DE102014102038B4 - Exhaust system component and method for connecting a first pipe component and a second pipe component of an exhaust system component - Google Patents

Abstract

Exhaust system component (1) for coupling a turbocharger with a first pipe component (2) and a second pipe component (3), which overlap in a coupling portion (17) and are interconnected in the coupling portion (17) via a coupling means, wherein the Coupling means is an expanding ring (18) which is arranged on the inside of the first pipe component (2) and the first pipe component (2) and the second pipe component (3) in the coupling portion (17) by widening of the expanding ring (18) are pressed together, characterized in that a wall region (24) of the first pipe component (2) is formed by means of the expanding ring (18) into a receptacle (25) of the second pipe component (3), wherein the expanding ring (18) consists of a heat-resistant, plastically deformable material and Wall region (24) of the first pipe component (2) by the expanding ring (18) is plastically deformed.

Description

The invention relates to an exhaust system component with a first pipe component and a second pipe component, which overlap in a coupling portion and are interconnected in the coupling portion via a coupling means. Furthermore, the invention relates to a method for connecting a first pipe component and a second pipe component of an exhaust gas system component.

The exhaust system of an internal combustion engine in the motor vehicle includes various exhaust system components, such as exhaust manifold, exhaust manifold, exhaust gas turbocharger, catalyst, muffler and exhaust pipes. The present invention relates in particular to the connection of two pipe components within an exhaust system component. An essential aspect of the invention relates to an exhaust gas turbocharger, in particular to an exhaust gas turbocharger with sheet metal turbine housing and in particular to the connection between an outlet flange of a sheet metal turbine housing and a decoupling element or expansion compensator necessary for the compensation of the thermal expansion.

In general, a durable connection between gas-conducting pipe components of an exhaust system component is desired. Furthermore, it is impurities within the system, for example, to avoid contamination from a welding process, as this may affect the function of the components or downstream components. This is especially true for exhaust gas turbochargers, which are exposed during operation considerable mechanical and especially highest thermal loads. Substantial influence on the service life of an exhaust gas turbocharger has thermally induced stresses.

The basic construction of a turbocharger and various turbocharger systems are in the DE 11 2010 001 696 T5 explained.

From the DE 10 2009 042 260 A1 goes out an exhaust gas turbocharger with an outer housing in which an impeller housing is arranged, wherein the outer housing is welded to a bearing flange. The bearing flange has an outside circumferential web over which the outer housing is welded to the bearing flange, wherein the web has a widened relative to its free end base portion.

The DE 10 2009 010 515 A1 criticizes that in the manufacture of a turbine housing of an exhaust gas turbocharger from sheet metal components is usually resorted to a welded joint, but has the disadvantages of welding distortion due to partial heating, spatter, welding impurities and limited accessibility for the required welding equipment. As a remedy suggests the DE 10 2009 010 515 A1 a turbine housing, which comprises at least two housing components made of sheet metal, which are connected to one another in a connection region, wherein the housing components are non-positively and / or positively connected with one another in the connection region.

As part of the DE 10 2011 050 506 B4 a turbine housing of a turbocharger is described, which has an outer housing and an inner housing. The inner housing is coupled to a tubular connecting piece for connecting a bearing housing of a turbine wheel. The inner housing and the nozzle are positively connected with each other, for which purpose the inner housing passes through the nozzle and is flanged radially outwardly on a flange collar of the nozzle. At the flanged end of a press ring for additional positional fixing is arranged.

The prior art also counts by the DE 10 2008 052 552 A1 a method for producing a turbine housing of a turbocharger and a corresponding turbine housing. In common construction, the exhaust gas turbocharger comprises an arranged in an outer housing impeller housing with a tubular nozzle, which sums in an outlet pipe, via which exhaust gas from the impeller housing in the direction of an outlet is transferable. The outlet pipe is coupled to the impeller housing so as to be relatively displaceable, wherein a metallic sealing ring is arranged between the nozzle and the outlet pipe. The metallic sealing ring is pushed over the connecting piece. Subsequently, an expanding mandrel is inserted into the neck to widen the neck.

Furthermore, by the DE 34 28 449 A1 an end connection of a winding tube is known, in which an internal annular construction is provided for fixing the winding tube in an end region via a fixed connection to an end connection. For this purpose, the annular part is deformed within the end connection in such a way that it fixes the winding tube in its position. This makes it possible to produce both a gas-tight and watertight connection between winding tube and end connection, without having to resort to a welding process.

