The invention relates to an exhaust gas turbocharger for an internal combustion engine, with a compressor and a turbine, wherein a compressor wheel is rotatably mounted in the compressor and a turbine wheel is rotatably mounted in the turbine, and the compressor wheel is mechanically connected to the turbine wheel by means of a rotatably mounted turboshaft, wherein the turbine wheel is connected to the turboshaft by a fastening element, and wherein the exhaust gas turbocharger has a device for recording the speed of the turboshaft.
The power which is generated by an internal combustion engine depends upon the air mass and the corresponding fuel volume which can be made available to the engine for combustion. If it is desired to increase the power of the internal combustion engine, more combustion air and more fuel has to be supplied. This power increase in a naturally aspirated engine is achieved by means of an increase of the swept volume or by means of the increase of speed. An increase of the swept volume, however, basically leads to heavier internal combustion engines which are larger in dimensions and therefore more expensive. The increase of speed brings along with it significant problems and disadvantages, especially in the case of larger internal combustion engines, and is limited for technical reasons.
A much used technical solution for increasing the power of an internal combustion engine is boosting. By this is meant the precompression of the combustion air by means of an exhaust gas turbocharger, or also by means of a flow compressor which is mechanically driven by the engine. An exhaust gas turbocharger basically comprises a flow compressor and a turbine, which are connected to a common shaft and which rotate at the same speed. The turbine converts the normally uselessly explosive energy of the exhaust gas into rotational energy, and drives the flow compressor. The flow compressor, which in this connection is also referred to as a compressor, draws in fresh air and delivers the precompressed air to the individual cylinders of the engine. An increased fuel volume can be fed to the larger air volume in the cylinders, as a result of which the internal combustion engine delivers more power. The combustion process, moreover, is favorably influenced so that the internal combustion engine achieves a better overall efficiency. Furthermore, the torque characteristic of an internal combustion engine which is boosted by a turbocharger can be extremely favorably designed. With vehicle manufacturers, existing naturally aspirated production engines can be significantly optimized by the use of an exhaust gas turbocharger without great constructional interventions on the internal combustion engine. Boosted internal combustion engines as a rule have a lower specific fuel consumption and have a lower emission of pollutants. Furthermore, turboengines as a rule are quieter than naturally aspirated engines of the same power, since the exhaust gas turbocharger itself functions as an additional silencer. In the case of internal combustion engines with a large operating speed range, for example with internal combustion engines for private motor vehicles, a high charge pressure is stipulated even at low engine speeds. For this, a charge pressure control valve, a so-called waste-gate valve, is introduced in these turbochargers. By the selection of a corresponding turbine casing, a high charge pressure is quickly built up even at low engine speeds. The charge pressure control valve (waste-gate valve) then limits the charge pressure to a constant value during increasing engine speed.
Alternatively to this, turbochargers with variable turbine geometry (VTG) come into use. In the case of these turbochargers, the charge pressure is governed by the change of the turbine geometry.
With increasing exhaust gas volume, the maximum permissible speed of the combination which comprises the turbine wheel, the compressor wheel and the turboshaft, which combination is also referred to as the rotating components of the turbocharger, can be exceeded. With an impermissible exceeding of the speed of the rotating components these would be destroyed which amounts to a total loss of the turbocharger. Even modern and small turbochargers with appreciably smaller turbine wheel and compressor wheel diameters, which have an improved rotational acceleration performance on account of a significantly smaller mass inertia moment, are affected by the problem of exceeding the permissible highest speed. Depending upon design of the turbocharger, even an exceeding of the speed limit by about 5% leads to the complete destruction of the turbocharger.
The charge pressure control valves, which according to the prior art are controlled by a signal which results from the generated charge pressure, have proved their worth for speed limitation. If the charge pressure exceeds a predetermined threshold value, then the charge pressure control valve opens and some of the exhaust gas mass flow bypasses the turbine. This absorbs less power because of the reduced mass flow, and the compressor power reduces by the same measure. The charge pressure and the speed of the turbine wheel and of the compressor wheel are reduced. This control, however, is relatively sluggish, since the pressure build-up during an overspeed of the rotating components is carried out with a time lag. Therefore, the speed control for the turbocharger with charge pressure monitoring in the high-dynamic range (load change) has to be engaged by correspondingly early load pressure reduction which leads to a loss of efficiency.
A direct measuring of the speed on the compressor wheel or on the turbine wheel turns out to be difficult, since, for example, the turbine wheel is thermally extremely stressed (up to 1000° C.), which prevents a measuring of the speed by conventional methods on the turbine wheel. In a publication of acam-Mess-electronic GmbH of April 2001, it is proposed to measure the compressor blade impulse in the eddy current principle and in this way to determine the speed of the compressor wheel. This method is costly and expensive, since at least one eddy current sensor would have to be integrated in the casing of the compressor, which, on account of the high precision with which components of a turbocharger are manufactured, would be extremely difficult. In addition to the precise integration of the eddy current sensor in the compressor casing, sealing problems arise, which, on account of the high thermal stress of a turbocharger, are only to be overcome with costly interventions into the design of the turbocharger.
It is the object of the present invention, therefore, to disclose an exhaust gas turbocharger for an internal combustion engine, in which the speed of the rotating components (turbine wheel, compressor wheel, turboshaft) can be simply and inexpensively recorded and also without significant constructional interventions into the construction of existing turbochargers.
This object is achieved according to the invention by the device for recording the speed having an element for variation of a magnetic field on the end of the turboshaft on the compressor side, and by the element for variation of the magnetic field being located between the turbine wheel and the fastening element, wherein the variation of the magnetic field is carried out in dependence upon the rotation of the turboshaft, and wherein a sensor element is located in the proximity of the element for variation of the magnetic field, which sensor element records the variation of the magnetic field and converts the variation into electrically evaluatable signals.
