Compliant Turbocharger Linkage for Heat- and Vibration-Induced Misalignment
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Solution Overview
Problem
Conventional linkages in turbochargers, subject to extreme heat and vibration, face challenges in maintaining robustness and longevity due to packaging restraints, requiring innovative designs to withstand high actuation cycles and misalignment caused by thermal and vibrational stresses.
Innovation Solution
The proposed linkage design features pairs of members with curved central portions that compress to increase stiffness and can translate and rotate, allowing for independent movement to compensate for misalignment, reducing noise and extending the number of actuation cycles, and includes varying thicknesses and rib configurations to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rigid linkages are used in turbochargers, then structural strength is maintained, but the linkage cannot compensate for misalignment caused by heat and vibration
Solution Approach 1:
The linkage is divided into multiple members (first member, second member, third member) connected by pins, allowing each segment to move independently. This segmentation enables the linkage to accommodate misalignment through relative movement between segments while maintaining overall structural integrity.
Solution Approach 2:
The linkage members are designed to be dynamic rather than rigidly fixed, allowing translation and rotation at the pin connections. This dynamic capability enables the linkage to adapt to thermal expansion and vibrational misalignment while maintaining connection between actuator and valve.
2Adaptability or versatility
If the linkage allows independent movement to compensate for misalignment, then adaptability improves, but stiffness decreases
Solution Approach 1:
Different parts of the linkage have different properties: the member bodies are designed with sufficient stiffness for structural integrity, while the pin connections provide localized flexibility for movement. This local differentiation allows the linkage to be stiff where needed and flexible where required for misalignment compensation.
Solution Approach 2:
The linkage members have asymmetric designs with varying thicknesses (first thickness, second thickness, third thickness) optimized for their specific functional requirements. This asymmetric design allows each member to have appropriate stiffness characteristics while maintaining the ability to move relative to connected members.
3Strength
If the linkage members have varying thicknesses to enhance structural integrity, then strength improves, but manufacturing complexity increases
Solution Approach 1:
The varying thicknesses of the linkage members are implemented through local quality variations rather than completely different component designs. This allows each member to have optimized thickness distribution for strength while potentially using similar manufacturing processes for all members, reducing overall manufacturing complexity.
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 improved linkage design enhances stiffness and durability, reduces noise, and increases the number of actuation cycles by effectively managing heat and vibration-induced stresses, thereby improving the robustness and reliability of the turbocharger system.
Implementation Method 1
The first member body has a first central portion having a curved shape increasing stiffness of the first member body in compression. The second member body has a second central portion having a curved shape increasing stiffness of the second member body in compression. Translation of the first member or the second member toward the other of the first member and the second member compresses the first central portion and the second central portion, increasing stiffness of the linkage.
Implementation Method 2
a first member first end pivotably coupled to the actuator by a first pin having a first axis of rotation, a first member second end pivotably coupled to the valve by a second pin having a second axis of rotation
Data Source
AI summary
A linkage extends between an actuator and a valve in a turbocharger. The linkage comprises two spaced member bodies having central portions with opposing curved shapes that extend between ends translatable along and rotatable about spaced pivots. Translation of one member toward the other member compresses the central portions, increasing overall stiffness of the linkage, and translation of one member away from the other member creates a gap between the central portions, allowing independent translation of the ends along the spaced pivots to compensate for misalignment between the actuator and the valve caused by heat and vibration. Another linkage extending between an actuator and a valve in a turbocharger includes two planar spaced member bodies extending between ends translatable along and rotatable about spaced pivots. The two member bodies have different thicknesses.