Patent Grant
11428114
The present invention relates to a lever for a VTG guide vane arrangement of a radial turbine. The invention furthermore relates to a VTG guide vane arrangement having such a lever, and to a radial turbine having such a VTG guide vane arrangement and to a supercharging device having such a radial turbine.
Ever-increasing numbers of vehicles of the newer generation are being equipped with supercharging devices in order to achieve the required aims and satisfy legal regulations. In the development of supercharging devices, it is the aim to optimize the individual components and the system as a whole with regard to their reliability and efficiency.
Known supercharging devices normally have at least one compressor with a compressor wheel which is connected to a drive unit via a common shaft. The compressor compresses the fresh air that is drawn in for the internal combustion engine or for the fuel cell. In this way, the air or oxygen quantity that is available to the engine for combustion or to the fuel cell for reaction, respectively, is increased. This in turn leads to an increase in performance of the internal combustion engine or of the fuel cell respectively. Supercharging devices may be equipped with different drive units. In particular, electric superchargers, in the case of which the compressor is driven by means of an electric motor, and turbochargers, in the case of which the compressor is driven by means of a turbine, in particular a radial turbine, are known in the prior art. By contrast to an axial turbine, as are used for example in aircraft engines, in which there is a substantially exclusively axial incident flow, it is the case in a radial turbine that the exhaust-gas flow is conducted substantially radially, and in the case of a mixed-flow radial turbine semi-radially, that is to say with at least a small axial component, from a spiral-shaped turbine inlet onto the turbine wheel. Aside from electric superchargers and turbochargers, combinations of both systems are described in the prior art, these also being referred to as E-turbos.
In order to increase the efficiency of turbines and adapt it to different operating points, variable guide vanes are commonly used in turbines, which variable guide vanes can be adjusted such that an incident-flow angle and a flow cross section of the flow that is conducted onto the turbine wheel can be variably set. Such systems are also known as variable turbine geometry, VTG or guide vane arrangement.
Known guide vane arrangements commonly have a vane bearing ring with a multiplicity of guide vanes mounted in a circle on said vane bearing ring, which guide vanes are each adjustable from a substantially tangential position with respect to the circle into an approximately radial position. An operating device is provided for generating control movements, which are to be transmitted to the guide vane arrangement with variable turbine geometry, by means of an adjusting ring which is arranged coaxially with the vane bearing ring and to which the guide vanes are movably connected. The operating device commonly has an actuator that is coupled via an adjusting shaft and an inner lever to the adjusting ring. For the mechanical coupling of the operating device to the adjusting ring, an engagement of the inner lever with an actuation pin of the adjusting ring is commonly provided. The large number of movable individual parts of the VTG guide vane arrangement commonly requires a complex and expensive assembly process and can lead to wear problems during operation.
It is an object of the present invention to provide an improved VTG guide vane arrangement with adjustable guide vanes.
The present invention relates to a lever for a VTG guide vane arrangement of a radial turbine, according to claim 1.
The lever according to the invention comprises a main body with a fork-shaped coupling section. The fork-shaped coupling section comprises, in turn, two limbs. A wear-resistant contact block is arranged on an inner side of at least one of the limbs. The wear-resistant contact block is designed for operative engagement with an adjusting ring of the VTG guide vane arrangement. This gives rise to the effect of increased wear resistance at least in the region of the engagement with the VTG guide vane arrangement. In this way, it is firstly possible for the durability of the lever and thus of the VTG guide vane arrangement to be increased. Secondly, other material regions of the lever and of the VTG guide vane arrangement that are not subjected to mechanical load, or are subjected at least to lower mechanical load, can be produced from materials that are optimized for other characteristics. To name just a few examples, it is for example possible for materials which are cheaper, weight-optimized, strength-optimized and/or optimized with regard to weldability to be used for the other material regions. This can yield a corresponding variety of advantages, such as assembly advantages, economical advantages, ecological advantages and/or performance-related advantages.
