Compressor Intermediate Wall Sealing via Segmented Bore Holes
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Solution Overview
Problem
Existing exhaust gas turbochargers with axial turbines face challenges in sealing the rear space of the compressor wheel, leading to air leakage and potential contamination of the bearing area, requiring complex machining processes for effective sealing.
Innovation Solution
A bearing device with a rotationally symmetrical, disc-shaped intermediate wall and a circumferential fastening flange, featuring multiple bores for sealing air ducts and fastening means, simplifies the sealing process by using a drillable design that aligns with the bearing housing, ensuring effective sealing and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a round pin is used for sealing air transition between the intermediate wall and bearing housing, then sealing function is achieved, but manufacturing complexity increases due to circular milling requirements
Solution Approach 1:
The sealing air duct is divided into multiple segments arranged radially, with each segment formed by a separate bore hole. This segmentation allows the use of simple drilling operations instead of complex circular milling, while maintaining the sealing function through the radial arrangement of multiple bore holes that collectively form the sealing air duct.
Solution Approach 2:
The complex circular milling process is replaced with a simpler drilling process. Instead of using a milling cutter to create a continuous circular groove, multiple discrete bore holes are drilled radially, which are then connected to form the sealing air duct. This substitution of machining operations reduces manufacturing complexity while achieving the same sealing effect.
2Ease of manufacture
If the intermediate wall is designed with rotational symmetry, then manufacturing is simplified, but sealing effectiveness may be compromised
Solution Approach 1:
The sealing air duct is segmented into multiple radial bore holes rather than a single continuous structure. This segmentation maintains rotational symmetry in the overall pattern while creating effective sealing through the radial arrangement, allowing the intermediate wall to be manufactured with simple drilling operations while preserving sealing effectiveness.
Solution Approach 2:
While the overall pattern maintains rotational symmetry for manufacturing simplicity, the individual sealing elements (bore holes) are arranged asymmetrically in a radial pattern. This radial arrangement creates effective sealing by directing sealing air flow in a controlled manner while preserving the rotational symmetry needed for simple manufacturing.
3Reliability
If multiple bores are arranged in the fastening flange for sealing air ducts, then sealing capability is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing air duct system is segmented into multiple separate bore holes arranged radially in the fastening flange. Each bore hole can be drilled independently using standard drilling operations, avoiding the need for complex multi-axis machining. The radial arrangement of these segmented bores creates effective sealing capability while maintaining manufacturing simplicity.
Solution Approach 2:
The bore holes in the fastening flange serve multiple functions: they form the sealing air ducts for sealing capability, and they provide mounting positions for fastening means. This multi-functionality reduces the need for additional features and simplifies the overall manufacturing process while maintaining reliable sealing.
Data Source
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AI summary
The wall (40) has a peripheral rotationally symmetrical disk-shaped base body provided with a central opening for passage of a rotor. A rotationally symmetrical shaped mounting flange (41) is provided for fixing the wall to a bearing housing (30) and provided with a planar contact surface for resting on a contact surface of the bearing housing. A sealing air passage (42) comprises holes (43) distributedly arranged in a circumferential direction of a virtual circumference for retaining of a fastening unit (50). A groove retains a seal ring. Independent claims are also included for the following: (1) a bearing device for supporting a rotor of a compressor (2) a radial compressor.