Variable Displacement Turbocharger Nozzle Ring Integration
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Solution Overview
Problem
There is a demand for reducing the size of variable capacity turbochargers, particularly in the mechanism that drives the nozzle vanes, as recent requirements call for a smaller turbocharger design.
Innovation Solution
The design incorporates a nozzle ring with cylindrical portions for axial support of shaft portions, link plates with mounting and extension portions, a drive ring with projection portions, and a facing member forming a clearance flow passage, along with pins and counter bore grooves to maintain clearance and reduce size, and an elastic member to press the nozzle ring against the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the mechanism for driving nozzle vanes is designed with traditional structures (shaft portions inserted into nozzle ring, link plates with engagement grooves, drive ring with guide rollers), then the nozzle vanes can be effectively controlled to adjust flow passage width, but the overall size of the turbocharger increases
Solution Approach 1:
The patent merges the drive ring and nozzle ring into a single integrated component. The drive ring is formed as an annular structure that directly supports the nozzle vanes while also serving as the driving element. This eliminates the need for separate link plates, engagement grooves, and guide rollers, significantly reducing the size and complexity of the mechanism while maintaining the ability to control nozzle vane angles for flow passage adjustment.
Solution Approach 2:
The integrated drive ring performs multiple functions simultaneously: it supports the nozzle vanes axially, provides the driving rotation to adjust vane angles, and defines the flow passage geometry. This multi-functionality consolidates what were previously separate components (nozzle ring, link plates, drive ring) into a single element, reducing overall turbocharger size.
2Volume of moving object
If the number of components in the nozzle drive mechanism is reduced to decrease size, then the overall turbocharger size decreases, but the precision of maintaining clearance and controlling flow passage may be affected
Solution Approach 1:
The patent employs a circular arc-shaped groove in the drive ring and a corresponding circular arc-shaped protrusion on the nozzle vane. This curved geometry ensures smooth rotational movement and maintains precise clearance between components during the swinging motion of the nozzle vanes. The circular arc design allows for accurate positioning while reducing the number of separate guiding components needed.
Solution Approach 2:
The patent optimizes the geometric parameters of the integrated drive ring, including the radius and shape of the circular arc groove, to maintain precise clearance and control flow passage characteristics. By carefully selecting and adjusting these dimensional parameters, the design achieves both size reduction and manufacturing precision.
Data Source
AI summary
A projecting portion is formed on a nozzle ring, projects to a radially outer side with respect to a cylindrical portion, extends in a circumferential direction, and is held in abutment against a housing from a side of a link plate. A plate is faced to the nozzle ring on a side of a nozzle vane, and is configured to form a flow passage in a clearance to the nozzle ring. A pin is inserted into a first insertion portion formed in the nozzle ring and a second insertion portion formed in the plate, and to which the nozzle ring and the plate are mounted while the clearance is maintained. A counter bore groove is formed in the first insertion portion of the nozzle ring on the side of the link plate, and cut out the projecting portion.