Wave Spring Biasing in Variable Turbine Geometry Assemblies

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Solution Overview

Problem

Variable turbine geometry assemblies in turbochargers suffer from repeated wear due to vibrations, leading to increased noise, vibrations, and harshness (NVH), as well as functional failures in controlling exhaust gas flow.

Innovation Solution

Incorporation of a wave spring that biases the adjustment ring and vane lever, reducing vibration and wear between components, thereby minimizing noise, vibrations, and harshness, and enhancing the durability and effectiveness of the variable turbine geometry assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a variable turbine geometry assembly is used to control exhaust gas flow, then the turbocharger can efficiently control air intake, but repeated vibrations cause wear on components leading to increased noise and potential failure

Engineering Contradiction:

Improveexhaust gas flow control efficiencyVSAvoidcomponent durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A wave spring is introduced between the adjustment ring and vane lever to cushion vibrations before they cause wear. The wave spring absorbs and dampens vibrational energy, preventing the repeated contact stresses that would otherwise degrade component reliability over time.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The wave spring acts as an intermediary element between the adjustment ring and vane lever. This intermediate component isolates the two parts from direct vibrational contact, reducing the transmission of harmful vibrations while maintaining the mechanical connection necessary for flow control.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If variable turbine geometry components are subjected to vibrations, then exhaust gas flow can be controlled, but wear increases leading to increased noise and harshness

Engineering Contradiction:

Improveexhaust gas flow controlVSAvoidnoise and vibrations

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The wave spring is positioned to cushion vibrations before they propagate through the variable turbine geometry assembly. By dampening vibrational energy at its source, the wave spring prevents the increased noise and harshness that would otherwise result from repeated component wear.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The wave spring serves as a vibrational intermediary that breaks the transmission path of harmful vibrations. This intermediate element isolates the adjustment ring and vane lever from direct vibrational coupling, significantly reducing the noise and harshness generated by the assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If repeated wear occurs on variable turbine geometry components, then vibrations increase, but this leads to functional failure of exhaust gas flow control

Engineering Contradiction:

Improvevibration responseVSAvoidflow control functionality

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The wave spring provides beforehand cushioning by continuously dampening vibrations during operation. This prevents the progressive wear that would otherwise occur from repeated vibrational stress, ensuring the flow control functionality remains reliable over extended operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The wave spring intermediary protects the critical flow control components from direct vibrational damage. By isolating the adjustment ring and vane lever through this intermediate element, the system maintains its flow control functionality while reducing the vibrational stress that would lead to failure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 wave spring configuration effectively reduces wear and noise, lowers the likelihood of functional failure, and provides a simple, cost-effective solution for maintaining efficient exhaust gas flow control in turbochargers.

Implementation Method 1

a wave spring operably in contact with at least one of the at least one vane lever and the adjustment ring. The wave spring is configured to bias one of the at least one vane lever and the adjustment ring toward the other of the at least one vane lever and the adjustment ring

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11834955B1Variable turbine geometry assembly

Publication Date: 2023.12.05 BORGWARNER INC

AI summary

A variable turbine geometry assembly for controlling flow of exhaust gas to a turbine wheel of a turbocharger includes an adjustment ring extending about an axis and rotatable about the axis, at least one vane lever coupled to the adjustment ring, and at least one vane coupled to the at least one vane lever. The at least one vane is moveable with respect to the adjustment ring when the adjustment ring rotates about the axis. The variable turbine geometry assembly further includes a wave spring operably in contact with at least one of the at least one vane lever and the adjustment ring. The wave spring is configured to bias one of the at least one vane lever and the adjustment ring toward the other of the at least one vane lever and the adjustment ring.