Elastic Spring Disk Wastegate Flap for Turbocharger Vibration Control
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Solution Overview
Problem
Existing exhaust-gas turbochargers face challenges in being cost-effective, low-maintenance, and efficient due to complex wastegate flap arrangements that are prone to vibration-induced issues and frictional wear.
Innovation Solution
The wastegate flap arrangement is designed with an elastic spring disk that directly seals the wastegate duct, connected via a direct and rigid linkage to a flap shaft, minimizing play and using a one-piece or welded lever and shaft configuration to prevent vibrations and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex wastegate flap arrangement is used, then the sealing performance is improved, but the device complexity and maintenance needs increase
Solution Approach 1:
The patent merges the flap plate and sealing element into a single integrated spring disk component. The spring disk serves dual functions as both the moving flap and the sealing element, eliminating the need for separate sealing rings or gaskets. This integration reduces the number of parts while maintaining effective sealing of the wastegate duct.
Solution Approach 2:
The patent changes the physical state and properties of the flap plate by using an elastic spring disk instead of a rigid plate. This parameter change allows the sealing element to adapt to surface irregularities and maintain sealing under varying pressure conditions, improving reliability while simplifying the overall structure.
2Ease of manufacture
If multiple separate components are used in the flap arrangement, then the ease of manufacture is improved, but the vibration-induced frictional wear and acoustic problems increase
Solution Approach 1:
The lever and flap shaft are merged into a single one-piece component, eliminating joints and connection points that could generate vibrations or frictional wear. This integration maintains ease of manufacture through common forging or machining processes while eliminating the harmful vibration-related effects mentioned in the problem statement.
3Productivity
If a rigid connection between lever and spring disk is used, then the operational efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent changes the connection interface to accommodate normal manufacturing tolerances. The spring disk's elastic properties and the designed contact surfaces allow for a direct connection that remains effective within standard tolerance ranges, achieving rigid enough coupling for efficient operation without requiring ultra-precise manufacturing.
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 design enhances the operational efficiency and reduces maintenance needs by ensuring a secure, low-friction seal and minimizing acoustic and vibration-related issues, resulting in a more reliable and cost-effective turbocharger operation.
Implementation Method 1
The elastically deformable spring disk seals off the wastegate duct as a result of the flexibility of said spring disk. Here, the spring disk compensates the distortion and the effects, for example an oblique position, owing to component tolerances.
Data Source
AI summary
An exhaust-gas turbocharger (1) with a turbine housing (2) which has a turbine housing inlet (8) and a turbine housing outlet (9) for exhaust gas, and which has a wastegate duct (19) between the turbine housing inlet (8) and the turbine housing outlet (9), and a flap arrangement (10) having a pivotable flap plate for opening and closing the wastegate duct (19), wherein the flap plate is in the form of an elastic spring disk (11).