In the arrangement of the element for variation of the magnetic field on the end of the turboshaft on the compressor side between the turbine wheel and the fastening element, it is advantageous that this region of the turbocharger is thermally relatively little stressed, since it lies a distance away from the hot exhaust gas flow and is cooled by the fresh air flow. Furthermore, the end of the turboshaft on the compressor side is easily accessible, as a result of which commercially available sensor elements, such as Hall sensor elements, magnetoresistive sensor elements or inductive sensor elements, can be located here without interventions, or with only minor interventions, into the design of the existing turbocharger, which enables an inexpensive measuring of speed in the turbocharger. By the signal which is generated by the sensor element, the charge pressure control valve can be very quickly and accurately controlled, or the turbine geometry of VTG chargers can be altered in order to avoid an overspeed of the rotating components. The turbocharger, therefore, can always be operated very close to its speed limit, as a result of which it achieves its maximum efficiency. A relatively large safety margin for the maximum speed limit, as is customary with pressure-controlled turbochargers, becomes unnecessary.
In a first development, the sensor element is formed as a Hall sensor element. Hall sensor elements are very well suited for recording the variation of a magnetic field, and, therefore, are very good to use for recording of speed. Hall sensor elements are very inexpensive commercially to purchase and they are usable even at temperatures up to about 160° C.
Alternatively to this, the sensor element is formed as a magnetoresistive (MR) sensor element. MR sensor elements for their part are well suited for recording the variation of a magnetic field and are inexpensively commercially purchasable.
In a next alternative development, the sensor element is formed as an inductive sensor element. Inductive sensor elements are also ideally suited for recording the variation of a magnetic field.
In a further development, the sensor element is located in the axial extension of the turboshaft. In this arrangement of the sensor element, the air flow in the air intake of the compressor is impeded to only a very small degree by the sensor element itself. As a result, the efficiency of the turbocharger is fully obtained.
Alternatively to this, the sensor element is located close to the end of the turboshaft on the compressor side. In this development, the variation of the magnetic field which is generated by a magnet which is located in the end of the turboshaft on the compressor side, can be recorded especially well, since, for example, the poles of a bar magnet can move past the sensor element one after the other.
In one development, the sensor element is integrated in a sensor which is formed as a plug-in finger probe which is pluggable into the air inlet by means of a recess in the compressor casing. Such a plug-in finger probe forms a very compact component which only slightly reduces the cross section of the air inlet. The installation of such a plug-in finger probe in a recess in the compressor casing proves to be very simple, which is especially a great advantage during the mounting process of the sensor element on the turbocharger.
According to a next alternative embodiment, the sensor element is integrated in a sensor which is seatable on the external wall of the compressor casing in the region of the air inlet. In this embodiment, no intervention whatsoever on the compressor casing or in the air inlet of the turbocharger has to be undertaken. The cross section of the air inlet is fully maintained and no undesired effects in the air flow upstream of the compressor wheel can be caused by the sensor element or the sensor. A powerful magnet, for example, which is located in the end of the turboshaft on the compressor side, generates a sufficiently sharp variation of the magnetic field in the sensor element, which is located on the external wall of the compressor casing, during rotation of the turboshaft, so that an electrical signal can be generated in the sensor which corresponds to the speed of the turboshaft.
In one development of the invention, the element for variation of the magnetic field is formed as a permanent magnet which is mounted in an enclosure. Such an enclosure prevents particles becoming detached from the magnet in the event of a possible break-up of the magnet and falling against the moving components of the turbocharger, which could lead to destruction of the turbocharger. Furthermore, a mass eccentricity on the turboshaft would result if particles were to become detached from the element for variation of the magnetic field. Such a mass eccentricity is effectively prevented by means of the enclosure.
Alternatively to this, the element for variation of a magnetic field is formed in the form of at least two magnetic dipoles which are mounted in the enclosure. Two magnetic dipoles fulfill the same function as a bar magnet, however they are lighter than a bar magnet, which is advantageous. A number of magnetic dipoles produce a high number of magnetic impulses, which is important if the position of the turboshaft is to be additionally recorded.
In one embodiment, the enclosure is formed as a cup-like constructional element. In a cup-like constructional element the magnets can be easily fitted in and/or glued in, which significantly simplifies the manufacture of the element for variation of the magnetic field. In this case, it is advantageous if the enclosure is formed from high-strength, low magnetic or non-magnetic metal.
In a further development, the element for variation of a magnetic field is formed as a bar magnet. A diametrally polarized bar magnet which rotates with the turboshaft generates an easily measurable variation of the magnetic field in its environment, by which the speed of the turboshaft, the compressor wheel and the turbine wheel is easily recordable.
Embodiments of the invention are exemplarily shown in the figures. In the figures:
As a great advantage to the measuring of the speed of the turboshaft 5 on the end 10 of the turboshaft 5 on the compressor side, the prevailing temperature is to be mentioned here. Exhaust gas turbochargers 1 are thermally highly stressed components, in which temperatures up to 1000° C. occur. Measurements cannot be taken at these temperatures by known sensor elements 19, such as Hall sensors or magnetoresistive sensors. Significantly lower temperature stresses arise on the end 10 of the turboshaft 5 on the compressor side. As a rule, temperatures of about 140° C. in continuous operation and 160 to 170° C. after peak load occur in the air inlet 24 of a compressor 3. By means of the magnetic field sensor 14 which is located in the cold induction air flow, its temperature stress in comparison to the installation at other points of the exhaust gas turbocharger is substantially reduced.
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Number | Date | Country | Kind |
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10 2004 052 695.8 | Oct 2004 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP05/54818 | 9/27/2005 | WO | 00 | 4/27/2007 |