DE202018002846U1 - Turbocharger for an internal combustion engine - Google Patents

Abstract

A turbocharger for an internal combustion engine, comprising a housing (1), at least one driven compressor blade, in particular at least one driving turbine blade, and an actuator assembly (2) for controlling the turbocharger, a first component (3, 15) of the actuator assembly (2) and a second component (6, 16) of the adjusting arrangement by means of a weld (8, 18) are materially interconnected, characterized in that the weld (8, 18) by deep welding through a closed area (9, 10, 19) of the first component (3, 15) is introduced through and at an interface (11, 17) between the first component (3, 15) and the second component (6, 16) is formed.

Description

Technical area

The invention relates to a turbocharger for an internal combustion engine according to the preamble of claim 1.

background

From the WO 2015/171541 A1 and from the practice of the construction of turbochargers, it is known to weld the flap plate of a wastegate by means of a laser beam with a carrier. For this purpose, the carrier has an approximately hemispherical, convex surface and the valve plate has a corresponding, approximately hemispherical concave surface. The ball shape can be used to accurately position the valve disk during welding. The laser beam aims tangentially into the gap between the hemispherical surfaces.

Furthermore, it is known from the practice of the construction of turbochargers to non-rotatably weld a swivel arm by means of tungsten inert gas welding with a spindle. For this purpose, an opening in the pivot arm is initially provided, after which a welding takes place in the opening at the boundary of the pivot arm and spindle.

It is the object of the invention to provide a turbocharger for an internal combustion engine, in which a simple and secure connection of components is given.

Summary of the invention

This object is achieved according to the invention for a turbocharger mentioned above with the characterizing features of claim 1.

The connection by means of deep welding, a simple assembly with low demands on a precise alignment of an energy source of the welding process is achieved.

Deep welding in the sense of the invention is generally understood to mean a welding process in which an energy source liquefies the material of a solid component from a first surface through an entire material thickness to an opposite, second surface in order to weld in the same process to one behind the other second surface arranged to achieve second component.

The material of the components is preferably in each case a metal, particularly preferably a steel. In particular, each may be high-alloyed and / or high-temperature-resistant steels. In further embodiments according to the invention, at least one of the components can also consist of a non-iron-based alloy, for example a nickel-based alloy. Preferably, the components consist of alloys that are resistant to a hot exhaust gas flow of an internal combustion engine.

An adjusting arrangement of the turbocharger in the sense of the invention means any movable mechanical component, in particular for influencing the operating state of the turbocharger.

In the present case, a turbocharger is understood in accordance with expanded parlance to mean a means for charging internal combustion engines by means of at least one driven compressor blade. The drive can basically also be done by an electric motor or the like. However, the drive is preferably carried out by at least one driving turbine blade or an exhaust gas turbine.

In a preferred embodiment of the invention, the deep welding is carried out by means of a laser beam. It is known that laser beams of high energy density (eg> 4 MW / cm ² ) can form particularly deep welding channels in steel due to gas bubble formation. A ratio of diameter to depth of such channels may be in high ranges> 3. But other sources of energy (arc, plasma jet, etc.) are also applicable in the context of the invention, provided that the thickness of the component to be welded through allows the applicability.

In an advantageous development, a laser beam generating laser device during the generation of the weld has an unchanged orientation. In particular, this means that a variable tilting of the laser device during welding, as used to produce welds in the sense of WO 2015/171541 A1 is required is waived. This allows a simple and cost-effective mounting of the laser device as well as an increased processing speed.

Generally advantageous, it is provided that the components are fixed by the weld inseparable from the housing. This means in particular that the components can not be dismantled without welding from the housing after welding. This allows a safe, durable and temperature-resistant assembly of components of problematic size.

In a generally preferred embodiment of the invention, the actuator assembly as a valve, particularly preferably an exhaust-side turbine control valve, more preferably a wastegate, for the controllable discharge of Turbine blade (s) formed. The high thermal loads of turbine control valves, in particular Wastegates make a mounting according to the invention by deep welding particularly useful. In the present sense, turbine control valves are all types of valves which regulate the hot exhaust gas flow to or from the turbine. In other embodiments, it may also be a different valve or another actuator assembly of the turbocharger, wherein, for example, an electric motor instead of turbine blade (s) can be used to drive the compressor blade (s).