In embodiments of the lever, in each case one wear-resistant contact block may be arranged on the inner side of both limbs and be designed for operative engagement with the adjusting ring of the VTG guide vane arrangement. This yields further increased wear resistance, because that side of the fork-shaped section which is in opposition to the natural restoring force of the guide vanes is also of wear-resistant form for potential contact with the VTG guide vane arrangement. The natural restoring force arises from the flow which is incident on the guide vanes and which generates a torque from a more tangential orientation of the guide vanes to a more radial orientation of the guide vanes. The adjusting ring or the actuation pin thus tends to lie against the fork-shaped section in the direction of rotation that corresponds to a movement in the direction of a more radial orientation of the guide vanes. In other words, the actuation pin tends to lie against the inner side of that limb in the direction of which the guide vanes orient themselves owing to a more radial orientation.
In embodiments of the lever that are combinable with the embodiment above, the wear-resistant contact block may form a coupling surface. The coupling surface may be capable of being placed in operative engagement with an actuation pin of the adjusting ring for the purposes of adjusting the VTG guide vane arrangement. The wear-resistant contact block may be subjected to mechanical postprocessing in order to form the coupling surface. In particular, the wear-resistant contact block may be subjected to cutting postprocessing in order to form the coupling surface. For example, the wear-resistant contact block may be ground in order to form the coupling surface. This gives rise to the effect of a very smooth surface, which in turn leads to reduced friction and/or increased wear resistance.
In embodiments that are combinable with any one of the preceding embodiments, the wear-resistant contact block may be subjected to postprocessing such that the coupling surface has an average roughness depth of Rz≤5 μm. The coupling surface may particularly preferably have an average roughness depth of Rz≤4 μm. At the least, the average roughness depth of the coupling surface may have a value of Rz≤20 μm, in particular of Rz<10 μm. An average roughness depth of 10 μm or less has proven to be more wear-resistant than greater roughness depths. In particular, average roughness depths of approximately 3 μm to 5 μm constitute a good compromise between increased wear resistance and good manufacturability.
In embodiments with two wear-resistant contact blocks, which are combinable with any one of the preceding embodiments, the wear-resistant contact blocks may be arranged spaced apart from one another such that a coupling cutout is formed between the wear-resistant contact blocks. The coupling cutout may be configured for operative engagement with the actuation pin of the adjusting ring. Thus, during operation when installed in a VTG guide vane arrangement, the wear-resistant contact blocks can come into low-wear contact with the actuation pin by way of the coupling cutout.
In embodiments that are combinable with any one of the preceding embodiments, the wear-resistant contact block may have a thickness of at least 0.1 mm between the inner side of the limb and the coupling surface formed by the wear-resistant contact block. For example, the thickness of the wear-resistant contact block may be 0.1 mm to 3.0 mm, in particular at least 0.5 mm, and preferably 0.6 mm to 1.0 mm. In some particularly preferred embodiments, the thickness of the wear-resistant contact block may be 0.8 mm+/−0.1 mm, which thicknesses lead to particularly good wear resistance and material efficiency. In some embodiments, the wear-resistant contact block may have a variable thickness, which is at least 0.5 mm at at least one location and is approximately 0.1 mm or less at at least one other location. By means of such embodiments, particularly material-efficient and positionally accurate or requirement-based wear resistance can be provided.
In embodiments that are combinable with any one of the preceding embodiments, the wear-resistant contact block may be fastened to the limb.
In embodiments that are combinable with the preceding embodiment, the wear-resistant contact block may be fastened in non-positively locking and/or positively locking fashion to the limb. For example, the wear-resistant contact block may be fastened to the limb by means of a screw connection. This allows easy assembly and easy maintenance.
As an alternative to the non-positively locking and/or positively locking fastening, the wear-resistant contact block may be fastened cohesively to the limb. For example, the wear-resistant contact block may be fastened to the limb by means of a welded connection and/or by means of a brazed connection. In some embodiments, the wear-resistant contact block may be fastened to the limb by powder-metallurgical methods.
