The present disclosure relates to an FRP impeller for a vehicle turbocharger.
As disclosed in Patent Documents 1 and 2, impellers for centrifugal compressors are known. The impeller disclosed in Patent Document 1 includes a hub portion formed on a rotational axis, and a plurality of blade portions attached to an outer peripheral surface of the hub portion. The blade portions are formed from a discontinuous fiber resin and at least a rear part of the hub portion is formed from a continuous fiber resin. The impeller of Patent Document 2 has a recessed portion formed on a rear surface thereof.
Patent Document 1: Japanese Unexamined Patent Publication No. 2014-238084
Patent Document 2: Japanese Unexamined Patent Publication No. 2011-085088
A hub portion (disk portion) of a fiber reinforced plastic (FRP) impeller conventionally employs a shape that protrudes toward the rear surface to relieve stress on an inner diameter portion of a boss portion. The weight and the moment of inertia of the impeller may be increased in such case. As a result, acceleration performance tends to decrease. An impeller having a recessed portion formed on a rear surface is also known as disclosed in Patent Document 2. By having the recessed portion formed, weight can be reduced.
The recessed portion on the rear surface of the impeller can contribute to improving acceleration performance and reducing weight. In other words, inertia can be reduced. The reduction in inertia is important in a compressor for a vehicle turbocharger which requires acceleration performance of the impeller. However, merely having a recessed portion increases stress. An increase in stress may cause damage to the impeller. The present disclosure describes an FRP impeller for a vehicle turbocharger that can prevent damage.
An FRP impeller for a vehicle turbocharger according to one embodiment of the present disclosure includes a boss portion being cylindrical and having an axis, a disk portion extending outward in a radius direction from the boss portion, and a plurality of blade portions protruding outward in the radius direction and toward one side of an axis direction along the axis from the boss portion and the disk portion, wherein the disk portion includes a front surface on which the blade portions are foisted, and a rear surface located opposite the front surface in the axis direction, wherein the disk portion has, on the rear surface, an end edge being annular and located on another side of the axis direction, and a recessed portion formed inward of the end edge in the radius direction and recessed more toward the one side of the axis direction than the end edge, and wherein the recessed portion includes a planar surface being annular, located at a bottom portion of the recessed portion farthest from the end edge in the axis direction, and extending along the radius direction.
One embodiment of the present disclosure provides an FRP impeller for a vehicle turbocharger that can prevent damage.
An FRP impeller for a vehicle turbocharger according to one embodiment of the present disclosure includes a boss portion being cylindrical and having an axis, a disk portion extending outward in a radius direction from the boss portion, and a plurality of blade portions protruding outward in the radius direction and toward one side of an axis direction along the axis from the boss portion and the disk portion, wherein the disk portion includes a front surface on which the blade portions are formed, and a rear surface located opposite the front surface in the axis direction, wherein the disk portion has, on the rear surface, an end edge being annular and located on another side of the axis direction, and a recessed portion formed inward of the end edge in the radius direction and recessed more toward the one side of the axis direction than the end edge, and wherein the recessed portion includes a planar surface being annular, located at a bottom portion of the recessed portion farthest from the end edge in the axis direction, and extending along the radius direction.
In this FRP impeller for a vehicle turbocharger, the recessed portion formed in the rear surface of the disk portion can contribute to reducing inertia and improving acceleration performance. Since the recessed portion has, on the bottom portion, the planar surface that extends along the radius direction, an increase in stress is prevented compared to a case in which the recessed portion is greatly hollowed out. Thus, this FRP impeller for a vehicle turbocharger is capable of preventing damage.
In some embodiments, a ratio of a maximum depth being a depth from the end edge to the planar surface in the axis direction, to a radius of the disk portion is 10 to 25%. In this case, the increase in stress is more appropriately prevented.
In some embodiments, the recessed portion includes a sloped surface connecting the planar surface to the end edge, and the sloped surface includes an inflection point in a cross-sectional shape taken in a plane including the axis. Since the inflection point is located between the planar surface and the end edge in this case, the shape of the recessed portion from the planar surface to the outer circumferential side can be appropriately set.
In some embodiments, the inflection point is located at a position between 40 to 60% of the disk portion in the radius direction from the axis. In this case, the shape of the recessed portion from the planar surface to the outer circumferential side is optimized.
