VTG Lever Assembly With Pre-Attached Locking Nut
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Solution Overview
Problem
Current fastening devices in variable turbine geometry (VTG) turbochargers face challenges in assembly time, manufacturing costs, and compatibility with existing materials, particularly due to tight clearance and high operating temperatures, while requiring resistance to corrosion and a low failure rate.
Innovation Solution
The use of a self-locking nut pre-assembled onto the VTG lever, which includes a ball stud bore and a nut aligned with the ball stud bore, where the nut engages with the ball stud to securely couple the VTG lever to the actuator linkage, allowing for easy assembly and operation in tight spaces with enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a loose nut is used to secure the ball stud to the VTG lever, then the fastening device can be easily assembled, but the assembly time increases and manufacturing costs increase due to additional parts
Solution Approach 1:
The patent combines the nut and the VTG lever into a single integrated component. The nut is formed as an integral part of the lever, eliminating the need for separate fastening operations and reducing assembly time while maintaining ease of manufacture through unified part fabrication
Solution Approach 2:
The integrated nut lever serves multiple functions: it acts as both the structural lever component and the fastening mechanism. This multi-functionality eliminates the need for separate nuts and reduces the total part count, thereby reducing assembly time and manufacturing complexity
2Volume of moving object
If the clearance between the actuator linkage, VTG lever, and fastening device is reduced, then the turbocharger size is minimized, but the working area becomes too small for efficient assembly and repair
Solution Approach 1:
By integrating the nut into the lever, the patent eliminates the need for additional fastening components that would occupy space. This consolidation maintains compact turbocharger sizing while improving assembly accessibility by reducing the number of components and simplifying the assembly process
3Loss of time
If new fastening devices are developed to simplify assembly, then assembly time is reduced, but the part count increases and manufacturing costs increase
Solution Approach 1:
The patent reduces part count by combining the nut and lever into a single integrated component. This consolidation simplifies the overall device complexity while maintaining reduced assembly time benefits, as fewer parts mean fewer assembly steps and less complexity in inventory management
Data Source
AI summary
An actuator assembly for a variable turbine geometry (VTG) turbocharger is disclosed. The actuator assembly may include an actuator and an actuator linkage having a first end coupled to the actuator and a second end defining a linkage joint. The actuator assembly may further include a VTG lever having a ball stud bore extending through the VTG lever. Additionally, the actuator assembly may include a ball stud including a first end partially disposed within the linkage joint and a second threaded end extending axially through the ball stud bore. Furthermore, a nut may be aligned with the ball stud bore and movably attached to the VTG lever prior to extending the ball stud through the ball stud bore, wherein the ball stud engages with the nut and fastens the ball stud to the VTG lever to operatively couple the VTG lever to the actuator linkage.