In embodiments that are combinable with any one of the preceding embodiments, the main body may be produced at least partially from a first material. In embodiments, the main body may be produced at least partially from the first material by powder-metallurgical methods. In embodiments, the first material may be a metallic material. In embodiments, the first material may be a steel alloy with good welding characteristics. For example, the first material may comprise or be composed of Fe17Crl3Ni, X30CrNiNbSi25-20, X6CrNiMoTi17-12-2 and/or X2CrNiMo17-12-2.
In embodiments that are combinable with any one of the preceding embodiments, the wear-resistant contact block may be produced from a second material. The second material may differ from the first material. In particular, the second material may have greater wear resistance than the first material. In embodiments, the wear-resistant contact block may be produced from the second material by powder-metallurgical methods. In embodiments, one or both limbs may be produced from the second material, in particular by powder-metallurgical methods. In some embodiments, the fork-shaped coupling section may be produced from the second material. In embodiments, the second material may be a metallic material. In particular, the second material may be a steel alloy with a cobalt content of at least 20%. For example, the second material may comprise or be composed of Co30Cr8W or Co30Mo9Cr.
In embodiments that are combinable with any one of the preceding embodiments, the lever may be produced by metal injection molding or composite casting.
In embodiments that are combinable with any one of the preceding embodiments, the main body may furthermore comprise a shaft section for coupling to an adjusting shaft. The shaft section may be arranged opposite the fork-shaped coupling section. In embodiments, the lever may have an at least partially arcuate profile from the shaft section to the fork-shaped coupling section. In the installed state, the arcuate profile gives rise to an arrangement of the fork-shaped coupling section axially closer to the adjusting ring, which can result in an improvement in the kinematics and a reduced risk of tilting. Alternatively or in addition to the arcuate profile, the lever may have a stepped formation between the shaft section and the fork-shaped coupling section. In particular, the lever may have a stepped formation axially from the shaft section to the fork-shaped coupling section, such that the fork-shaped coupling section is arranged closer to the adjusting ring in the installed state. This, too, can give rise to an improvement in the kinematics and a reduced risk of tilting.
In embodiments that are combinable with any one of the preceding embodiments, the wear-resistant contact block may have a hardness of at least 500 HV0.1. In particular, the wear-resistant contact block may have a hardness of between 500 HV0.1 and 1000 HV0.1. Preferably, the wear-resistant contact block may have a hardness of between 650 HV0.1 and 800 HV0.1.
The invention furthermore relates to a VTG guide vane arrangement of a radial turbine for a supercharging device. The VTG guide vane arrangement comprises a vane bearing ring, a multiplicity of guide vanes and an adjusting ring. The multiplicity of guide vanes is mounted rotatably in the vane bearing ring. The adjusting ring is configured to rotate the guide vanes. The VTG guide vane arrangement furthermore comprises a lever according to any one of the preceding embodiments. The lever is in operative engagement with an actuation pin of the adjusting ring in order to rotate the adjusting ring.
In embodiments of the VTG guide vane arrangement, the guide vanes may each have a vane shaft and a vane lever. The vane levers may be operatively coupled to the adjusting ring. The guide vanes may be mounted rotatably in the vane bearing ring by means of the vane shafts in a manner distributed in the circumferential direction. In embodiments, the adjusting ring may have engagement recesses into which the vane levers engage.
In embodiments of the VTG guide vane arrangement that are combinable with any one of the preceding embodiments, the coupling surface of the wear-resistant contact block may be oriented perpendicular to an axis of the actuation pin. The wear resistance can be increased in this way.
In embodiments of the VTG guide vane arrangement that are combinable with any one of the preceding embodiments, the actuation pin may be arranged between the wear-resistant contact blocks.
The invention furthermore relates to a radial turbine for a supercharging device. The radial turbine comprises a turbine housing, a turbine wheel and a VTG guide vane arrangement according to any one of the preceding embodiments. The turbine housing defines a supply duct and an outlet duct. The turbine wheel is arranged in the turbine housing between the supply duct and the outlet duct. In embodiments, the VTG guide vane arrangement is arranged radially outside the turbine wheel.