In some embodiments, a ratio of a length in the radius direction of a region including the planar surface and having a depth in the axis direction 10% or less of the maximum depth, to the radius of the disk portion is 10 to 25%. In this case, the size of the region of the planar surface to be formed in the recessed portion cart be appropriately set. As a result, inertia is reduced and the increase in stress is prevented.
In some embodiments, a ratio of a length of the planar surface in the radius direction to the radius of the disk portion is 5 to 8%. In this case, the size of the region of the planar surface to be formed is optimized.
In some embodiments, a ratio of a length in the radius direction of a region including the planar surface and having a slope angle with respect to the planar surface of 20° or less, to the radius of the disk portion is 13 to 25%. In this case, the size of the region that includes the planar surface and both sides of the planar surface in the radius direction can be appropriately set. As a result, inertia is reduced and the increase in stress is prevented.
In some embodiments, a thickness of an outer circumferential end of the disk portion in the axis direction is equal to or less than a thickness of a rear edge of each blade portion located at the outer circumferential end. The weight of the outer circumferential side can significantly impact the inertia of the whole impeller. Inertia is effectively reduced by the thickness of the outer circumferential end of the disk portion being equal to or less than the thickness of the rear edge of the blade portion.
Embodiments according to the present disclosure will be described below with reference to the drawings. It should be noted that like elements are given like reference signs in the description of the drawings and redundant explanation is omitted.
An electric turbocharger (vehicle turbocharger) 1 having a compressor impeller (FRP impeller for a vehicle turbocharger) 8 according to a First Embodiment applied thereto is described with reference to
The electric turbocharger 1 includes a rotating shaft 12 which is rotatably supported in a housing 2, and the compressor impeller 8 which is attached to a distal end (one end) 12a of the rotating shaft 12. The housing 2 includes a motor housing 3 that accommodates the rotor part 13 and the stator part 14, and an end wall 4 that closes an opening on another end (right side in the figure) of the motor housing 3. The motor housing 3 has, on the one end (left side in the figure), a compressor housing 6 that accommodates the compressor impeller 8. The compressor housing 6 includes an inlet port 9, a scroll portion 10, and an outlet port 11.
The compressor impeller 8 is made, for example, of carbon fiber reinforced thermo plastic (CFRTP) to reduce weight. The compressor impeller 8 may be made of carbon fiber reinforced plastic (CFRP). It should be noted that the material of the compressor impeller 8 is not limited thereto and may be other FRPs.
The rotor part 13 is fixed to a central portion of the rotating shaft 12 in an axis direction and includes a permanent magnet (not shown) attached to the rotating shaft 12. The stator part 14 is fixed to an inner surface of the motor housing 3 so as to surround the rotor part 13, and includes a coil portion (not shown). When an alternating current is passed through the coil portion of the stator part 14, the rotating shaft 12 and the compressor impeller 8 rotate in unison due to the interaction between the rotor part 13 and the stator part 14. When the compressor impeller 8 rotates, the compressor impeller 8 sucks in outside air through the inlet port 9, compresses the air through the scroll portion 10, and discharges the compressed air from the outlet port 11. The compressed air discharged from the outlet port 11 is supplied to the internal combustion engine mentioned above.
The electric turbocharger 1 includes two bearings 20 which are press fit into the rotating shaft 12 and rotatably support the rotating shaft 12 with respect to the housing 2. The bearings 20 are respectively provided near the distal end 12a and near a base end 12b of the rotating shaft 12, and support the rotating shaft 12 at both ends. The bearings 20 are, for example, grease-lubricated radial ball bearings. One of the bearings 20 is attached to a rear surface side (right side in the figure) of the compressor impeller 8. The compressor impeller 8 and the bearing 20 are fixed to the rotating shaft 12 by a shaft end nut 16 that is mounted on the distal end 12a of the rotating shaft 12. The other bearing 20 is attached between the rotating shaft 12 and the end wall 4. The rotating shaft 12 and the compressor impeller 8 and the rotor part 13 which are fixed to the rotating shaft 12 integrally form a rotating part inside the housing 2.
