Turbocharger Wastegate Valve Rotation Restriction Mechanism
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Solution Overview
Problem
Turbochargers experience noise issues due to wastegate valve rotation and frictional sounds, which existing solutions attempt to address with belleville springs but require additional components and complex configurations to restrain rotation and prevent noise.
Innovation Solution
A simpler mechanism using a biasing portion, such as a leaf or coil spring, is fixed to the wastegate valve and support plate to restrain the wastegate valve's rotation, preventing frictional sounds and noise by maintaining contact and reducing vibration-induced contact and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the wastegate valve and support plate are completely fixed to each other, then the structural stability is improved, but the wastegate valve cannot close the through-hole when force tilting acts on the surface, causing gaps and leakage
Solution Approach 1:
The patent applies the dynamics principle by allowing the wastegate valve to rotate relative to the support plate through a pin connection instead of completely fixing it. This dynamic arrangement enables the valve to adapt to tilted surfaces and maintain sealing contact while still providing structural stability through the constrained rotation mechanism.
2Reliability
If a clearance is provided between the wastegate valve and support plate to allow rotation, then the sealing reliability is improved, but frictional sounds and noises occur due to rotation and repeated contact during engine vibration
Solution Approach 1:
The patent introduces a resin layer as an intermediary substance between the wastegate valve and support plate. This resin layer acts as a mediator that dampens frictional sounds and noises during rotation and repeated contact, while still allowing the necessary relative movement to maintain sealing reliability on tilted surfaces.
3Object-affected harmful factors
If a belleville spring is added to suppress noises by keeping contact with biasing force, then the noise is reduced, but the device complexity increases and welding space is insufficient
Solution Approach 1:
The patent replaces the complex belleville spring mechanism with a simpler resin layer that provides noise suppression functionality. The resin layer is a cost-effective, simple-to-apply material that achieves the same noise reduction effect without requiring additional mechanical components or welding operations.
4Adaptability or versatility
If the wastegate valve is made swingable to allow rotation, then the adaptability to tilted surfaces is improved, but frictional sounds occur between the support plate and wastegate valve
Solution Approach 1:
The resin layer serves as an intermediary that enables the swingable connection between the wastegate valve and support plate while simultaneously suppressing frictional sounds. This intermediary material allows relative movement for adaptability to tilted surfaces while dampening the harmful frictional noises that would otherwise occur during rotation.
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 solution effectively suppresses noise by ensuring consistent contact between the wastegate valve and support plate, reducing engine vibration-induced noise and maintaining a cost-effective production process.
Implementation Method 1
a biasing portion, one end of which is fixed to any one of the main body and the projecting portion and the other end of which is fixed to the support plate, and configured to restrain rotation of the wastegate valve and to bias the support plate and the any one of the main body and the projecting portion in opposite directions
Data Source
AI summary
A turbocharger includes: a turbine housing including a through-hole through which a turbine impeller is bypassed; and a wastegate valve configured to open and close the through-hole. A biasing portion biases the wastegate valve and a support plate in opposite directions, and restrains rotation of the wastegate valve relative to the support plate.