EP2553275B1 - Turbocharger casing including valve housing and manufacturing process of such a casing - Google Patents

Description

The invention relates to a turbocharger housing with at least one valve device, for example a compressor housing with a diverter valve. Furthermore, the invention relates to a method for producing such a turbocharger housing.

Turbochargers usually have a turbine which is arranged in an exhaust gas flow and is connected via a shaft to a compressor in the intake tract. In general, a turbine wheel and a compressor wheel are arranged on the shaft. About the exhaust gas flow of a connected engine, the turbine wheel of the turbine is driven. The turbine wheel in turn drives the compressor wheel of the compressor. As a result, the compressor can increase the pressure in the intake tract of the engine, so that a larger amount of air enters the cylinder during the intake stroke. This has the consequence that more oxygen is available and a correspondingly larger amount of fuel can be burned.

In order to largely prevent or reduce the falling of the speed of the turbocharger, for example, in an engine thrust operation modern turbocharger have diverter valves. These diverter valves are located on the turbocharger in the compressor housing, which is made of aluminum. The function of the diverter valve is realized via channels between an inlet side and an outlet side and a valve seat, which represents the sealing plane. These overflow channels and also the valve seat usually have complex geometries.

From the WO 2008/055588 a compressor housing of a turbocharger is known, which is a diverter valve or recirculation valve having. The compressor housing in this case has a valve flange to which the recirculation valve can be fastened. For this purpose, the valve flange has a flange surface, in which an inlet opening is arranged, to which a connecting channel connects to the compressor inlet. Furthermore, the valve flange has a valve seat for the closing element of the recirculation valve. A channel axis of the connecting channel is arranged at an angle β to the valve seat. Furthermore, the flange surface is disposed at an angle α to a reference surface which is perpendicular to the turbocharger axis and axially bounds the volute of the compressor housing toward the bearing housing side. The compressor housing has the disadvantage that it has a complex shape and the predetermined angle α, β are difficult to realize with sufficient accuracy.

From the EP 0 468 676 A1 a compressor is known which comprises a compressor housing rotatably mounted compressor wheel. The compressor housing is connected to the housing of an external control valve, via which a recirculation path connects the discharge opening of the compressor housing with the inlet opening of the compressor housing to regulate the flow through the compressor wheel.

From the not pre-published DE 10 2009 012 732 A1 is also known a compressor housing, which is connected to an external clock valve.

From the DE 690 05 357 T2 For example, a wastegate device is known which has a first housing and an external second housing which is bolted to the first housing. In the first housing, a first bypass line and a second bypass line are provided. In the second housing a membrane made of rubber is provided, in which a valve disc is integrated. The position of the valve disc may be changed to connect or disconnect the two bypass conduits and the first housing. Accordingly, it is the object of the present invention to provide a simplified manufacture turbocharger housing with a valve device and a method for producing such a turbocharger housing.

This object is achieved by a turbocharger housing having a valve device with the features of patent claim 1 and a method for producing a turbocharger housing having a valve device having the features of patent claim 8.

Accordingly, the invention provides a turbocharger housing having a valve means formed in the turbocharger housing, the valve means having at least a first passage portion and a second passage portion, and wherein the valve means further comprises a valve space formed in the turbocharger housing and a valve seat formed in the turbocharger housing. The first channel section connects a main channel of a suction side in the compressor housing with the valve chamber. The second channel section connects a volute housing a pressure side in the compressor housing with the valve chamber. Essential for the invention is that the two channel sections are formed without undercuts over their entire extent and are arranged parallel to each other with their longitudinal axes.

The turbocharger housing has the advantage that it is formed by means of a simply designed and inexpensive slide element with a valve device in the die-cast can. The tool slide element can be designed simply because the valve device has two mutually parallel channel sections, which are formed without undercuts. As a result, the slide element can also very easily be introduced into the diecasting tool in the die casting process and easily removed again from the latter and the turbocharger housing.

Advantageous embodiments and modifications of the invention will become apparent from the dependent claims and the description with reference to the drawings.

Fig. 1

eine Schnittansicht eines Turboladergehäuses mit einer Ventileinrichtung gemäß der Erfindung, wobei zur Ausbildung der Ventileinrichtung in das Turboladergehäuse ein Werkzeugschieberelement teilweise eingeführt ist;

Fig. 2

die Schnittansicht des Turboladergehäuses gemäß Fig. 1, ohne das Werkzeugschieberelement;

Fig. 3

eine Vorderansicht des Werkzeugschieberelement gemäß Fig. 1;

Fig. 4

eine Seitenansicht der Werkzeugschieberelements gemäß Fig. 1 und 3;

Fig. 5

eine Perspektivansicht des Werkzeugschieberelements gemäß Fig. 1, 3 und 4;

