Technical Field
This document discloses a joint between a turbine disk and a shaft of a turbocharger that reduces heat transfer from the turbine disk to the shaft
Description of the Related Art
Turbochargers increase the power density of an internal combustion engine by compressing the air entering the intake manifold of the engine. Turbochargers include a turbine and a compressor. The turbine may include a turbine inlet and outlet duct that surrounds a turbine disk. The turbine disk may be connected to a plurality of turbine blades or the disk and blades may be unitary in structure and referred to as a blisk. The compressor may include a compressor housing that surrounds a compressor disk. A common shaft may connect the compressor disk to the turbine disk. A flow of exhaust gas from the engine proceeds through an exhaust manifold to the turbine inlet duct, which imparts rotation to the turbine disk, the shaft and the compressor disk. As the compressor disk spins, fresh air is compressed and forced into the intake manifold of the engine thereby boosting the power density of the engine. The shaft connecting the turbine disk to the compressor disk typically passes through a journal bearing and a lubricating oil bath.
Heat from the exhaust gas creates high operating temperatures for turbocharger components, especially the turbine Hades, which readily transfer heat to the turbine disk. The high operating temperature of the turbine disk needs to be attenuated before it is communicated to the lubricating oil bath and the journal bearing. One method to achieve this attenuation is to provide a pocket or cavity between the turbine disk and the shaft as disclosed in U.S. Pat. No. 7,241,416. However, this technique leads to reduced strength at the joint between the turbine disk and the shaft and it further undermines the capability of the turbine disk to withstand a severe loading event, such as a blade loss. Accordingly, there is a need for a turbine disk/shaft connection that reduces heat transfer from the turbine disk to the shaft, the journal bearing and the oil bath without compromising the structural integrity of the turbine disk/shaft connection.
In one aspect, this document discloses an exhaust gas turbocharger, which may include a turbine disk connected to a connected turbine disk hub. The turbocharger may also include a shaft including a proximal end that includes a shaft hub. The turbine disk hub may be coaxially connected to the shaft hub at a joint. The turbine disk hub and the shaft hub may form a cavity between the turbine disk and the proximal end of the shaft. The turbocharger may further include a sleeve including an inner surface that surrounds and engages at least part of the turbine disk hub and at least part of the shaft hub. The sleeve may also surround the joint and at least partially surround the cavity.
In another aspect, this document discloses a method for connecting a turbine disk to a shaft. The method may include forming a turbine disk hub on a distal side of the turbine disk, wherein the turbine disk hub forms a turbine disk pocket. The method may further include forming a shaft hub on a proximal end of the shaft, wherein the shaft hub forms a shaft pocket. The method may further include connecting the turbine disk hub to the shaft hub to form a joint between the turbine disk hub and the shaft hub and a cavity that includes the turbine disk pocket and the shaft pocket. The method may further include placing a sleeve around the joint and around at least part of the cavity.
In another aspect, this document discloses a power system that may include an engine, an exhaust manifold fluidly connected to the engine and a turbocharger fluidly connected to the exhaust manifold. The turbocharger may include a turbine inlet duct configured to receive exhaust from the exhaust manifold. The turbine inlet duct may be fluidly connected to a turbine outlet duct. The turbocharger may also include a turbine disk disposed within the turbine inlet and outlet duct. The turbine disk may be connected to a turbine disk hub. The turbocharger may further include a shaft including a proximal end that includes a shaft hub. The turbine disk hub may be coaxially connected to the shaft hub at a joint. The turbine disk hub and the shaft hub may include a cavity between the turbine disk and the proximal end of the shaft. The turbocharger may further include a sleeve that includes an inner surface that surrounds and engages at least part of the turbine disk hub and at least part of the shaft hub. The sleeve may further surround the joint and at least partially surround the cavity.
The features, functions, and advantages discussed above may be achieved independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.
For a more complete understanding of the disclosed methods and apparatuses, reference should be made to the embodiments illustrated in greater detail in the accompanying drawings, wherein:
The drawings are not to scale and illustrate the disclosed embodiments diagrammatically and in partial views. In certain instances, this disclosure may omit details which are not necessary for an understanding of the disclosed methods and apparatuses or which render other details difficult to perceive. Further, this disclosure is not limited to the particular embodiments illustrated herein.
With reference to the drawings, the term “distal” refers to parts or areas of a component that face or are disposed to the left in the drawings. See, e.g., the turbine disk distal wall 11 and the distal end 12 of the turbine disk hub 13 in
The power source 21 may include an engine block 24 that at least partially defines a plurality of cylinders 25. A piston (not shown) may be slidably disposed within each cylinder 25 to reciprocate between a top-dead-center position and a bottom-dead-center position, and a cylinder head (not shown) may be associated with each cylinder 25. Each cylinder 25, piston, and cylinder head may together at least partially define a combustion chamber. In the embodiment illustrated in
The air induction system 22 may include, among other things, at least one compressor 26 that may embody a fixed geometry compressor, a variable geometry compressor, or any other type of compressor configured to receive air and compress the air to a desired pressure level. The compressor 26 may direct air to one or more intake manifolds 27 associated with the power source 21. it should be noted that the air induction system 22 may include multiple compressors 26 arranged in a serial configuration, a parallel configuration, or a combination serial/parallel configuration, as will be apparent to those skilled in the art.
