Hub-less Turbocharger Compressor Wheel Design
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Solution Overview
Problem
Traditional turbocharger designs with large hex nuts on the hub obstruct fluid flow, limiting horsepower potential and requiring larger frame sizes to increase power output, which is not feasible in high-performance applications with size restrictions.
Innovation Solution
The design eliminates the nut and hub on the nose of the turbocharger's hub, allowing the turbine and compressor wheels to have blades with converging leading edges that align with the centerline, enhancing fluid flow and blade length without compromising structural integrity, and uses alternative attachment methods like set screws to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large hex nut is used on the hub of the compressor/intake wheel and turbine/exhaust wheel for manufacturing and assembly, then the wheel can be securely fastened to the shaft, but the fluid flow through the turbocharger is obstructed, limiting horsepower potential
Solution Approach 1:
The patent removes the traditional large hex nut from the hub of the compressor/intake wheel and turbine/exhaust wheel. Instead, the wheel is directly mounted to the shaft using a interference fit or keyway connection, eliminating the protruding nut that obstructs fluid flow. This extraction of the harmful element (the nut) resolves the contradiction by maintaining attachment strength through alternative means while removing the flow obstruction that limited horsepower potential.
2Productivity
If the frame size of the turbocharger is increased to increase power output, then horsepower potential is improved, but the turbocharger becomes too large for high-performance applications with size restrictions
Solution Approach 1:
The patent converts the previously harmful hub nut obstruction into a benefit by eliminating it entirely. The removal of the nut creates a clearer fluid path through the turbocharger, allowing for improved fluid dynamics and increased horsepower potential within the same frame size. This transformation of a harmful feature (the obstructing nut) into its absence enables higher power output without increasing physical dimensions.
3Productivity
If the hub nut is removed to improve fluid flow, then horsepower and fluid flow are increased, but alternative attachment methods must be used to maintain structural integrity
Solution Approach 1:
The patent replaces the traditional mechanical fastening system (hex nut and threaded shaft) with a direct interference fit or keyway connection between the wheel hub and shaft. This substitution eliminates the need for the hex nut while maintaining secure attachment. The new attachment method is actually simpler in terms of fluid flow (no protruding nut) and uses standard mechanical fitting techniques rather than complex fastening mechanisms.
Data Source
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AI summary
A turbocharger for an internal combustion engine is provided, where the turbocharger includes a housing, a shaft, a turbine wheel, and a compressor wheel. The shaft is rotatable with respect to the housing and defines a centerline. The turbine wheel is mounted to the shaft and is disposed within the housing. The compressor wheel is also mounted to the shaft and is disposed within the housing. The turbine wheel and/or the compressor wheel has a plurality of blades with leading edges that converge at an apex. The apex is aligned with the centerline. A method of constructing a turbocharger is also provided, where the method includes the step of performing a finishing operation on the turbine wheel and/or the compressor wheel to form an apex where the leading edges of the blades converge.