Turbocharger Balancing Device Decoupling Plate
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Solution Overview
Problem
Existing balancing devices for turbochargers face challenges in reducing cycle times due to lengthy fixation processes and risk of mass distortion, with previous solutions being either time-consuming or costly and prone to measurement falsification and component failure.
Innovation Solution
A decoupling plate with circumferential slots allows for resilient separation of inner and outer plate portions, reducing mass and enabling secure, automatic fixation of the hull group with hydraulic cylinders, while maintaining stability and allowing for adaptive force compensation during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support structure is used to fix the core assembly in the central fixture, then the fixation is achieved, but the support structure is very bulky and massive, thus increasing the masses that must be accelerated during the balancing process, which can lead to inaccuracies in the balancing result
Solution Approach 1:
The base body is divided into an inner plate section and an outer plate section that are elastically connected through circumferential slots. This segmentation allows the inner section to move independently with the core assembly while the outer section remains stationary, reducing the mass that must be accelerated during balancing.
Solution Approach 2:
The connection between the inner and outer plate sections is made elastic through the circumferential slots, allowing dynamic movement and adaptation during operation. This elastic connection enables the inner section to follow the core assembly's motion without adding significant mass to the rotating system.
2Reliability
If bolts are used to secure the body assembly in the balancing machine, then the fixation is achieved, but the fixing process is very time-consuming, which significantly increases the cycle times of the balancing machine
Solution Approach 1:
The base body is pre-designed with integrated hydraulic cylinders and circumferential slots that enable quick attachment and detachment of the core assembly. The hydraulic system can be pre-positioned and activated without requiring time-consuming bolt fastening operations, significantly reducing cycle times.
Solution Approach 2:
Hydraulic cylinders are used to provide rapid and reliable fixation of the core assembly. The hydraulic system can be activated and deactivated quickly compared to mechanical bolt fastening, enabling fast cycle times while maintaining secure fixation during the balancing process.
3Reliability
If window elements are provided between hydraulic cylinders and fuselage assembly to allow resilient attachment, then the fixation is achieved, but these windows are very difficult to manufacture and reproduce
Solution Approach 1:
The base body is segmented into inner and outer plate sections with circumferential slots that provide the resilient attachment function. This segmentation eliminates the need for complex window elements while achieving the same resilient fixation through a simpler, more manufacturable slot-based design.
Solution Approach 2:
The complex window element structure is extracted and replaced with a simpler circumferential slot design. The essential function of resilient attachment is maintained through the slot geometry and elastic connection, while the manufacturing complexity is significantly reduced.
4Stability of the object's composition
If a one-piece decoupling element with spring elements is used, then the elastic connection is achieved, but if the balancing device is incorrectly configured, the spring elements will break and the entire decoupling element must be replaced
Solution Approach 1:
The decoupling element is segmented into separate inner and outer plate sections connected by circumferential slots. This segmentation means that if damage occurs, only the inner plate section needs replacement, not the entire decoupling element, improving reliability and reducing waste.
Solution Approach 2:
The design allows for selective replacement of the inner plate section if damaged, while the outer plate section and circumferential slots remain intact and reusable. This partial discarding and recovering approach reduces the need to replace the entire decoupling element.
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 solution significantly reduces cycle times, minimizes mass-related distortions, and enhances the stability of the balancing device, reducing the risk of measurement falsification and component failure, while allowing for efficient adaptation to different hull group dimensions.
Implementation Method 1
the base body has several circumferential slots through which the inner plate section is resiliently decoupled from the outer plate section
Implementation Method 2
several hydraulic cylinders arranged around the receptacle are provided on the base body by means of which the rotating element can be fixed or fixed in the central receptacle
Data Source
Figure 1
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Figure 3
AI summary
Balancing device (1), in particular for turbochargers, with a base body (6) which has a centrally arranged receptacle (7) in which a rotational element (3, 4, 5) to be balanced can be axially inserted in order to hold the rotational element (3, 4, 5) in the receptacle (7) rotating about its axis of rotation, wherein several hydraulic cylinders (8) arranged around the central receptacle (7) are provided on the base body (6) by means of which the rotational element, in particular a core assembly (2) of the turbocharger, can be fixed in the central receptacle (7).The base body (6) is designed as a decoupling plate (9) which has an inner plate section (10) and an outer plate section (11) which is elastically connected to the inner plate section (10) and surrounds the inner plate section (10) and is arranged in a fixed position, wherein the decoupling plate (9) has several circumferential slots (12) via which the inner plate section (10) is resiliently decoupled from the outer plate section (11) in such a way that several, separate holding sections (13) are formed on the decoupling plate (9).