Fig. 6

eine weitere Perspektivansicht des Werkzeugschieberelements gemäß Fig. 1, 3, 4 und 5;

Fig. 7

eine perspektivische Schnittansicht des Turboladergehäuses mit der Ventileinrichtung gemäß Fig. 1, wobei das Werkzeugschieberelement teilweise aus dem Turboladergehäuse entfernt ist;

Fig. 8

die perspektivische Schnittansicht des Turboladergehäuses mit der Ventileinrichtung gemäß Fig. 7, aus Sicht der Ventileinrichtung;

Fig. 9

eine Schnittansicht des Turboladergehäuses und des Werkzeugschiebelements, wobei das Werkzeugschieberelement vollständig aus dem Turboladergehäuse entfernt ist;

Fig. 10

eine perspektivische Schnittansicht des Turboladergehäuses und des Werkzeugschieberelements gemäß Fig. 1 , wobei das Werkzeugschieberelement vollständig aus dem Turboladergehäuse entfernt ist und das Turboladergehäuse aus Sicht der Ventileinrichtung gezeigt ist;

Fig. 11

eine weitere Perspektivansicht des Turboladergehäuses und des Werkzeugschieberelements gemäß Fig. 1 , wobei das Werkzeugschieberelement vollständig aus dem Turboladergehäuse entfernt ist; und

Fig. 12

eine andere Perspektivansicht des Turboladergehäuses aus Richtung der Ventileinrichtung.

The invention will be explained in more detail with reference to the exemplary embodiments indicated in the schematic figures of the drawings. Show it:

Fig. 1

a sectional view of a turbocharger housing with a valve device according to the invention, wherein a tool slide element is partially inserted to form the valve means in the turbocharger housing;

Fig. 2

the sectional view of the turbocharger housing according to Fig. 1 without the tool slide element;

Fig. 3

a front view of the tool slide element according to Fig. 1 ;

Fig. 4

a side view of the tool slide element according to Fig. 1 and 3 ;

Fig. 5

a perspective view of the tool slide element according to Fig. 1 . 3 and 4 ;

Fig. 6

a further perspective view of the tool slide element according to Fig. 1 . 3, 4 and 5 ;

Fig. 7

a perspective sectional view of the turbocharger housing with the valve device according to Fig. 1 wherein the tool slide element is partially removed from the turbocharger housing;

Fig. 8

the perspective sectional view of the turbocharger housing with the valve device according to Fig. 7 , from the perspective of the valve device;

Fig. 9

a sectional view of the turbocharger housing and the Werkzeugschiebelements, wherein the tool slide element is completely removed from the turbocharger housing;

Fig. 10

a perspective sectional view of the turbocharger housing and the tool slide element according to Fig. 1 wherein the tool slide element is completely removed from the turbocharger housing and the turbocharger housing is shown from the perspective of the valve device;

Fig. 11

another perspective view of the turbocharger housing and the tool slide element according to Fig. 1 wherein the tool slide element is completely removed from the turbocharger housing; and

Fig. 12

another perspective view of the turbocharger housing from the direction of the valve device.

In all figures, identical or functionally identical elements and devices have been provided with the same reference numerals, unless stated otherwise.

In Fig. 1 is a sectional view of a finished turbocharger housing 10 with at least one valve device 12 according to the invention shown. The turbocharger housing 10 is in the Die casting process produced, for example as aluminum die casting or from another suitable for the die casting material or material combination. For this purpose, a die-casting tool 14 is provided, in which a tool slide element 16 is arranged, as shown by way of example in FIG Fig. 1 is shown to form a valve device 12 in the turbocharger housing 10. In this case, the die-cast tool can be formed, for example, in a horizontal or substantially horizontal plane divided into two mold halves 18, 20, as in Fig. 1 is indicated by a dashed line. The die casting tool and its two mold halves are in Fig. 1 only indicated and greatly simplified and shown purely schematically. A mold half 18 can in this case, for example, the inner channel 22 and the volute casing 24 and the other mold half 20, the outer contour of the turbocharger housing 10, as in Fig. 1 is indicated. In this case, the die casting tool 14 may be formed such that the tool slide element 16 is received in a mold half of the die casting tool or in both mold halves 18, 20 of the diecasting tool.

In the in Fig. 1 Completely manufactured turbocharger housing 10, the tool slide element 16 is shown partially inserted, with which the valve means 12, here for example a diverter valve, has been formed in the turbocharger housing 10.

The turbocharger housing 10 according to the invention is designed in the present example as a separate compressor housing which can be fastened, for example, to a bearing housing of the turbocharger. Likewise, however, a compressor housing section of a turbocharger housing, which is integrally formed, for example, with a bearing housing, may also be formed with a valve device 12 according to the invention (not shown).

