Modular Nozzle Ring Segmentation for Turbocharger Flow Control
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Solution Overview
Problem
Current manufacturing processes for nozzle rings in exhaust gas turbochargers face challenges in achieving cost-effectiveness while maintaining optimal flow control and flexibility, with existing methods either being expensive or resulting in poor flow control due to the use of thin sheet metal profiles.
Innovation Solution
A modular nozzle ring design composed of individual guide vanes and fastening rings, where guide vanes have bolts for attachment to one fastening ring and adjustable positioning in another, allowing for variable angular positions and lengths without the need for multiple casting models, enabling the use of different materials and reducing production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If investment casting process is used for one-piece nozzle ring manufacturing, then flow control is good, but production flexibility is limited and costs are high due to separate casting models for each blade angle position
Solution Approach 1:
The nozzle ring is divided into separate components: individual guide vanes and a common ring structure. The guide vanes can be manufactured using investment casting with high precision for optimal flow control, while the common ring serves as a reusable base for multiple blade angle positions. This segmentation allows precise casting of only the critical flow-guiding elements rather than entire nozzle rings for each configuration.
Solution Approach 2:
The common ring is designed as a universal component that can accommodate guide vanes with different angular positions and blade lengths. By creating a multi-functional base structure that supports various vane configurations, the system achieves production flexibility without sacrificing the flow control quality provided by precisely cast guide vanes.
2Manufacturing precision
If welded or soldered guide vanes are used in individual rings, then flow control is optimal, but production costs are higher compared to sheet metal variants
Solution Approach 1:
The guide vanes are separated from the ring structure and manufactured as individual precision-cast components. This allows the expensive but high-precision investment casting process to be applied only to the guide vanes where flow control is critical, rather than casting entire nozzle rings. The common rings can be manufactured using more economical processes.
Solution Approach 2:
Different manufacturing processes are applied to different parts of the nozzle ring system based on their functional requirements. The guide vanes receive high-precision investment casting for optimal flow control, while the common rings use more cost-effective manufacturing methods. This local differentiation of quality and process optimizes the overall cost-performance ratio.
3Ease of manufacture
If sheet metal profiles are welded or soldered between fastening rings, then production costs are reduced, but flow control is significantly poorer and walls are thin and susceptible to erosion
Solution Approach 1:
The guide vanes are segmented as separate precision-cast components rather than being formed from sheet metal. This segmentation enables the use of investment casting for the guide vanes to achieve optimal flow control, while the common rings provide the structural support at lower cost.
Solution Approach 2:
The nozzle ring system combines different material forms and manufacturing processes: precision-cast metal guide vanes for flow control and economically manufactured common rings for structural support. This composite approach optimizes both performance and cost by matching material and process selection to functional requirements.
4Adaptability or versatility
If modular nozzle ring with identical blades is used, then production flexibility is improved, but flow guidance is poorer compared to one-piece investment casting
Solution Approach 1:
The system is segmented into precision-cast guide vanes and common rings. The guide vanes are manufactured with high precision using investment casting to ensure optimal flow guidance, while the common rings provide modular support structures. This segmentation allows the critical flow-guiding elements to maintain high precision even in modular configurations.
Solution Approach 2:
High manufacturing precision is applied locally to the guide vanes where flow control is critical, while the common rings use more economical manufacturing processes. This localized quality differentiation ensures that flow guidance performance is maintained in the critical areas while reducing overall production costs and improving flexibility.
Data Source
Figure 1
Figure 2~13
Figure 3~5
AI summary
The ring (1) has a set of guide vanes (12) arranged among fastening rings (10, 11, 11') and fixed in respective angular position, where the rings are arranged coaxially. The guide vanes include a positioning aid on an end face partially corresponding to an outer contour of the end face. The guide vanes are fixed with regard to angular position by the arrangement of the positioning aid in an opening (14) corresponding to the shape of the positioning aid in the second fastening ring. An independent claim is also included for a method for manufacturing a nozzle ring.