The compressor impeller 8 according to the embodiment will be described in detail with reference to
The boss portion 31, the disk portion 32, and the blade portions 33 described above are integrally formed. As shown in
Each blade portion 33 includes a front edge 33a that is located toward the one side of the axis X direction and a rear edge 33b that is located at an outer circumferential end 32c of the disk portion 32. In this embodiment, the front edge 33a extends from the boss portion. The rear edge 33b extends from the disk portion toward the one side of the axis X direction. An average of angles formed between the front edge 33a and the axis X along the front edge 33a is greater than an angle formed between the rear edge 33b and the axis X along the rear edge 33b. The front edge 33a and the rear edge 33b are connected by an edge of the blade portion whose center of curvature is located outward in the radius direction toward the one side of the X direction. It should be noted that the plurality of blade portions 33 may include full blades that extend from an inlet to an outlet of the fluid and splitter blades that are disposed between adjacent full blades. In the description below, the blade portion 33 means a full blade.
The compressor impeller 8 according to the embodiment is characterized by its rear surface shape. The rear surface shape of the compressor impeller 8 will be described in detail below with reference to
The circular recessed portion 40 formed between the end surface 32d and the boss portion 31 is recessed more toward the one side of the axis X direction than the end surface 32d. The recessed portion 40 has a shape that corresponds to the trajectory of curves shown in
The recessed portion 40 includes an annular planar surface 34 that extends along the radius direction. The planar surface 34 extends, for example, in a direction perpendicular to the axis X. The planar surface 34 is located at a bottom portion of the recessed portion 40 that is farthest from the end surface 32d in the axis X direction. As shown in
As shown in
As shown in
The sloped surface 37 includes a second curved portion 38 which is continuous with the outer circumference of the planar surface 34 and is shaped to protrude toward the one side of the axis X direction, and a third curved portion 39 which is continuous with the outer circumference of the second curved portion 38 and is shaped to protrude toward the other side of the axis X direction. In a cross-sectional shape taken in a plane including the axis X, the sloped surface 37 includes an inflection point Pd that is located at a boundary between the second curved portion 38 and the third curved portion 39. This inflection point Pd is a point at which gradient strength transitions from increasing to decreasing when viewed outward in the radius direction.
The rear surface 32b of the disk portion 32 includes an outer circumferential endpoint Pf of the end surface 32d. A thickness tf of the outer circumferential end 32c of the disk portion 32 in the axis X direction is equal to or less than a thickness of the rear edge 33b of the blade portion 33 located at the outer circumferential end 32c.
The rear surface shape of the disk portion 32 mentioned above will be described further in detail from the various aspects below.
A predetermined depth region Ra that includes the planar surface 34 and has a depth in the axis X direction which is 10% or less of the maximum depth Zbf may be set for the recessed portion 40. As shown in
Furthermore, a predetermined slope angle region Rb that includes the planar surface 34 and has a slope angle θ relative to the planar surface 34 of 20° or less may be set for the recessed portion 40. As shown in
The inflection point Pd in the recessed portion 40 may be located at a position between 40 to 60% of the disk portion 32 in a radius RD direction from the axis X.
Low inertia and acceleration performance are required for the compressor impeller 8 for a vehicle turbocharger. Thus, in the compressor impeller 8, the recessed portion 40 allows for reduction in weight and in the moment of inertia. In this embodiment, stress that may occur in the compressor impeller 8 is considered on the basis of the material, FRP. In other words, the recessed portion 40 is formed within an allowable range of material strength. As a result, cost of the material is reduced, acceleration performance is increased, and power consumption of the electric turbocharger 1 is improved.
In this embodiment, peak stress that occurs in a CFRTP impeller and tip displacement are reduced by appropriately setting the following four parameters of the recessed portion 40.
In an impeller according to a comparative example that has no planar surface 34 and in which the depth of the recessed portion is greater than that of the embodiment above, the normalized inertia was 0.6. However, in this impeller, high stresses of 0.96, 1.27, and 1.43 were generated respectively in a bottom portion C, a disk portion A, and blade base portions B.
In an impeller according to a comparative example that has no planar surface 34 but in which the depth of the recessed portion is the same as that of the embodiment above, the not finalized inertia was 0.81. In this impeller, stresses of 0.85, 0.93, and 0.93 were generated respectively in the bottom portion C, the disk portion A, and the blade base portions B.