Furthermore counts by the WO 02/14729 A a connector of the prior art, which is intended to couple a hose to a tubular member. This is at both Impact edges, both of the tube and the hose, a connecting means provided, which is able to connect both components firmly together.

Also the US 2014/0044606 A1 shows the connection of a hose for the exhaust gas tract of a motor vehicle, wherein a receiving device is provided to receive at least a portion of a hose and to fix locally.

Furthermore, a pipe component and a method for producing a pipe component by the WO 2013/186360 A1 to the prior art, which is intended to connect two pipes. For this purpose, located at least in a section of an outer tube, an inner tube part which is deformed such that it engages in the groove-shaped structure of the outer tube and so produces a gas-tight connection between the outer tube and the inner tube. The arrangement of the inner tube member is provided in particular at locations which are subject to a special mechanical stress and thus make the use of a reinforcing element necessary.

The invention is based on the prior art, the object to improve an exhaust system component functionally with a durable connection of a first pipe component and a second pipe component of the exhaust system component and a method for this purpose show. In particular, the invention has the object to provide an exhaust gas turbocharger with a durable connection between an outlet flange of a sheet-metal turbine housing and a necessary for the compensation of thermal expansion expansion compensator or Entkoppelungselementes.

The solution of the objective part of the task consists in an exhaust system component with the features of claim 1.

Advantageous embodiments and further developments of the exhaust gas system component according to the invention are the subject of the dependent claims 2 to 4.

A method according to the invention shows claim 5.

The exhaust system component comprises a first pipe component and a second pipe component which each overlap with a pipe section in a coupling section. In the coupling section, the pipe components are connected to one another via a coupling means. According to the invention, the coupling means is an expanding ring which is arranged on the inside of the first pipe component. The first pipe component and the second pipe component are pressed together in the coupling section by widening the expanding ring.

To produce the connection between the first pipe component and the second pipe component, a pipe section of the first pipe component and a pipe section of the second pipe component are guided into one another, so that they are arranged overlapping. The overlap area forms the coupling section. Subsequently, an expanding ring is positioned axially on the inside of the first pipe component in the coupling section, whereupon the expanding ring is radially widened by means of an expanding tool. When expanding the Expandierringes a wall portion of the first pipe member is plastically deformed and pressed into a receptacle in the pipe section of the second pipe component.

The receptacle is in particular a circumferential groove. The Expandierring consists of a heat-resistant plastically deformable material, in particular of metal. The material of the Expandierringes should have a same at least substantially the same coefficient of expansion as the material of the first pipe component and the second pipe component in the region of the connection point or the coupling portion. This means that if the first pipe component and the second pipe component consist of a ferritic steel material, the expansion ring should also be ferritic. The expanding ring is made of an austenitic steel material, if the pipe components are made of an austenitic steel. This requirement of the use of materials with matched coefficients of expansion aims to avoid possible noise developments.

An essential aspect of the invention is aimed at an exhaust gas system component in the form of an exhaust gas turbocharger and in particular at the turbine housing of an exhaust gas turbocharger. The first pipe component is in particular a necessary for the compensation of thermal expansion decoupling element in the form of a strain equalizer. Such a expansion compensator is in particular a pipe component with integrated bellows. The second pipe component is preferably the outlet flange of a sheet-metal turbine housing of an exhaust gas turbocharger.

Preferably, the expansion of the expanding ring is carried out stepwise. The expansion process is continued until the outer diameter of the Expandierringes, the outer wall of the first pipe component in the expanded pipe section and the inner diameter of the receptacle or the groove in the second tubular component in the relaxed state zero gaps, thus close to each other.

Between the first pipe component and the second pipe component a non-positive and positive connection is made. The deformation of at least a part of the first wall region of the first pipe component takes place in such a way that it is formed and pressed into the receptacle of the second pipe component.