The invention furthermore relates to a supercharging device for an internal combustion engine or a fuel cell. The supercharging device comprises a bearing housing, a shaft and a compressor with a compressor wheel. The shaft is mounted rotatably in the bearing housing. The supercharging device furthermore comprises a radial turbine according to any one of the preceding embodiments. The turbine wheel and the compressor wheel are arranged rotationally conjointly on the shaft at opposite ends.
In embodiments, the supercharging device may furthermore comprise an electric motor. In embodiments, the electric motor may be arranged in the bearing housing. The electric motor may be configured to drive the shaft in rotation.
In the context of this application, the expressions “axial” and “axial direction” relate to an axis of rotation of the radial turbine 110 or of the turbine wheel 114 and/or of the VTG guide vane arrangement 1 or of the adjusting ring 20. With regard to the figures (see for example
The radial turbine 110 comprises a turbine housing 112, a turbine wheel 114 and a VTG guide vane arrangement 1. The VTG guide vane arrangement 1 is illustrated only schematically in
The compressor 120 comprises a compressor housing 122 and a compressor wheel 124 arranged rotatably therein. The supercharging device 100 furthermore comprises a shaft 140 that is rotatably mounted in the bearing housing 130. The turbine wheel 114 and the compressor wheel 124 are arranged rotationally conjointly on the shaft 140 at opposite ends. The housings 112, 130 and 122 are arranged along an axis of rotation R of the shaft 140.
The supercharging device 100 may basically be used, and/or correspondingly configured or dimensioned, for an internal combustion engine or a fuel cell.
In the embodiment of
The turbine housing 112 is shown partially in section in
In this regard,
With regard to
The lever 10 is coupled via an adjusting shaft arrangement 50 to the operating device 60. In the exemplary embodiment of
The fork-shaped coupling section 14 comprises two limbs 15. In other words, the two limbs 15 form a fork shape. The limbs 15 are spaced apart from one another such that, between them, there is formed a coupling cutout 18 for coupling to the adjusting ring 20. In other words, the fork-shaped coupling section 14 forms the coupling cutout 18 between the limbs 15. The limbs 15 may be arranged at least partially parallel to one another. The coupling cutout 18 may be of U-shaped form. The fork-shaped coupling section 14 is designed for operative engagement with the adjusting ring 20. The two limbs 15 are spaced apart from one another and comprise two inner sides 15a, which point toward one another. A wear-resistant contact block 16 is arranged on a respective inner side 15a of the limbs. By being arranged on the limb inner sides 15a, the wear-resistant contact blocks are designed for operative engagement with the actuation pin 22 of the adjusting ring 20 (see for example
Even though it is the case in the embodiments illustrated here that in each case one wear-resistant contact block 16 is arranged on the inner side 15a of both limbs 15, it is also possible in alternative embodiments for a wear-resistant contact block 16 to be arranged only on the inner side 15a of one of the limbs 15. This can yield advantages in terms of assembly, such as faster production and/or cost advantages owing to a smaller required material quantity of wear-resistant material. On the other hand, the contact blocks on both sides can give rise to further increased wear resistance, because that side of the fork-shaped section 14 which is in opposition to the natural restoring force of the guide vanes 40 is also of wear-resistant form for potential contact with the actuation pin 22. The natural restoring force arises from the flow or gas pressure which is incident on the guide vanes 40 and which generates a torque from a more tangential orientation of the guide vanes 40 to a more radial orientation of the guide vanes 40. The adjusting ring 20 or the actuation pin 22 thus tends to lie against the fork-shaped section 14 in the direction of rotation that corresponds to a movement in the direction of a more radial orientation of the guide vanes 40. In other words, the actuation pin 22 tends to lie against the inner side 15a of that limb 15 in the direction of which the guide vanes 40 orient themselves owing to a more radial orientation. The statements below relating to the contact blocks 16 or coupling surfaces 16a can apply both to embodiments with one contact block 16 and to embodiments with two contact blocks 16. In the case of two contact blocks 16, these may be of identical or different design with regard to one or more features.