Generally advantageous, it can be provided that the components are subjected to force during the welding, so that a play-free stop is present in the welded state. For example, a game in a spindle for driving a flap plate can be eliminated by a force-loaded stop the flap plate against its seat during welding. As a result, the flap plate during operation can close completely and accurately, without further corrective measures are necessary.

In a first embodiment of the invention, it is provided that the first component comprises a pivot arm and the second component comprises a spindle, wherein the pivot arm is fixed by means of the weld rotationally fixed on the spindle. As a result, the non-detachable and accurate mounting of a valve, for example a turbine control valve, preferably a wastegate, allows. In this embodiment, a flap plate is expediently connected to the swivel arm or is connected to it in a subsequent assembly step. In principle, however, the flap plate can also be formed in one piece with the swivel arm.

In a preferred development, the weld seam has a defined seam course in at least one planar welding field. Depending on the optimization of the welded joint, this may be, for example, a rectangular, zigzag-shaped, Z-shaped, S-shaped, circular or other course. Preferably, there are defined seam courses in at least two spaced-apart planar welding fields in order to ensure a particularly reliable and torque-resistant connection. The various welding fields can be deep-welded, for example, via an access through respective different flanges of the housing.

In a further preferred embodiment of the invention, the second component comprises a flap plate, and the first component comprises a carrier of the flap plate. Preferably, the carrier is formed integrally with a rotatable spindle for pivoting the flap plate. Further preferably, the flap plate and the carrier border on a part-spherical interface together. This allows a total determination of the invention of flap plate and carrier. At the same time there are a kraftbeaufschlagte, backlash-free position of the spindle and a suitably aligned or sealed against a seat pressed flap plate.

For appropriate implementation, the carrier has an axis of the flap plate at least partially circumferential collar, wherein the weld is introduced through the collar. The weld can the flap plate as far as possible, in particular more than 180 °, rotate around to ensure a secure down.

In the interest of high stability and resistance to surface corrosion, the first component in the region of the weld preferably has a thickness of at least 1.0 mm, particularly preferably at least 2.0 mm.

Further advantages and features of the invention will become apparent from the embodiments described below and from the dependent claims.

Hereinafter, two preferred embodiments of the invention will be described and explained in more detail with reference to the accompanying drawings.

list of figures

• 1 shows a three-dimensional view of a turbocharger, in which a welding according to a first embodiment of the invention is introduced by a laser device.
• 2 shows a schematic sectional view through an actuating arrangement 1 ,
• 3 shows a three-dimensional view of a swivel arm with flap plate of the turbocharger 1 ,
• 3a shows several alternative seam courses of a weld of the swing arm 3 ,
• 4 shows a side sectional view of an actuating arrangement of a turbocharger according to a second embodiment of the invention.
• 5 shows the actuator assembly 4 in a sectional view from the front.
• 6 shows the actuator assembly 4 in a sectional view from above.
• 7 shows a flap plate of the actuator assembly 4 ,
• 8th shows a support with spindle of the actuator assembly 4 ,
• 9 shows a partial spatial sectional view of a turbocharger.

Detailed description

The in 1 and 9 shown turbocharger for an internal combustion engine is designed as exhaust turbocharger with a turbine control valve in the form of a wastegate for controlling a turbine power. The turbocharger includes a housing 1 , at least one driven compressor blade (see 9 at the compressor wheel 20), at least one driving turbine blade (see 9 on the turbine wheel 30) and an actuator assembly 2 for controlling the turbocharger in the form of a valve, in this case an exhaust-side wastegate.

A first component 3 the actuator assembly 2 is formed as a pivot arm, wherein the pivot arm 3 a flapper plate 4 wearing. A fastening member 5 holds the flap plate 4 on the swivel arm 3 in a known way with a defined game.

A second component 6 the actuator assembly 2 is as a spindle 6 formed, which in a known manner in a sleeve (not shown) is rotatably mounted. The sleeve in turn is in a passage of the housing 1 established. The spindle 6 is in the outer area with a driving mechanism, for example a linkage with a pressure cell or an electric actuator, connected (not shown).