The exhaust system 23 may include, among other things, an exhaust manifold 28 connected to one or both of the banks of cylinders 25. The exhaust system 23 may also include at least one turbine 29 driven by the exhaust from the exhaust manifold 28 to rotate the compressor(s) 26 of the air induction system 22. The compressor 26 and the turbine 29 may together form a turbocharger 33. The turbine 29 may embody a fixed geometry turbine, a variable geometry turbine, or any other type of turbine configured to receive exhaust and convert energy in the exhaust to mechanical rotation. After exiting the turbine 29, the exhaust may discharge to the atmosphere through an aftertreatment system 34 that may include, for example, a hydrocarbon doser, a diesel oxidation catalyst (DOC), a diesel particulate filter (DPF), and/or another treatment device or system known in the art. It should. be noted that the exhaust system 23 may include multiple turbines 29 arranged in a serial configuration, a parallel configuration, or a combination serial/parallel configuration, as will be apparent to those skilled in the art.
As illustrated in
As shown in
Referring to
The sleeve 55 is disposed within a turbine seal carrier 61. The turbine seat carrier 61 includes a proximal end 62. Further, the sleeve 55 also includes a proximal end 63. The proximal end 63 of the sleeve 55 connects to a proximal ridge 64. Further, referring to
The turbocharger 33 employs compressed air generated by the compressor (not shown) to seal the lubricating oil within the turbocharger 33. Thus, incoming flow from the compressor (not shown) flows in the proximal direction, as indicated by the arrow 71 in
Further, conductive heat transfer from the turbine disk 39 to the sleeve 55 is minimized by reducing the contact between the sleeve 55 and the turbine disk 39. The proximal end 63 of the sleeve 55 makes only a minimal contact with the turbine disk 39 as shown in
Finally, it will be noted that the cavity 51 is a combination of a pocket formed in the distal side of the turbine disk 39 by the turbine disk hub 13 and a pocket formed in the proximal end 52 of the shaft 42 by the shaft hub 16. More specifically, the turbine disk hub 13 includes a cylindrical wall 76 that extends from the distal end 12 of the turbine disk hub 13 to a turbine disk fillet 77. The turbine disk fillet 77 is disposed between the cylindrical wall 76 and the turbine disk distal wall 11. Similarly, the shaft hub 16 includes a shaft cylindrical wall 78 that extends from the proximal end 15 of the shaft hub 16 to a shaft fillet 79, which is disposed between the shaft cylindrical wall 78 and the shaft proximal wail 14, These two pockets are combined when the distal end 12 of the turbine disk hub 13 is joined to the proximal end 15 of the shaft hub 16 to form the joint 53. The joint 53 may be formed in a number of conventional ways, including, but not limited to, frictional welding.
This document discloses a turbocharger 33 that provides an attenuation of heat transfer from the turbine blades 46 and turbine disks 39 to the shaft 42 that connects the turbine disks 39 to a compressor disk (not shown). One design feature contributing to the heat attenuation is the formation of the cavity 51 between the turbine disk 39 and the shaft 42. The cavity 51 is formed by creating a shaft hub 16 that extends proximally towards the turbine disks 39 and a turbine disk hub 13 that extends distally towards the shaft 42, The proximal end 15 of the shaft hub 16 may be joined to the distal end 12 of the turbine disk hub 13 using a welding process, such as a frictional welding process to form a joint 53. Because the joint 53 is annular in configuration, a reinforcing sleeve 55 is placed around the joint 53 and at least partially around the turbine disk hub 13 and shaft hub 16. The sleeve 55 reinforces the joint 53. Further, in addition to heat transfer attenuation provided by the cavity 51, the sleeve 55 also provides heat attenuation. Specifically, because compressed air is used to seal lubricating oil within the turbocharger 33 and because this compressed air is at a lower temperature than the exhaust flow that drives the turbine disk 39, the compressed air generated by the compressor 26 is a convenient source of cooling air for the sleeve 55. The sleeve 55 includes an outer surface 57 with a plurality of alternating ridges 58 and grooves 59, which enable the cooling air from the compressor to envelope the sleeve 55. Further, a radial gap 67 is provided between the proximal ridge 64 of the sleeve 55 and the engagement surface 65 of the turbine inlet scroll 37, which provides a small but continuous flow of cooling air through the radial gap 67. The flow of cooling air through the radial gap 67 prevents exhaust from entering the radial gap 67 and interfering with the cooling aspects provided by the flow of compressed air that envelopes the sleeve 55. The proximal end 63 of the sleeve 55 makes only minimal contact with the turbine disk 39 and an annular air chamber 74 is created between the angled wall 72 of the sleeve 55 and the outer fillet 73 of the turbine disk 39.
This document discloses a method for connecting a turbine disk 39 to a shaft 42. The method may include forming a turbine disk hub 13 on a distally facing side of the turbine disk 39. The method may further include forming a shaft hub 16 on a proximal end 52. of the shaft 42. The turbine disk hub 13 forms a turbine disk pocket and the shaft hub forms a shaft pocket. The method may further include connecting the turbine disk hub 13 to the shaft hub 16 to form a joint 53 between the turbine disk hub 13 and the shaft hub 16 and a cavity Si that is a combination of the turbine disk pocket and the shaft pocket. The method may further include placing a sleeve 55 around the joint 53 and around at least part of the cavity 51. As noted above, the sleeve 55 provides reinforcement for the joint 53 and a cooling function separate and apart from the cooling function provided by the cavity 51.
While only certain embodiments of been set forth, alternative embodiments and various modifications will be apparent from the above description to those skilled in the art. These and other alternatives are considered equivalents and within the spirit and scope of the present disclosure.