Segmented Filter Muffler Connections for Turbocharger Vibration
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Solution Overview
Problem
Exhaust gas turbochargers experience excessive vibration and heat-induced preload reduction in screw connections due to mechanical vibrations, leading to potential disconnection issues between the filter silencer and compressor housings.
Innovation Solution
Implementing separate screw connections between the filter silencer and the outer compressor housing, and between the inner and outer compressor housings, with radially distributed fastening means to reduce load and enhance elasticity, allowing for improved accessibility and alignment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filter silencer is rigidly connected to the compressor housing by means of a fastening flange with screw connections, then the silencer is securely attached, but the preload in the screw connection is reduced due to creeping of the heated mounting flange under mechanical vibrations
Solution Approach 1:
The mounting flange is divided into two separate flanges: a first flange for connecting the inner compressor housing and a second flange for connecting the filter silencer. This segmentation allows each flange to be independently optimized and prevents the heating and creeping issues that occur when both connections share a single flange, thereby maintaining screw connection preload and reliability under thermal and vibrational loads.
2Ease of manufacture
If the compressor housing is divided into inner and outer housing parts with screw connections, then assembly and disassembly of the compressor wheel is facilitated, but the connection is exposed to heavy loads and heat during operation
Solution Approach 1:
The compressor housing is segmented into inner and outer housing parts that can be separately assembled and disassembled for compressor wheel maintenance. The separate flange design ensures that the connection points are strategically positioned to handle thermal and vibrational loads effectively, maintaining connection strength while preserving assembly ease.
3Ease of operation
If the axial distance between the foot and the silencer is very large, then assembly is simplified, but engine vibrations excite the muffler to excessively vibrate
Solution Approach 1:
The mounting system uses separate flanges positioned at optimized locations on the compressor housing. This segmentation allows the silencer to be mounted at an appropriate distance from the engine foot, simplifying assembly while the distributed flange configuration reduces vibration excitation by preventing resonant coupling.
Data Source
Figure 1
Figure 2
AI summary
The aim of the invention is to create an optimized compressor stage for exhaust gas turbocharger applications. In particular, the connection between the muffler, the inner and outer compressor housing should be improved. Said aim is achieved by creating separate connections between the filter muffler (2) and the external compressor housing (11) as well as between the internal compressor housing (12) and the external compressor housing (11). The two separate connections are arranged on the same flange of the external compressor housing while being separated from one another.