During the assembly of the turbocharger, the swivel arm 3 through a first flange opening 1a of the housing 1 introduced, after which the spindle 6 inserted through the sleeve or the passage and into a hole 7 of the swivel arm 3 is inserted.

According to the invention now the swivel arm 3 and the spindle 6 non-rotatable and cohesive by a weld 8th interconnected, with the weld 8th by deep welding through a closed area 9 . 10 of the first component 3 is introduced through and at an interface 11 between the first component 3 and the second component 6 is trained.

The material of the components is presently a metal, namely a steel. These are in each case high-alloyed and high-temperature-resistant steels which are stable with respect to the hot exhaust gas flow of the internal combustion engine flowing along the components.

According to the above-described assembly, the components 3 . 6 through the weld 8th insoluble in relation to the housing 1 established.

In the present case has the swivel arm 3 to improve the definition of a first closed area 9 in the form of a flat welding field and a second shot area offset therefor 10 in the form of a flat welding field. Here, the first closed area 9 by means of a laser device 12 with a laser beam 13 through the first flange opening 1a to be welded through as access. The welding fields 9 . 10 are each made slightly thickened, so that any local material weakening is compensated by the welding. The profiling of welding fields 9 . 10 is preferably also designed so that the length of the through-welding for different positions, taking into account the beam direction of the laser is approximately constant.

The second closed area may be through another second flange opening 1b of the housing 1 , in this case an outlet opening for the overflowing exhaust gas, are welded through.

Depending on requirements, a secure connection of the components 3 . 6 already achieved, if only one of the two welding fields 9 . 10 is welded through. Thus, depending on the housing shape or circumstances, either only the first welding field 9 or only the second welding field 10 to be used for determination. If a particularly secure fixing is desired and an arrangement of openings / flanges of the housing 1 this allows both welding fields 9 . 10 be welded through.

3a shows various possible seam courses of the weld in each case one of the closed areas or area welding fields 9 . 10 , As shown, the seam courses can be circular, rectangular, Z-shaped or zigzag-shaped. Other gradients such as S-shaped or otherwise shaped are possible depending on the requirements.

In the present case, this has the laser beam 13 generating laser device 12 during the production of the weld 8th an unchanged orientation. This means that a variable tilting of the laser device during welding is dispensed with.

The parallel alignment of adjacent laser beams 13 is in 2 outlined. By connecting the maximum penetration depths of adjacent laser beams 13 results in a dashed curve 14 in the cross section of the spindle 6 , The total maximum penetration depth of the laser beams is around 5.5 mm. The first component or the swivel arm 3 has in the area of his Welding depending on the position of the weld in the direction of the laser beams a thickness of about 3-4 mm.

4 to 8th show a second preferred embodiment of the invention. In this case, the first component comprises a carrier 15 , and that the second component comprises a flap plates 16 who is on the carrier 15 is determined. In the present case is the carrier 15 integral with a rotatable spindle 15b for pivoting the flap plate 16 and the vehicle 15 educated.

The flapper plate 16 and the carrier 15 borders over a part-spherical contact surface or interface 17 together. A defined closed area, in this case a collar 19 as the environment of a weld 18 (as dashed line in 6 shown) of the carrier 15 , is penetrated by a laser beam with sufficient energy density, the laser beam in the depth direction also across the interface 17 material of the first component or carrier 15 melts and so the two components 15 . 16 at the interface 17 welded together. As a result, an inventive determination of flap plate 16 and carriers 15 achieved.

During the welding is a kraftbeaufschlagte, play-free position of the spindle 15b. in front. The flapper plate 16 is aligned in accordance with the operation and is pressed against a seat (not shown) by force. Due to the partial spherical shape of a concave surface 16a of the flapper plate 16 and a corresponding convex surface 15a of the carrier 15 a corresponding relative displacement is allowed around a center of the part ball before welding. As a result, a play-free stop can be achieved in the welded state.

Overall, this is a game of the spindle 15b for driving the flap plate 16 by the force-loaded stop of the flap plate 16 eliminated against its seat during welding. In addition, the flap plate closes 16 in the operation of the turbocharger completely and accurately, without further rectification measures are necessary after installation.