As can be seen in particular in
The wear-resistant contact blocks 16 are ground in order to form the coupling surface 16a. The grinding can result in a very smooth surface, which in turn leads to reduced friction and/or increased wear resistance. The coupling surfaces 16a have average roughness depths of approximately 3 μm to 5 μm. It would also be possible for wear-resistant contact blocks 16 not to be subjected to postprocessing, or to be subjected to some other form of postprocessing. This range constitutes a good compromise between increased wear resistance and good manufacturability. In alternative embodiments, it is however also possible for the coupling surfaces 16a to have average roughness depths of less than 3 μm or more than 5 μm. For example, the wear-resistant contact blocks 16 may be subjected to postprocessing such that the coupling surfaces 16a have an average roughness depth between approximately Rz=1 μm and Rz=10 μm. In particular, average roughness depths of Rz≤20 μm have proven to be more wear-resistant than greater roughness depths. The coupling surfaces 16a preferably have average roughness depths of Rz≤5 μm. The coupling surfaces 16a may particularly preferably have an average roughness depth of Rz≤4 μm. As already mentioned, these statements may apply equally or differently to one or both of the coupling surfaces 16a, if present. The wear-resistant contact blocks 16 may be subjected to mechanical postprocessing, chemical postprocessing or energy-based postprocessing (for example by electromagnetic radiation) in order to form the coupling surface 16a. In other words, the contact blocks 16 or the surface thereof may be processed, in particular mechanically processed, in order to form the respective coupling surface 16a. In particular, the wear-resistant contact block 16 may be subjected to cutting postprocessing in order to form the coupling surface 16a. The coupling surfaces 16a of the wear-resistant contact block 16 are preferably oriented perpendicular to an axis of the actuation pin 22. In other words, this means that a normal vector with respect to the coupling surface 16a is oriented perpendicular to the axis of the actuation pin 22. The wear resistance can be increased in this way. Alternatively, the coupling surfaces 16a may be entirely or partially oriented in inclined or curved fashion with respect to the actuation pin 22.
The wear-resistant contact blocks 16 have a thickness 17 of at least 0.1 mm. The thickness 17 of the wear-resistant contact blocks 16 extends from the inner side 15a of the corresponding limb 15 to the coupling surface 16a formed by the corresponding wear-resistant contact block 16. In other words, the thickness 17 extends substantially orthogonally with respect to a longitudinal extent of the limbs 15. For example, the thickness 17 of the wear-resistant contact block 16 may be 0.1 mm to 3.0 mm, in particular at least 0.5 mm, and preferably 0.6 mm to 1.0 mm. In some particularly preferred embodiments, the thickness 17 of the wear-resistant contact block 16 may be 0.8 mm+/−0.1 mm, which thicknesses lead to particularly good wear resistance and material efficiency. In some embodiments, the wear-resistant contact block 16 may have a variable thickness 17, which is at least 0.5 mm at at least one location and is approximately 0.1 mm or less at at least one other location. By means of such embodiments, particularly material-efficient and positionally accurate or requirement-based wear resistance can be provided. The embodiments described immediately above may apply to both or one of the two wear-resistant contact blocks 16. Likewise, the embodiments described immediately above are applicable to configurations of the lever 10 with only one wear-resistant contact block 16.