As in the example in Fig. 1 is shown, at least one valve device 12 is formed in the turbocharger housing 10. In this case, the tool slide element 16 is designed such that the valve chamber 26, preferably the entire valve chamber, the valve seat 28 and one or more channels 30, 32 of the valve device 12 in the turbocharger housing 10 form or form.

In the in Fig. 1 and the following ones FIGS. 2 to 12 As shown, a diverter valve is provided as a valve device 12.

To form the diverter valve 12 as a valve means 12, the corresponding tool slide member 16 has two channel section projections 34, 36, i. a first channel section projection 34 of e.g. is disposed outside and a second channel section projection 36 of the e.g. is arranged inside. The first outer channel section projection 34 forms the outflow or outlet channel 38, which is connected, for example, to an inlet region of the suction side or the intake channel of the compressor. The second inner channel portion projection 36 in turn forms e.g. the inlet or inlet channel 40, which is connected to the input area of the pressure side of the compressor.

The two channel section projections 34, 36 of the tool slide element 16 are arranged in such a way to each other, so that the tool slide element 16 can be easily pulled out or removed from the die-cast tool 14 and the turbocharger housing 10 following a die-casting process for forming the turbocharger housing 10. The tool slide element 16 is designed for this purpose without undercuts or has no undercut. The two channel section projections 34, 36 of the tool slide element 16 are arranged in the longitudinal direction parallel to each other, wherein the two channel section projections 34, 36 with their longitudinal axes 42 while parallel and offset from each other or parallel and can be provided with their longitudinal axes 42 in a vertical or vertical plane lying or coaxial with each other, as in the following 3 and 4 is shown.

Furthermore, the tool slide member 16 has a valve space portion 44, wherein the valve space portion 44 is formed so as to form the complete valve space 26 or substantially the entire valve space 26 in the turbocharger housing 10. In addition, the tool slide element 16 has a valve seat portion 46 for forming the valve seat 28 in the turbocharger housing 10. The valve seat 28 is formed on the tool slide element 16 in the form of a valve seat projection 48, for example, a circumferential projection. The projection 48 for the valve seat 28 may also be formed in the outer first channel portion projection 34 temporarily. The valve seat projection 48 also has no undercut, so that the tool slide member 16 can be easily pulled out of the die casting tool 14 and the finished shaped turbocharger housing 10.

In Fig. 2 is the sectional view of the finished turbocharger housing 10 according to Fig. 1 shown without the tool slide element. How out Fig. 2 can be removed, the compressor housing 10 has a diverter valve 12 as a valve device. The two channels 30, 32 of the diverter valve 12 are formed parallel to each other. The inlet channel 40 of the diverter valve 12 is connected to the pressure side or in this case the spiral 24 of the compressor housing 10 and the outlet channel 38 to the inlet regions of the suction side of the compressor. Furthermore, the diverter valve 10 has a valve seat 28 and a valve space 26 which is completely formed by the tool slide element 16. The Fig. 3 to 6 As shown in the front view of the tool slide element 16, the two channel section projections 34, 36 are arranged parallel to each other and not offset from each other or the longitudinal axes 42 of the two channel section projections 34, 36 are both in a common vertical plane 50th . As in Fig. 3 is indicated by a dot-dash line, the two channel section projections 34, 36 but also be arranged in parallel and offset from each other. In this case, the longitudinal axes 42 of the two channel section projections 34, 36 are provided in two mutually offset vertical planes 50, 51. The two channel section projections 34, 36 may have an arbitrary cross-sectional shape, as long as the channel section projections 34, 36 do not form or have undercuts. For example, one or both of the channel section projections 34, 36 may have a constant cross section, for example, a cylindrical cross section flattened on one side. Likewise, one or both of the channel section projections 34, 36 may be longitudinally tapered or have a longitudinally tapered cross section, as in the first outer channel section projection 34 Fig. 3 In addition, the valve seat projection 48 may be provided, for example, with a flat 52 on one or both sides, depending on the function and intended use.

Fig. 4 shows the tool slide element 16 according to Fig. 3 in a side view. The transition between the valve seat projection 48 and the first outer channel section projection 34 is shown.

Fig. 5 shows a perspective view of the tool slide element 16 from behind. In this case, the valve seat projection 48 and the portion 44 for forming the valve space, and the outer channel section projection 34 can be seen. The formation of the end 54 of the tool slide element 16 as a flat surface is greatly simplified and purely exemplary. Depending on how For example, the connection between the die casting tool and the tool slide element 16 is provided, the tool slide element 16 and its end 54 may be designed accordingly.

Fig. 6 shows a perspective view of the tool slide element 16 from the front. In this case, the first and second channel portion projection 34, 36 are shown, which are parallel to each other with their longitudinal axes 42 and also not offset from each other or without an offset to each other. Further, the valve seat projection 48 is shown, which merges into the outer channel section projection 34.