Due to the mechanical positive and positive connection impurities, for example by welding processes, can be avoided in gas-conducting areas of the exhaust system. Also, axial length variations can be compensated from previous manufacturing steps. As a result, the functionality of the exhaust system component and the reliability is improved. In an exhaust gas turbocharger this leads to the fact that no axial forces are transmitted to the inner spiral. Furthermore, the contour gap is kept constant to the turbine. Maintaining exact gap dimensions of individual components of the turbocharger or of the turbocharger housing during operation means that the turbocharger can work with high efficiency. Overall, lower power fluctuations of the individual turbine housings result due to smaller tolerance widths.

The invention is described below with reference to an embodiment. Show it:

1 a view of an exhaust manifold with affiliated turbine housing of an exhaust gas turbocharger;

2 a section through the turbine housing of 1 along the line AA with the representation of a mounting situation of an expanding ring and

3 the cutout X from the 2 ,

Based on 1 to 3 is an exhaust system component according to the invention 1 and the connection of a first pipe component 2 and a second pipe component 3 the exhaust system component 1 described. In the exhaust system component 1 In the exemplary embodiment illustrated here, this is concretely an exhaust-gas turbocharger with a turbine housing 4 in sheet metal construction. The first pipe component 2 is an outlet tube and designed as a strain equalizer for the compensation of thermal expansion. The second pipe component 3 is an outlet flange of the sheet metal turbine housing 4 of the turbocharger.

A turbocharger delivers compressed air to the engine intake, allowing more fuel to be burnt and engine power boosted without significantly increasing engine weight. A turbocharger consists essentially of a turbine and a compressor, which are mounted on a common shaft. The exhaust gas stream rotates the turbine wheel on the exhaust side. Its torque is then transmitted via the shaft to the compressor wheel in the intake system.

1 shows a view of an exhaust manifold with attached turbine housing 4 an exhaust gas turbocharger. The turbine housing 4 is closer to recognize in the 2 ,

The turbine housing 4 includes an outer shell 5 that with a bearing flange 6 connected is. The outer shell 5 limits a gas-tight interior. Inside the outer shell 5 there is an impeller housing 7 made of two sheet metal shells 8th . 9 is formed on the outer circumference of the impeller housing 7 welded together. The left sheet metal shell shown in the image plane 8th has a tubular neck 10 on, moving in the direction of the first pipe component 2 extends. The first pipe component 2 is an outlet tube, which is designed on a part of its length as a bellows and thus acts as a strain equalizer. The expansion compensator forms a necessary for the compensation of thermal expansion decoupling element.

The turbine wheel, not shown, protrudes into the nozzle 10 which is adapted in its contour to the outer contour of the turbine wheel. The first pipe component 2 is with its inlet-side nozzle-shaped pipe section 11 over the neck 10 the sheet metal shell 8th guided. Here is between the pipe section 11 of the pipe component 2 and the neck 10 a sliding ring 12 integrated. An outer end ring 13 completes the arrangement.

The stub 10 directs this out of the impeller housing 7 escaping gas over the first pipe component 2 the second pipe component 3 to. The second pipe component 3 is - as already mentioned - the outlet flange of the turbine housing 4 or is part of the outlet flange. A circumferential outer ring 14 the outlet flange is at the bearing flange 6 opposite end of the outer shell 5 together. The second pipe component 3 has an inner socket-shaped pipe section 15 on, in which the first pipe component 2 with an outlet pipe section 16 is inserted. The overlapping pipe sections 15 . 16 of the first pipe component 2 and the second pipe component 3 form a coupling section 17 in which the first pipe component 2 and the second pipe component 3 by means of a coupling agent in the form of an expanding ring 18 are connected.

In the expanding ring 18 it is a closed rotationally symmetrical ring made of a heat-resistant, plastically deformable material, in particular steel.

The 2 shows a mounting situation of the expanding ring 18 for making a connection between the first pipe component 2 and the second pipe component 3 , The pipe section 16 of the first pipe component 2 and the pipe section 15 of the second pipe component 3 are pushed together and overlap in the coupling section 17 , The expanding ring 18 becomes inside of the first pipe component 2 positioned axially. Here is the expanding ring 18 on an expanding tool 19 postponed. The expanding tool 19 has a spreading cone 20 that consists of individual expansion segments 21 is formed. At the free end of the expansion cone 20 is the expanding ring 18 added. This is the expansion cone 20 a recording extension 22 with a stop 23 educated.

