Transverse Flux Linear Actuator for Turbocharger Flap Control
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Solution Overview
Problem
Existing linear actuators for adjusting turbocharger flaps in motor vehicles face challenges such as low dynamics, high production costs, and inefficiencies, particularly with pneumatic and electromechanical systems, which result in imprecise control and susceptibility to failures due to leaks and high energy requirements.
Innovation Solution
A two-phase transverse flux linear actuator with a spindle nut or wobble sleeve driven by an electric motor, featuring a rotor between two single-phase stators and using reluctance machines for efficient angle measurement without additional sensors, and a compact design with aluminum tape spools and permanent magnet rings for enhanced torque and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pneumatic linear actuators are used to adjust turbocharger flaps, then the actuators are inexpensive and simple to manufacture, but the flap position cannot be set exactly and intermediate positions can only be implemented imprecisely and with low dynamics
Solution Approach 1:
The patent replaces the pneumatic system with an electromechanical system using a brushless DC motor coupled directly to the flap shaft. This substitution eliminates the need for pneumatic pressure supply while enabling precise electronic control of flap position through motor commutation, achieving both manufacturing simplicity and positioning precision.
Solution Approach 2:
The invention changes the control parameter from pneumatic pressure regulation to electrical commutation control. By controlling the motor's phase currents and commutation timing, the system achieves precise angular positioning of the flap shaft, transforming the control mechanism from imprecise pneumatic adjustment to precise electronic control.
2Device complexity
If pneumatic linear actuators are used, then the actuators are simple in design, but they require an expensive pressure supply and are susceptible to failure due to leaks
Solution Approach 1:
The patent substitutes the pneumatic actuation system with an electromechanical motor system. The brushless DC motor provides direct mechanical drive to the flap shaft, eliminating pneumatic seals, pressure supply lines, and associated leak risks. The system achieves comparable design simplicity while dramatically improving reliability through the absence of pneumatic components.
3Productivity
If conventional electromechanical linear actuators with worm gears are used, then high transmission ratios are achieved, but the efficiency scatter is high and self-locking requires low nominal efficiency leading to high safety factors and expensive design
Solution Approach 1:
The patent extracts and eliminates the worm gear transmission stage from the actuator design. By coupling the motor directly to the flap shaft, the system achieves the required transmission ratio through the motor's own gearless direct drive capability, removing the inefficient worm gear mechanism and its associated energy losses and efficiency variability.
Solution Approach 2:
The invention replaces the mechanical worm gear self-locking mechanism with electronic control of the brushless DC motor. The motor's electromagnetic braking and controlled commutation provide inherent holding capability without requiring low-efficiency worm gears, thereby eliminating energy losses associated with mechanical self-locking while maintaining position stability.
4Ease of manufacture
If electromechanical linear actuators with plastic spindle nuts and claw-pole stepper motors are used, then the actuators can be manufactured with low cost, but the efficiency is low due to high wear and low motor efficiency with only about 30% efficiency achieved
Solution Approach 1:
The patent employs a composite construction combining aluminum housing, steel motor components, and plastic cooling fins. This composite approach maintains manufacturing cost-effectiveness while using high-performance materials where needed (steel for motor durability, aluminum for housing and heat dissipation) to achieve superior efficiency compared to all-plastic constructions.
Solution Approach 2:
The invention replaces the claw-pole stepper motor with a brushless DC motor. This substitution dramatically improves efficiency by eliminating the high leakage fluxes between claw poles that limit stepper motor efficiency to around 30%. The brushless DC motor achieves significantly higher efficiency while maintaining cost-effectiveness through simpler construction and higher power density.
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
The solution achieves high dynamics, reduced production costs, and improved efficiency with low inertia and small dimensions, enabling precise control and reliable operation of turbocharger flaps with reduced energy consumption and minimal sensor requirements.
Implementation Method 1
an electric motor, in particular a two-phase transverse flux machine, whose rotor (10) is arranged between two single-phase stators (11)
Implementation Method 2
The rotor (10) may include a threaded spindle nut (09) or a wobble sleeve (28) and/or magnetic rings
Implementation Method 3
the rotor (10) may include a threaded spindle nut (09) or a wobble sleeve (28) and/or magnetic rings, whose rotation is converted into a linear movement of a spindle shaft (07)
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a linear actuator, in particular for adjusting the flaps in motor vehicle turbochargers, comprising an adjusting element (07) that can be linearly displaced by an electric motor. The claimed linear actuator is characterized in that the electric motor is a two-phase transverse flux machine, a rotor (10) is arranged between two opposite single-phase stators, and the rotor (10) is connected in a rotationally fixed manner to a rotatable and linearly stationary rotational element (09, 28) that engages with the linearly movable adjusting element (07) in order to cause a linear movement of said adjusting element (07) when the rotational element is rotated.