Pre-assembled Wastegate Subassembly for Turbocharger
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Solution Overview
Problem
Conventional wastegate valve assembly processes in turbochargers are inefficient, requiring complex welding and limited visibility, leading to increased manufacturing costs and reduced aerodynamic performance due to larger valve receiving areas.
Innovation Solution
A pre-assembled wastegate subassembly that includes a mounting plate, valve shaft, and wastegate valve, allowing for easy detachment and reattachment to the turbocharger housing, reducing manufacturing complexity and optimizing aerodynamics by minimizing the valve receiving area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wastegate valve assembly processes are used, then the wastegate valve can be installed in the turbocharger, but the assembly process is complex requiring welding with limited visibility, increasing manufacturing costs
Solution Approach 1:
The wastegate assembly is divided into separate components (mounting plate, wastegate valve, actuator) that can be manufactured independently and then assembled as a subassembly, eliminating complex welding operations and improving manufacturability
Solution Approach 2:
The wastegate subassembly is pre-assembled with all components positioned and secured before installation into the turbocharger housing, allowing for easier assembly and reduced manufacturing complexity
2Productivity
If conventional wastegate valve assembly is used, then the valve can be installed, but the valve receiving area is larger, reducing aerodynamic performance
Solution Approach 1:
The mounting plate is designed as a separate component that defines a compact valve receiving area, separating the valve installation function from the housing structure and minimizing the space required
Solution Approach 2:
The mounting plate provides a structured platform that organizes the wastegate components in a compact arrangement, optimizing the spatial configuration to minimize the valve receiving area while maintaining functionality
3Ease of repair
If conventional wastegate assembly is used, then the valve can be installed, but servicing is time-consuming due to complex assembly requirements
Solution Approach 1:
The wastegate subassembly is designed as a modular unit that can be quickly removed and replaced as a complete assembly, eliminating the need for complex disassembly and reducing servicing time
Solution Approach 2:
The subassembly is pre-configured with all necessary components (mounting plate, valve, actuator) properly positioned and secured, allowing for rapid installation and servicing without requiring complex assembly procedures
Data Source
AI summary
A turbocharger turbine (2) includes a wastegate subassembly (50) that includes a mounting plate (51) having a bore (55) therethrough, a valve shaft (60) disposed in the bore (55), and a wastegate valve (30) including a valve body (31) and a valve arm (36) that secures the valve body (31) to an end of the valve shaft (60). The wastegate subassembly (50) is preassembled prior to assembly with the turbocharger (1), and is detachably secured to an outer surface of the turbine exhaust gas inlet (10) such that valve body (31) is positioned to control exhaust gas flow through a bypass port (13) that extends between the exhaust gas inlet (10) and an exhaust gas outlet (12), and bypasses the turbine wheel (16).