The expanding ring 18 is then using the expanding tool 19 radially expanded. In particular, the expansion of the expanding ring 18 carried out gradually. When expanding the Expandierringes 18 becomes a wall area 24 in the pipe section 16 of the first pipe component 2 plastically deformed and into a receptacle 25 in the pipe section 15 of the second pipe component 3 pressed. The recording 25 is by a circumferential groove in the pipe section 15 of the second pipe component 3 educated.

3 shows an enlarged section of the coupling portion 17 between the first pipe component 2 and the second pipe component 3 ,

When expanding the Expandierringes 18 is by the outer contour of the wall area 24 in the pipe section 15 of the first pipe component 2 plastically deformed and in the receptacle 25 of the second pipe component 3 pressed. For this purpose, the outer contour of the expanding ring 18 geometric to the cross-sectional configuration of the recording 25 Voted. After the expansion process, the outer diameter of the expanding ring 18 , the outer wall of the first pipe component 2 in the wall area 24 and the inner diameter of the receptacle 25 in the second pipe component 3 positively joined together and have zero gaps in the relaxed state. In this way, a durable connection of the first pipe component 2 with the second pipe component 3 ensured. Due to the nature of the connection and axial length variations can be compensated from previous manufacturing steps. This results in that no axial forces are transmitted to the inner spiral. It is particularly advantageous that the contour gap 26 to the turbine between nozzles 10 and the pipe section 11 can be kept small. Overall, the inventive design leads to it being within a series of turbine housings 4 Only small fluctuations in performance of turbine housing to turbine housing there.

LIST OF REFERENCE NUMBERS

1

Exhaust component

2

first pipe component

3

second pipe component

4

turbine housing

5

outer shell

6

Lagerflansch

7

impeller housing

8th

sheet metal shell

9

sheet metal shell

10

 Support

11

 pipe section

12

 sliding ring

13

 end ring

14

 outer rim

15

 pipe section

16

 pipe section

17

 coupling portion

18

 Expandierring

19

 expansion tool

20

 expansion cone

21

 spacer segment

22

 Seat extension

23

 attack

24

 wall area

25

 admission

26

 contoured gap

Claims (6)

Exhaust System Component ( 1 ) for the affiliation of a turbocharger with a first pipe component ( 2 ) and a second pipe component ( 3 ) located in a coupling section ( 17 ) overlap and in the coupling section ( 17 ) are interconnected via a coupling means, wherein the coupling means is an expanding ring ( 18 ), which inside of the first pipe component ( 2 ) is arranged and the first pipe component ( 2 ) and the second pipe component ( 3 ) in the coupling section ( 17 ) by expanding the Expandierrings ( 18 ) are pressed together, characterized in that a wall area ( 24 ) of the first pipe component ( 2 ) by means of the expanding ring ( 18 ) into a recording ( 25 ) of the second pipe component ( 3 ) is formed, wherein the expanding ring ( 18 ) consists of a heat-resistant, plastically deformable material and the wall area ( 24 ) of the first pipe component ( 2 ) through the expanding ring ( 18 ) is plastically deformed. Exhaust system component according to claim 1, characterized in that the receptacle ( 25 ) is a circumferential groove. Exhaust system component according to at least one of claims 1 or 2, characterized characterized in that the first pipe component ( 2 ) is at least an indirect component of a strain equalizer. Exhaust system component according to at least one of claims 1 to 3, characterized in that the second pipe component ( 3 ) an outlet flange of a sheet metal turbine housing ( 4 ) is an exhaust gas turbocharger. Method for connecting a first pipe component ( 2 ) and a second pipe component ( 3 ) an exhaust system component for the affiliation of a turbocharger, characterized in that a pipe section ( 16 ) of the first pipe component ( 2 ) and a pipe section ( 17 ) of the second pipe component ( 2 ) are arranged overlapping each other and an expanding ring ( 18 ) inside the first pipe component ( 2 ) is positioned axially, whereupon the expanding ring ( 18 ) using an expanding tool ( 19 ) is expanded radially and when expanding the Expandierrings ( 18 ) a wall area ( 24 ) of the pipe section ( 16 ) of the first pipe component ( 2 ) plastically deformed and into a receptacle ( 25 ) in the pipe section ( 15 ) of the second pipe component ( 3 ) is pressed. Method according to claim 5, characterized in that the widening of the expanding ring ( 18 ) is carried out step by step.

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