Web-like Connecting Component for Two-Stage Supercharger Mounting
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Solution Overview
Problem
Two-stage supercharging systems for internal combustion engines face challenges due to high mechanical and thermal loads on turbine housings, leading to potential mechanical fracture and complex fastening requirements.
Innovation Solution
A fastening device with a one-piece connection component that separates mechanical and thermal loads, allowing the charging devices to expand freely and reducing thermal stresses, featuring a web-like design for robustness and material optimization, with integrated lubricant supply and discharge channels to minimize sealing points and facilitate easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the charging devices are attached directly to an internal combustion engine component, then the fastening structure is simple, but thermal stresses cause mechanical fracture of the turbine housing
Solution Approach 1:
A connecting component is introduced as an intermediary element between the charging devices and the internal combustion engine component. This connecting component absorbs thermal expansion forces, preventing them from being transmitted to the turbine housing and engine component, thereby eliminating thermal stress-induced mechanical fracture while maintaining a relatively simple fastening structure.
Solution Approach 2:
The fastening system is segmented into distinct functional zones: the charging devices are thermally isolated from the engine component by the connecting component, which acts as a separate thermal and mechanical zone. This segmentation allows thermal loads to be managed independently from structural loads, preventing stress concentration at the turbine housing.
2Loss of substance
If the connecting component is designed as web-like structure, then material usage is optimized, but structural robustness may be compromised
Solution Approach 1:
The connecting component employs a web-like structure consisting of thin, flexible walls that provide sufficient structural strength to transmit mechanical loads while allowing thermal expansion. This thin-walled design minimizes material usage while maintaining the necessary robustness to handle operational forces.
Solution Approach 2:
The connecting component is made from materials with high strength-to-weight ratios, combining structural integrity with thermal resistance. These composite or specially selected materials enable the web-like structure to achieve both material optimization and structural robustness simultaneously.
3Reliability
If multiple fastening means are used for preassembled two-stage supercharging system, then attachment reliability is improved, but assembly time and complexity increase
Solution Approach 1:
The bearing components and connecting component are merged into a single integrated unit that functions as a preassembled two-stage supercharging system. This consolidation reduces the number of separate fastening operations needed, as the entire assembly can be mounted to the engine component as one unit, thereby reducing assembly time while maintaining attachment reliability through the robust connecting component design.
4Manufacturing precision
If the charging devices are constrained during attachment, then positioning precision is improved, but thermal expansion causes thermal stresses
Solution Approach 1:
The connecting component is designed with geometric parameters that allow controlled thermal expansion. The structure includes expansion compartments and flexible walls that can accommodate dimensional changes due to thermal effects, enabling the charging devices to expand freely while maintaining precise positioning relative to the engine component.
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
Enables simple and reliable attachment of the two-stage supercharging system, reducing thermal and mechanical stresses, minimizing torque generation during vibrations, and allowing for quick assembly with fewer fastening means, thus lowering material requirements and assembly complexity.
Implementation Method 1
the charging devices can expand freely, so that no thermal stresses can arise
Implementation Method 2
A lubricant supply channel (40) which leads from an inlet (41) to the bearing components (21, 22) and has feed openings (50) which open into the bearing bores (27, 30)
Implementation Method 3
enables lubricant to be supplied to the bearing components in a simple manner
Implementation Method 4
The local separation of the mechanical and thermal loads takes place by means of the connection component which is designed in one piece with the bearing components
Data Source
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AI summary
The device (20) has two bearing components (21, 22) for respectively mounting two supercharging devices. A connecting component (23) is provided for connection of the bearing components. The connecting component is formed as a single-piece with the bearing components and is fastenable to a combustion engine component. The connecting component extends essentially web-like in a connecting direction (33). The connecting component includes a fastening section (34) arranged axially between the bearing components, and connecting sections (35, 36) arranged double-sided to the fastening section.