Turbocharger Impeller Rotator Balancing via Connecting Member Deformation
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Solution Overview
Problem
Conventional methods for correcting rotational balance in turbocharger impeller rotators are complex and require excessive cutting, leading to labor inefficiencies and increased disposal costs due to the need for repeated cutting operations.
Innovation Solution
The method involves plastic deformation of a connecting member, such as a nut, attached to the shaft connecting the turbine and compressor impellers, to achieve rotational balance by offsetting and compensating for imbalances between the two impellers, reducing the number of processing steps and cut amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used to correct rotational balance of both compressor and turbine impellers, then rotational balance can be corrected, but the process becomes complicated requiring multiple repeated cutting steps
Solution Approach 1:
The patent segments the balancing correction process by applying different methods to different components: the turbine impeller is balanced through cutting operations, while the compressor impeller is balanced through plastic deformation of its connecting member (nut). This segmentation allows each component to be corrected independently in a single step rather than requiring repeated alternating corrections of both components.
Solution Approach 2:
Instead of continuing to use cutting operations for both components as done conventionally, the patent inverts the approach by using plastic deformation for the compressor impeller's connecting member. This alternative method achieves the same balancing goal but eliminates the need for repeated cutting steps and complex process coordination.
2Manufacturing precision
If conventional cutting methods are used to correct rotational balance, then imbalance can be reduced, but large cut amounts require disposal of impeller parts
Solution Approach 1:
The patent changes the physical state and properties of the connecting member through plastic deformation, transforming it from a rigid fastening element into a balancing mass. By controlling the degree of deformation, the exact amount of mass removal needed for balancing is achieved without requiring large cuts that would compromise the impeller structure or necessitate part disposal.
Solution Approach 2:
Instead of discarding the connecting member (nut) when large cuts are required for balancing, the patent recovers and utilizes the connecting member itself as the balancing mass. The deformed connecting member becomes an integral part of the balancing solution, eliminating material waste and disposal costs.
3Manufacturing precision
If repeated cutting operations are performed to achieve proper rotational balance, then balancing accuracy can be improved, but labor time and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the impeller rotator with both compressor and turbine impellers in place before performing balancing operations. This allows the imbalance characteristics of the complete assembly to be measured and corrected in a single operation on the connecting member, rather than requiring multiple repeated corrections of individual components.
Solution Approach 2:
The patent merges the balancing correction operations for both compressor and turbine impellers into a single unified process. By correcting the imbalance of the complete rotator assembly through deformation of one connecting member, multiple separate cutting operations are consolidated into one operation, significantly improving productivity and reducing labor 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 approach simplifies the balancing process, reduces man-hours, and minimizes material disposal by allowing for efficient assembly and correction of rotational balance with fewer steps and less material removal, resulting in a more cost-effective and efficient manufacturing process.
Implementation Method 1
The connecting member is plastic-deformed so as to decrease overall imbalance of the turbine impeller, the compressor impeller, and the shaft
Data Source
AI summary
An impeller rotator (21) includes a turbine impeller (11), a compressor impeller (12), a shaft (13) connecting the turbine impeller (11) to the compressor impeller (12), and a connecting member (16) fastening one of the turbine impeller and the compressor impeller to one axial end region of the shaft, and the connecting member (16) is plastic-deformed so as to decrease overall imbalance of the turbine impeller (11), the compressor impeller (12), and the shaft (13).