Turbocharger Compressor Wheel Balancing Mark for Higher Material Removal
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Solution Overview
Problem
Existing methods for balancing the compressor wheel of a turbocharger are suboptimal in terms of flow dynamics, strength, and space requirements, as they either damage the blades or require repeated tool applications, limiting material removal and increasing production time.
Innovation Solution
A method involving a milling tool that first creates a recess on the compressor wheel and then converts it into a pear segment-shaped balancing mark in a single pass, allowing for greater material removal without increasing space requirements and maintaining the supporting cross-section's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If material is removed from the hub contour by one-dimensional advance of milling tool, then balancing is achieved, but the space requirement increases and blade spacing must be enlarged
Solution Approach 1:
The patent transitions from one-dimensional milling tool advance to two-dimensional movement by introducing radial and tangential components. The milling tool moves radially inward to create a recess, then tangentially along the hub contour to form the pear-shaped balancing mark, enabling greater material removal within limited space without enlarging blade spacing.
2Strength
If milling tool radius is increased to reduce stress peaks, then strength is improved, but the quantity of material that can be removed decreases
Solution Approach 1:
The balancing mark is divided into two formation stages: first creating a recess by moving the tool radially inward, then forming the final pear shape by moving tangentially. This segmentation allows using a milling tool with larger radius for strength reasons while still achieving sufficient material removal through the two-stage process.
3Manufacturing precision
If repeated application of milling tool is used to create balancing mark, then manufacturing precision can be maintained, but production time increases
Solution Approach 1:
The patent implements continuous two-dimensional movement of the milling tool combining radial and tangential components in a single pass. This eliminates the need for repeated tool applications while maintaining manufacturing precision through controlled continuous motion, thereby reducing production time.
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
This method enables increased material removal with reduced production time and improved accuracy, while minimizing the weakening effect on the compressor wheel's structure.
Implementation Method 1
a milling tool is firstly moved in a first direction on the compressor wheel in order to introduce a recess into the inflow side of the compressor wheel, and then the milling tool located in the recess runs out in a second direction in order to convert the recess into a pear segment-shaped balancing mark
Data Source
AI summary
The invention relates to a method for introducing a balancing mark into the compressor wheel of a turbocharger. According to the method, a milling tool is firstly moved in a first direction in order to introduce a recess into the compressor wheel, and the milling tool located in the recess then runs out in a second direction in order to convert the recess into a pear segment-shaped balancing mark. The invention furthermore relates to a turbocharger which comprises a compressor wheel that has one or more pear segment-shaped balancing marks.