In an impeller according to an example that corresponds to the embodiment above, the normalized inertia was 0.81. In this impeller, the radius of the second curved portion 38 is greater than the radius of the first curved portion 36. In this impeller, stresses of 0.95, 0.95, and 0.76 were generated respectively in the bottom portion C, the disk portion A, and the blade base portions B. Thus, by having the planar surface 34 and appropriately setting the four parameters, the normalized stress of each part is kept at less than 1 while achieving low inertia.
The impeller according to the example has a configuration that corresponds to that of the embodiment above. As shown in
The impeller according to the comparative example has no planar surface 34 and has the recessed portion that is deeper than that of the impeller according to the example. As shown in
In a traditional CFRTP impeller, a peak stress is generated in the bottom portion C as shown in
In the compressor impeller 8 according to the embodiment, the recessed portion 40 formed in the rear surface 32b of the disk portion 32 can contribute to reducing inertia and improving acceleration performance. Since the recessed portion 40 has, on the bottom portion, the planar surface 34 that extends along the radius direction, the increase in stress is prevented compared to a case in which the recessed portion 40 is greatly hollowed out. Thus, the compressor impeller 8 is capable of preventing damage. In particular, the increase in stress is also appropriately prevented in a vehicle turbocharger that uses a thin rotating shaft 12.
The increase in stress is more appropriately prevented by the ratio of the maximum depth Zbf to the radius RD of the disk portion 32 being 10 to 25%.
Since the inflection point Pd is formed on the sloped surface 37 between the planar surface 34 and the end surface 32d, the shape of the recessed portion 40 from the planar surface 34 to the outer circumferential side is appropriately set.
The shape of the recessed portion 40 from the planar surface 34 to the outer circumferential side is optimized by the inflection point Pd being located at a position between 40 to 60% of the disk portion in the radius RD direction from the axis X.
The size of the region of the planar surface 34 to be formed in the recessed portion 40 is appropriately set by the ratio of the length of the predetermined depth region Ra (Zbd/Zbf=0.1) in the radius direction to the radius RD of the disk portion 32 being 10 to 25%. As a result, inertia is reduced and the increase in stress is prevented.
The size of the region of the planar surface 34 to be formed is optimized by the ratio of the length of the planar surface 34 in the radius direction to the radius RD of the disk portion 32 being 5 to 8%.
The size of the region that includes the planar surface 34 and both sides of the planar surface 34 in the radius direction may be appropriately set by the ratio of the length of the predetermined slope angle region Rb (slope angle θ=20°) in the radius direction to the radius RD of the disk portion 32 being 13 to 25%. As a result, inertia is reduced and the increase in stress is prevented.
Inertia is effectively reduced by the thickness tf of the outer circumferential end 32c of the disk portion 32 being equal to or less than the thickness of the rear edge 33b.
Although the embodiment of the present disclosure has been described above, the present invention is not limited thereto. The shape of the recessed portion 40 can be varied as appropriate. For example, as shown in
The FRP impeller for a vehicle turbocharger according to the present disclosure may be an impeller that does not satisfy any or a portion of the numerical ranges described above (numerical ranges relating to the planar surface 34, maximum depth Zbf, predetermined depth region Ra, predetermined slope angle region Rb, and thickness tf).
The FRP impeller for a vehicle turbocharger according to the present disclosure may be an impeller in which a metal piece/metal plate is inserted in the rear surface 32b of the disk portion 32.
The FRP impeller for a vehicle turbocharger according to the present disclosure may be applied to a turbocharger having a turbine.
According to various embodiments of the present disclosure, an FRP impeller for a vehicle turbocharger that can prevent damage is provided.
1 Electric turbocharger (vehicle turbocharger)
8 Compressor impeller (FRP impeller for a vehicle turbocharger)
31 Boss portion
32 Disk portion
32a Front surface
32b Rear surface
32c Outer circumferential end
32d End surface (end edge)
33 Blade portion
33a Front edge
33b Rear edge
34 Planar surface
37 Sloped surface
40 Recessed portion
Pd Inflection point
Ra Predetermined depth region
Rb Predetermined slope angle region
tf Thickness (of outer circumferential end)
Zbf Maximum depth
Number | Date | Country | Kind |
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2017-118853 | Jun 2017 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2018/022946 | 6/15/2018 | WO | 00 |