This application claims priority to International Patent Application No. PCT/EP2021/071496, filed Jul. 30, 2021, which claims priority to GB Patent Application No. 2011956.6, filed Jul. 31, 2020 the disclosures of which are hereby expressly incorporated by reference in their entirety.
The present disclosure relates to turbine housings with extended tongue features acting as both an anti-rotation device and providing improved aerodynamic performance through optimised profile machining. The present disclosure also relates to nozzle rings and assemblies for use in turbomachines, as well as turbomachines including such turbine housings, nozzle rings, or assemblies. The present disclosure also relates to method of manufacturing such apparatuses.
Turbochargers are well-known devices for supplying air to the intake of an internal combustion engine at pressures above atmospheric pressure (boost pressure). A conventional turbocharger essentially comprises an exhaust gas driven turbine wheel mounted on a rotatable shaft within a turbine housing. Rotation of the turbine wheel rotates a compressor wheel mounted on the other end of the shaft within a compressor housing. The compressor wheel delivers compressed air to the inlet manifold of the engine, thereby increasing engine power. The turbocharger shaft is conventionally supported by journal and thrust bearings, including appropriate lubricating systems, located within a central bearing housing connected between the turbine and compressor wheel housing.
In known turbochargers, the turbine stage comprises a turbine chamber within which the turbine wheel is mounted; an annular inlet passageway defined between facing radial walls arranged around the turbine chamber; an inlet volute arranged around the inlet passageway; and an outlet passageway extending from the turbine chamber. The passageways and chambers communicate such that pressurised exhaust gas admitted to the inlet volute flows through the inlet passageway to the outlet passageway via the turbine and rotates the turbine wheel.
It is known to improve turbine performance by providing vanes, referred to as nozzle vanes, in the inlet passageway so as to deflect gas flowing through the inlet passageway towards the direction of rotation of the turbine wheel. Each vane is generally laminar, and is positioned with one radially outer surface arranged to oppose the motion of the exhaust gas within the inlet passageway, i.e. the circumferential component of the motion of the exhaust gas in the inlet passageway is such as to direct the exhaust gas against the outer surface of the vane. The nozzle vanes are generally provided on a nozzle ring.
Turbines may be of a fixed or variable geometry type. Variable geometry type turbines differ from fixed geometry turbines in that the geometry of the inlet passageway can be varied to optimise gas flow velocities over a range of mass flow rates so that the power output of the turbine can be varied to suit varying engine demands. For instance, when the volume of exhaust gas being delivered to the turbine is relatively low, the velocity of the gas reaching the turbine wheel is maintained at a level that ensures efficient turbine operation by reducing the size of the inlet passageway.
In one known type of variable geometry turbine, an axially moveable wall member, generally referred to as a “nozzle ring”, defines one wall of the inlet passageway. The position of the nozzle ring relative to a facing wall of the inlet passageway is adjustable to control the axial width of the inlet passageway. Thus, for example, as gas flowing through the turbine decreases, the inlet passageway width may also be decreased to maintain gas velocity and to optimise turbine output. Such nozzle rings comprise a generally annular wall and inner and outer axially extending flanges. The flanges extend into a cavity defined in the turbine housing, which is a part of the housing that in practice is provided by the bearing housing, which accommodates axial movement of the nozzle ring.
In contrast to a variable geometry turbine, in a fixed geometry turbine the relative position of the nozzle ring to the facing wall is fixed.
The present disclosure aims to provide new and useful assemblies for use in a turbomachine, as well as new and useful turbo-machines, especially turbo-chargers, incorporating such assemblies.
In general terms, the present disclosure proposes that the nozzle ring and the turbine housing are provided with a complementary tongue and slot which are configured to engage with one another and to thereby prevent relative rotation of the nozzle ring and the turbine housing. The tongue may be in the form of a vane or a portion of a vane. The slot is located in a position where it is desirable to have a vane or is adjacent a complementary portion of a vane such that when the tongue engages with the slot, a vane is provided in a desired location. The tongue can be shaped to have the optimal desired geometry for gas flow. The slot may also be referred to as a cut-out. The slot, also known as a cut-out, is configured to engage with a complementary protrusion, referred to as a tongue, in order to restrict relative rotation of the turbine housing and nozzle ring.
As such, according to a first aspect of the present disclosure, there is provided an assembly for a turbocharger, the assembly comprising a turbine housing and a nozzle ring, wherein one of the turbine housing and the nozzle ring comprises a tongue and the other of the turbine housing and the nozzle ring comprises a corresponding slot or cut-out, the tongue and slot or cut-out being configured to engage and prevent relative rotation of the turbine housing and the nozzle ring.
In use, exhaust gas is incident on the vanes of the nozzle ring and this imparts a rotational force on the nozzle ring. In previous assemblies, the nozzle ring is fixedly attached to the turbine housing by way of rivets or welding. However, these attachment methods require additional assembly steps as well as additional parts, whereas the present disclosure allows for more efficient assembly and the use of fewer parts. The engagement of the tongue and the slot prevents or substantially prevents the nozzle ring from rotating relative to the turbine housing. Of course, there may be some slight movement due to manufacturing tolerances, but such rotation is limited by the engagement of the tongue and the slot. The tongue is in the form of a protrusion which engages with a surface of the complementary cut-out. The tongue and the slot or cut-out are configured to form a vane when in the assembled condition. A vane portion may be provided adjacent the slot or cut-out, the vane portion being configured to engage with the tongue in the assembled condition to form a vane.
