Modular Turbine Housing Assembly via Sheet Metal Segmentation
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Solution Overview
Problem
Conventional turbine housings made of sheet metal face challenges in manufacturing complexity, weight, heat capacity, and cost due to complex scroll part formation and inadequate sealability, particularly when connected to bearing housings.
Innovation Solution
A turbine housing assembly is broken down into modular components such as a scroll part, exhaust part, and connection part, all formed from single pieces of sheet metal, with the scroll part and exhaust part connected via a gap to reduce heat transfer and allow for less expensive materials, and the connection part formed separately to enhance assembly and sealability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the scroll part is formed by bringing two right-and-left sheet metal members into contact and welding them, then the exhaust gas flow path can be formed, but the manufacturing process becomes troublesome and complex
Solution Approach 1:
The turbine housing is divided into modular components: the scroll part formed from a single sheet metal piece, and the exhaust part formed separately from another sheet metal piece. This segmentation allows each part to be manufactured independently with simpler processes, then assembled together to form the complete exhaust gas flow path system.
Solution Approach 2:
The scroll part and exhaust part are joined together through welding at their interface, combining two separately manufactured components into a functional whole that forms the complete exhaust gas flow path from inlet to outlet.
2Ease of operation
If the scroll part is directly connected to the bearing housing, then assembly is simplified, but sealability with respect to exhaust gas deteriorates
Solution Approach 1:
The exhaust part serves as an intermediary component between the scroll part and the bearing housing. It provides a dedicated interface for connection to the bearing housing with proper sealing arrangements, while maintaining the simplicity of sheet metal construction. The exhaust part acts as a mediator that ensures both sealability and ease of assembly.
3Strength
If the turbine housing is made as a single integrated component, then structural integrity is improved, but weight and heat capacity increase
Solution Approach 1:
The turbine housing is segmented into multiple sheet metal components (scroll part, exhaust part, and other housing sections) that are assembled together. This segmentation reduces the overall weight and heat capacity compared to a single integrated casting, while maintaining structural integrity through proper joining methods.
4Temperature
If high heat resistance material is used throughout the turbine housing, then thermal resistance is improved, but cost increases
Solution Approach 1:
Different parts of the turbine housing are made from materials with appropriate heat resistance for their specific locations. The scroll part, which is exposed to high-temperature exhaust gas, uses high heat resistance material. The exhaust part and other components exposed to lower temperatures can use less expensive materials with lower heat resistance, reducing overall material cost while maintaining adequate thermal performance.
Data Source
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AI summary
An object is to provide a turbine housing assembly in which reduction of weight, facilitation of manufacture, cost-cutting, and reduction of heat capacity are further promoted compared to a conventional turbine housing made of sheet metal. A turbine housing assembly includes a plurality of constituent members connected to one another to constitute a turbine housing into which a turbine wheel is inserted. The turbine housing assembly at least includes a scroll part 2 and an exhaust part 8 of a tubular shape having a separate body separate from the scroll part 2. The scroll part 2 is formed by processing a single piece of sheet metal so that, on a back face side of a bottom face part 22 of the scroll part 2, a recess portion 8a on which a through-hole of an exhaust gas outlet 2B is formed and a projecting portion 22a formed by a bottom surface of an exhaust gas flow path 2A projecting toward the back face side are formed, the projecting portion 22a surrounding the recess portion 22b. The recess portion 22b of the scroll part 2 is connected to an end portion 8a of the exhaust part 8 in a turbine axial direction so that the exhaust part 8 is in communication with the exhaust gas outlet 2B of the scroll part 2 in a state where a gap "a" is formed between an outer circumferential face of the exhaust part 8 and the projecting portion 22a of the scroll part 2.