The collar 19 of the carrier 15 revolves around a central axis of the flap plate 16 at least partially. The weld 18 gets through the collar 19 introduced as a closed area. The weld 18 can be a central axis A of the flapper plate 16 along the collar 19 as far as possible, in particular more than 180 °, embraced to ensure a secure fixing. The geometry allows guidance of the laser device 12 in unaltered orientation, for example parallel to the central axis A of the flap plate 16. On a continuously changing tilting of the laser device during the introduction of the weld 18 can be dispensed with.

The part-spherical interface 17 has a radius of curvature, the same diameter of the flap plate 16 is considerably larger than a radius of curvature known from the prior art (see, for example, US Pat 6 of the WO 2015/171541 A1 ). In the present case, the radius of curvature corresponds approximately to the diameter of the flap plate 16 ,

The carrier 15 has in the area of the weld 18 or the welded-through collar 19 a thickness of just 2.1 mm.

LIST OF REFERENCE NUMBERS

1

casing

1a

first flange opening

1b

second flange opening

2

Stella order

3

first component, swivel arm

4

flap plate

5

attachment member

6

second component, spindle

7

Bore of the swivel arm

8th

Weld

9

first welding field, closed area

10

second welding field, closed area

11

interface

12

laser device

13

laser beam

14

Curve, course of the penetration depth

15

first component, carrier

15a

convex surface

15b

Spindle of the carrier

16

second component, flap plate

16a

concave surface

17

Interface, partly spherical

18

Weld

19

Collar, closed area

A

Axle of the flap plate

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2015/171541 A1 [0002, 0012, 0041]

Claims (13)

A turbocharger for an internal combustion engine, comprising a housing (1), at least one driven compressor blade, in particular at least one driving turbine blade, and an actuator assembly (2) for controlling the turbocharger, wherein a first component (3, 15) of the actuator assembly (2) and a second component (6, 16) of the actuating arrangement by means of a weld (8, 18) are materially interconnected, characterized in that the weld (8, 18) by deep welding through a closed area (9, 10, 19) of the first component ( 3, 15) and is formed at an interface (11, 17) between the first component (3, 15) and the second component (6, 16). Turbocharger after Claim 1 , characterized in that the deep welding by means of a laser beam (13). Turbocharger after Claim 2 characterized in that the laser beam (13) generating laser device (12) during generation of the weld seam (8, 18) has an unchanged orientation. Turbocharger according to one of the preceding claims, characterized in that the components (3,6) by the weld (8, 18) are fixed inextricably relative to the housing (1). Turbocharger according to one of the preceding claims, characterized in that the adjusting arrangement (2) as a valve, in particular an exhaust-side turbine control valve, in particular a wastegate (4, 16), for the controllable discharge of the turbine blade (s) is formed. Turbocharger according to one of the preceding claims, characterized in that the components (15, 16) are subjected to force during the welding, so that a play-free stop is present in the welded state. Turbocharger according to one of the preceding claims, characterized in that the first component comprises a pivot arm (3) and the second component comprises a spindle (6), wherein the pivot arm (3) by means of the weld seam (8) rotationally fixed on the spindle (6). Fixierst is. Turbocharger after Claim 7 , characterized in that the weld seam (8) has a defined seam course in at least one planar welding field (9, 10), in particular in at least two flat welding fields (9, 10). Turbocharger after one of Claims 1 to 6 , characterized in that the second component comprises a flap plate (16), and that the first component comprises a support (15) of the flap plate (16). Turbocharger after Claim 9 , characterized in that the carrier (15) is formed integrally with a rotatable spindle (15b) for pivoting the flap plate (16). Turbocharger after Claim 9 or 10 , characterized in that the flap plate (16) and the carrier (15) via a part-spherical boundary surface (15a, 16a, 17) adjoin one another. Turbocharger after one of Claims 9 to 11 , characterized in that the carrier (15) has an axis (A) of the flap plate (16) at least partially encircling collar (19), wherein the weld seam (18) through the collar (19) is introduced therethrough. Turbocharger according to one of the preceding claims, characterized in that the first component (3, 15) in the region of the weld seam (8, 18) has a thickness of at least 1.0 mm, in particular at least 2.0 mm.

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