The tongue may be located on either the turbine housing or the nozzle ring. Consequently, the slot or cut-out may be located on the other of the turbine housing or the nozzle ring. Preferably the turbine housing comprises the tongue and the nozzle ring comprises the slot or cut-out.
The tongue may extend radially inwardly from a surface of the turbine housing. The tongue may be integrally formed with the turbine housing. This allows the tongue to be provided without any additional requirement to attach it to the turbine housing. Alternatively, the tongue may be a separately formed insert. In such embodiments, the turbine housing and the tongue may have complementary mating features which retain the tongue in the turbine housing. Such mating features may comprise a push fit connection. By providing the tongue as a separate element, it is possible to easily alter the select of the tongue insert to interact favourably with the vanes on a corresponding nozzle ring.
The nozzle ring may have an outer circumference and an inner circumference, and the slot or cut-out may extend radially inwardly from the outer circumference towards the inner circumference. In other embodiments, the slot or cut-out may extend from the inner circumference to the outer circumference. It will be appreciated that the slot or cut-out does not necessarily have to extend normal to the circumference and may instead be angled. It will also be appreciated that the slot or cut-out does not necessarily need to define an area which is closed off on three sides or more. The slot or cut-out can be u-shaped or can be v-shaped.
The nozzle ring may comprise a plurality of vanes. The slot or cut-out may be positioned on the nozzle ring adjacent to a vane portion, preferably radially adjacent. In embodiments, the plurality of vanes are evenly distributed around the nozzle ring. Since it is desired in embodiments for the tongue portion to form at least part of one of the vanes when in the assembled condition, the slot or cut-out is positioned adjacent to a vane portion. That is to say that the slot is positioned between two vanes where a vane would otherwise have been present. By vane portion it is meant that the radially inner portion of a vane is provided and the slot or cut-out is located at the position of where the radially outer portion of the vane would have otherwise been located. As such, when the tongue engages with the slot or cut-out, it forms a complete vane composed of the vane portion disposed on the nozzle ring and the tongue portion disposed on the turbine housing. It will be appreciated that the reverse may also be the case, that is where the vane portion comprise a radially outer portion of a vane and the slot or cut-out is located at the position where the radially inner portion of the vane would otherwise have been located.
The tongue may comprise at least a portion with a geometry substantially corresponding to the vanes of the nozzle ring. As it is desired for the tongue of embodiments of the present disclosure to form at least part of one of the vanes on the nozzle ring, it preferably has substantially the same geometry as the remainder of the vanes on the nozzle ring. The vanes on the nozzle ring which are not at least partially formed from the tongue are generally fully disposed between the inner circumference of the nozzle ring and the outer circumference of the nozzle ring. Since the tongue extends from the turbine housing, the radially outer portion may extend beyond the outer circumference of the nozzle ring and so the overall shape of the tongue may slightly differ from that of the other vanes on the nozzle ring. However, the portion of the tongue which extends in the same relative position of the other vane members on the nozzle ring has substantially the same geometry as such other vanes.
The slot or cut-out may be positioned on the nozzle ring such that in an assembled configuration, the tongue forms a vane with a corresponding vane portion on the nozzle ring. In this way, the anti-rotation device serves a dual function of preventing relative rotation of the nozzle ring with respect to the turbine housing and also forms a part of the aerodynamic features of the nozzle ring. Therefore, the present disclosure provides advantageous aerodynamic performance whilst allowing more efficiently assembly of the apparatus and whilst also requiring fewer parts.
The tongue may be a cast feature. The tongue may be cast alongside the remainder of the turbine housing. As such, the tongue may be an integral or one-piece feature of the turbine housing. By casting the tongue as part of the turbine housing, there are no additional steps required to attach the tongue to the housing. This provides for easier manufacture of the turbine housing having the tongue feature. After casting, the cast tongue portion may be machined, such as by milling, into the desired aerodynamic shape. This is since the tongue will form at least part of a vane to redirect the flow of exhaust gas in the desired direction when in the assembled configuration and then in use. In other embodiments, the tongue is a separately formed insert. By providing the tongue as a separate element, it may be possible to more readily provide tongue elements having a range of different geometries which may be selected depending on the nature of the vanes on the corresponding nozzle ring. Thus, a single turbine housing could be used in conjunction with nozzle rings having different vane geometries, but simply selecting the appropriate tongue element for engagement with the turbine housing.
The assembly may comprise two or more tongues and slots or cut-outs. Whilst a single tongue/slot or cut-out pairing may be sufficient, it is also contemplated that there may be multiple tongue/slot or cut-out pairings as required. Any suitable number may be provided. Where there are multiple tongue/slot or cut-out pairings, they are preferably evenly distributed around the turbine housing/nozzle ring. The tongues may be provided as integral elements and/or as separately formed elements.
