and plastic deformation to dissipate kinetic energy, thereby protecting housing connections without significant increases in size or material demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expansion bolts and screwed flange connections are used to absorb axial bursting forces, then the housing connections are protected from failure, but the construction volume increases and production accuracy requirements increase
Solution Approach 1:
The patent employs a bellows structure (flexible shell) as the absorption element that can elastically and plastically deform to absorb axial bursting forces. This flexible structure absorbs the kinetic energy of flying fragments through its deformation capacity, protecting housing connections without requiring large construction volumes or high production accuracy like rigid expansion bolts would demand
Solution Approach 2:
The absorption element changes its physical state from rigid to flexible through controlled elastic and plastic deformation. The bellows structure transitions from its initial configuration to a deformed state during bursting events, absorbing energy through parameter changes in its structural geometry and material stress state
2Stability of the object's composition
If long expansion fitting screws are used to absorb axial bursting forces, then the housing insert wall is protected from twisting, but the structural mass and production costs increase
Solution Approach 1:
The bellows-shaped absorption element serves as a flexible shell structure that prevents twisting of the housing insert wall through its deformable geometry. The circumferential support ring with axially directed webs provides rotational stability while the flexible design allows energy absorption without requiring heavy, rigid fastening components
3Reliability
If holding devices are added to the housing insert wall to catch fragments, then fragment containment is improved, but the device complexity and construction volume increase
Solution Approach 1:
The bellows-shaped absorption element performs multiple functions simultaneously: it absorbs axial bursting forces, prevents housing insert wall twisting, contains flying fragments, and protects housing connections. This multi-functional design eliminates the need for separate holding devices, reducing overall device complexity while maintaining comprehensive protection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The absorption element effectively relieves axial loads on housing connections, ensuring containment of compressor wheel fragments and reducing the risk of housing failure while minimizing installation space and material usage.
Implementation Method 1
The absorption element is designed in the form of a peripheral bellows. The bellows of the absorption element forms a compression zone which, in the event of a compressor wheel bursting, can first be deformed elastically and then plastically.
Implementation Method 2
The bellows of the absorption element forms a compression zone which, in the event of a compressor wheel bursting, can first be deformed elastically and then plastically.
Data Source
Figure 1~3
Figure 2
AI summary
The compressor of an exhaust gas turbocharger comprises a compressor wheel (14), an outer compressor housing (101), and a housing insert (102, 103) arranged radially outside of the compressor wheel (14), wherein the housing insert has an insert wall contour, which together with a hub of the compressor wheel (1) delimits a flow channel, and the housing insert (10) is fastened to the outer compressor housing (20) in the axial direction. According to the invention, the housing insert piece comprises an absorption element in the form of a circumferential bellows (105) for securing (106, 109) to the outer compressor housing (101) in order to transfer axial forces from the insert wall contour (11). The kinetic energy released during failure is absorbed by the elastic and plastic deformation bellows-shaped absorption element. The claimed absorption element thus requires the smallest possible installation space for high axial unloading of the housing connection between the inner and outer compressor housing parts and/or between the compressor housing and the bearing housing in the event that the compressor wheel bursts.