In the exemplary embodiment of
The first material may for example be a steel alloy with good welding characteristics. For example, the first material may comprise or be composed of Fel7Crl3Ni, X30CrNiNbSi25-20, X6CrNiMoTi17-12-2 and/or X2CrNiMo17-12-2. Other suitable metallic and non-metallic materials may additionally be used for the first material. Good welding characteristics can be understood for example to mean a temperature-stable and weldable alloy. In other words, good weldability can refer to a greater suitability for welding, and/or in particular better weldability, than the second material. The second material may for example be a steel alloy with a cobalt content of at least 20%. For example, the second material may comprise or be composed of Co30Cr8W and/or Co30Mo9Cr. Other suitable metallic and non-metallic materials may additionally be used for the second material. In particular, materials with a high hardness and/or high wear resistance are suitable as second material. In particular, the wear-resistant contact blocks 16 or the second material may have a hardness of between 500 HV0.1 and 1000 HV0.1. The second material or the main body 12 may for example have a hardness of 120 HV10 to 300 HV10.
In embodiments, the wear-resistant contact blocks 16 may have a hardness of at least 500 HV0.1.
In particular, the wear-resistant contact blocks may have a hardness of between 500 HV0.1 and 1000 HV0.1. Preferably, the wear-resistant contact blocks 16 may have a hardness of between 650 HV0.1 and 800 HV0.1.
The wear-resistant contact blocks 16 may be fastened to the limbs 15 by powder-metallurgical methods. In other words, the wear-resistant contact blocks 16 may be fastened to the limbs 15 by means of a powder injection molding connection or by means of a sintering operation. In embodiments, the main body 12 may be produced by powder-metallurgical methods. In particular, the lever 10 may be produced by powder-metallurgical methods. For example, the lever 10 may be produced by metal injection molding.
In preferred embodiments, only the two wear-resistant contact blocks 16 are produced from the second material. The rest of the lever 10, in particular the main body 12, is preferably produced from the first material. In other embodiments, it is for example possible for a region greater than the wear-resistant contact blocks 16 or one or both limbs 15 or the fork-shaped coupling section to be produced partially or entirely from the second material. In embodiments, it is possible for only one or both of the wear-resistant contact blocks 16 to be produced from the second material. In embodiments, it is alternatively or additionally possible for one or both limbs 15 to be produced partially or entirely from the second material. In some embodiments, the fork-shaped coupling section 14 may be produced partially or entirely from the second material. In particular, the elements stated here may be produced by powder-metallurgical methods. The main body 12 may consequently be produced at least partially from the first material. In embodiments, the main body 12 may be produced at least partially from the first material by powder-metallurgical methods.
In alternative embodiments, for example in the case of a positively locking or non-positively locking connection between the limbs 15 and the wear-resistant contact blocks 16, the wear-resistant contact blocks 16 and/or the main body 12 may be produced by fusion casting or in some other manner.
In embodiments, the wear-resistant contact blocks 16 may be fastened in non-positively locking and/or positively locking fashion to the limbs 15. For example, the wear-resistant contact blocks 16 may be fastened to the limbs 15 by means of a screw connection. This allows easy assembly and easy maintenance. As an alternative to the non-positively locking and/or positively locking fastening, the wear-resistant contact blocks 16 may be fastened cohesively to the limbs 15. For example, the wear-resistant contact blocks 16 may be fastened to the limbs 15 by means of a welded connection and/or by means of a brazed connection.
As shown in the example of
The production of the lever 10 by powder metallurgical methods will be discussed below; this represents one option for the production process. During the production by powder metallurgical methods, the lever 10 or the main body 12 and the wear-resistant contact blocks 16 are produced in a component composite. One option for the production of the component composite composed of the main body 12 and wear-resistant contact blocks 16 is a metal injection molding (MIM) composite casting operation. Metal injection molding refers to metal powder injection molding (powder injection molding). In this regard, a metal powder provided with a binding agent is processed in an injection molding operation. The binding agent is subsequently removed (debinding) and a sintering process is carried out.
Although the present invention has been described above and defined in the appended patent claims, it should be understood that the invention may alternatively also be defined in accordance with the following embodiments:
| Number | Date | Country | Kind |
|---|---|---|---|
| 20 2021 105 795.5 | Oct 2021 | DE | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20100028142 | Hashimoto | Feb 2010 | A1 |
| 20150086340 | Ramb | Mar 2015 | A1 |