The tongue may include a sealing surface. The slot may include a sealing surface. The sealing surface of the tongue may be configured to engage with the corresponding sealing surface of the slot or cut-out to form a seal along substantially the entire length of the portions of the sealing surfaces which overlap with one another. Since the interface between the two sealing surfaces is a potential area for leakage of gases, and therefore a loss of efficiency, the tongue and the slot or cut-out preferably form a seal. In cases where the tongue and the slot or cut-out meet one another at a point, there is a greater chance that gas will be able to leak past. In addition, there is likely to be greater wear at that point due to the small surface area. In contrast, by providing complementary sealing surfaces on the tongue and the slot or cut-out, the risk of leakage of gas is reduced and wear is also reduced. As such, the tongue may be conformal with the slot or cut-out when mated. The sealing surface of the tongue may be conformal with the sealing surface of the slot or cut-out when mated. In embodiments, the tongue may comprise a mating surface, preferably a planar mating surface. The mating surface is configured to engage with a corresponding mating surface associated with the slot or cut-out. The mating surface may be planar, but in embodiments may be partially convex and/or concave.
According to a second aspect of the present disclosure, there is provided a turbine housing including a radially inwardly extending tongue configured to engage with a corresponding slot or cut-out in a nozzle ring to prevent relative rotation between the turbine housing and the nozzle ring.
The tongue may have the geometry of a portion of a vane such that in an assembled condition, the tongue forms at least a portion of a vane with a corresponding vane portion on the nozzle ring.
According to a third aspect of the present disclosure, there is provided a nozzle ring for a turbomachine, said nozzle ring including a slot or cut-out extending inwardly from an outer circumference of the ring, said slot or cut-out being configured to engage with a tongue of a turbine housing when in an assembled condition.
The slot or cut-out may be positioned at least partially radially outboard of a vane portion such that in an assembled condition, a tongue of a turbine housing engages with the slot or cut-out and forms a vane with the vane portion. It will be appreciated that, in all aspects of the present disclosure, the slot or cut-out may extend in a circumferential direction as well as in a radial direction, such that the slot or cut-out is angled with respect to a radial direction and, in examples, an exclusively radial direction.
The slot or cut-out may be positioned radially outboard of a vane portion such that, in an assembled condition, a tongue of a turbine housing engages with the slot or cut-out and forms a vane with the vane portion.
As such, the turbine housing of the second aspect of the present disclosure may combine with the nozzle ring according to the third aspect of the present disclosure to form an assembly according to the first aspect of the present disclosure.
According to a fourth aspect of the present disclosure, there is provided a turbine assembly comprising a turbine wheel and a turbine housing according to the first or second aspect of the present disclosure. Alternatively or additionally, there is provided a turbine assembly comprising a turbine wheel and a nozzle ring according to the first or third aspect of the present disclosure. In embodiments, there is provided a turbine assembly comprising a turbine wheel and a turbine housing and a nozzle ring according to any of the first to third aspects of the present disclosure. The turbine assembly may be of a fixed or variable type geometry.
According to a fifth aspect of the present disclosure, there is provided a turbocharger comprising a turbine assembly according to the fourth aspect of the present disclosure.
According to a sixth aspect of the present disclosure, there is provided a method of manufacturing a turbine housing according to any other aspect of the present disclosure, wherein said method includes casting a turbine housing having a tongue extending radially inwardly, and machining, preferably milling, the tongue to have a geometry substantially corresponding to the geometry of a vane of a nozzle ring. Alternatively, the method may comprise providing a turbine housing having a mating feature configured to receive a separately formed tongue portion, and engaging a separately formed tongue portion with the mating feature.
The turbine housing according to the second aspect of the present disclosure may be the turbine housing of the assembly of claim 1. As such, all features describing the first or second aspects of the present disclosure equally apply to the other of the first and second aspects of the present disclosure.
It will be appreciated that where appropriate any of the above aspects may incorporate one or more features of any of the other aspects.
Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, of which:
In summary, the present disclosure provides for an anti-rotation device which also serves as a vane in the assembled condition.
Number | Date | Country | Kind |
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2011956 | Jul 2020 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/071496 | 7/30/2021 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2022/023569 | 2/3/2022 | WO | A |
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20040109755 | Meier | Jun 2004 | A1 |
20150300243 | Myers | Oct 2015 | A1 |
20200024988 | Comeau | Jan 2020 | A1 |
20200300161 | Rost | Sep 2020 | A1 |
Number | Date | Country |
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1273760 | Jan 2003 | EP |
3140518 | Jul 2019 | EP |
2008139130 | Nov 2008 | WO |
2009076062 | Jun 2009 | WO |
Entry |
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International Preliminary Report on Patentability received for PCT Patent Application No. PCT/EP2021/071496, mailed on Feb. 9, 2023, 7 pages. |
International Search Report and Written Opinion for International patent application No. PCT/EP2021/071496. filed Jul. 30, 2021, mailed Oct. 25, 2021. |
Number | Date | Country | |
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20230287806 A1 | Sep 2023 | US |