In the FIGS. 7 and 8 a sectional perspective view of the compressor housing 10 is shown according to the invention. In this case, the tool slide element 16 is shown, with which a diverter valve 12 is formed in the compressor housing 10. The tool slide element 16 is partially pulled out of the diverter valve 12 out. The tool slide element 16 is in this case designed such that in the fully inserted state, the first and second channel section projections 34, 36 of the tool slide element 16, as previously in Fig. 1 is indicated, extend into the spiral or spiral housing 24 and the main channel 22 of the compressor housing 10, which are formed for example by one of the two mold halves of the die-casting tool.

Fig. 9 shows the compressor housing 10 and the tool slide element 16 in a sectional view. In this case, the diverter valve 12 is shown with its inlet channel 40 and outlet channel 42, the valve seat 28 and the valve chamber 26. In imported State fits the tool slide element 16 with its contour exactly in the contour of the diverter valve 12th

In Fig. 10 the compressor housing 10 and the tool slide element 16 is shown in a perspective sectional view. In this case, the valve chamber 26 and the valve seat 28, and the inlet channel 40 and the outlet channel 42 of the diverter valve 12 are shown. The valve seat 28 forms a section of the outlet channel or outer channel section 30.

Next is in Fig. 11 a perspective view of the compressor housing 10 and the tool slide element 16 is shown. As described above, the turbocharger housing 10 or here the compressor housing 10 is produced by die casting. The tool slide element 16 is, for example, made of metal or another suitable solid or resistant material, which preferably allows multiple use of the tool slide element 16.

Fig. 12 shows the compressor housing 10 in a perspective view, wherein the compressor housing 10 thereof is shown from the side of the diverter valve 12. In this case, the valve chamber 26 and the valve seat 28 of the diverter valve 12 is shown, as well as its outer outlet channel 38 and the inner inlet channel 40. The outer periphery of the valve seat 26 is flattened in the region of the outer channel 28, here the outlet channel, to a part of the Channel 28 to form. In other words, the portion of the valve seat 28 which forms part of the channel 28 is suitably adapted with its contour to the channel 28 to allow optimum flow through the channel.

The turbocharger housing with valve device described above, for example in the form of a compressor housing with a diverter valve, has the advantage that the housing with valve can be easily produced by die-casting. In this case, the compressor housing can be produced for example in aluminum die-cast or another suitable die-cast.

Due to the parallel axial and, for example, coaxial arrangement of the channels of the diverter valve in the tool slide direction in the die casting tool, the entire valve chamber, the valve seat and also the overflow channels of the diverter valve can be represented in a die-cast tool slide element. This allows either a livelihood without any additional mechanical processing, or only a minimal amount of processing, which can affect the sealing and mounting geometry, i. the sealing seat and the mounting holes of the diverter valve, limited.

The arrangement and location of the tool slide element in the die casting tool can reduce the number and complexity of moving parts. This manufacturing costs can be reduced because the feasibility of a pressure-castable compressor housing is improved with a diverter valve. Furthermore, the complexity of the tool slide element can be reduced and the tool slide element can be simplified. Another advantage is that the processing of the compressor housing or its diverter valve can be reduced or even allows geometries that require no additional mechanical processing, resulting in a further reduction in manufacturing costs.

Although the present invention has been described above with reference to the preferred embodiments, it is not limited thereto but can be modified in a variety of ways within the scope of its definition by the appended claims.

Claims (6)

1. Turbocharger housing (10) with a valve device (12) formed in the turbocharger housing,
   wherein the turbocharger housing is a compressor housing, wherein the valve device (12) is an overrun air recirculation valve,
   wherein the valve device has a valve chamber (26) formed in the compressor housing and a valve seat (28) formed in the valve chamber,
   wherein the valve device has at least a first passage section (30) and a second passage section (32),
   wherein the first passage section (30) forms an outlet passage (38), which is connected to a main passage (22) of an intake side in the compressor housing and opens into the valve chamber (26),
   wherein the second passage section (32) forms an inlet passage (40), which is connected to a spiral housing (24) of a pressure side in the compressor housing and likewise opens into the valve chamber (26),
   characterized
   in that the first passage section (30) and the second passage section (32), over their entire extent, are formed free of an undercut and are arranged with their longitudinal axes (42) parallel to one another.
2. Turbocharger housing according to Claim 1,
   characterized
   in that at least one out of the first passage section (30) and the second passage section (32) tapers proceeding from its end in the valve chamber (26) towards its respectively opposite end.
3. Turbocharger housing according to either of Claims 1 and 2,
   characterized
   in that the valve seat (28) of the valve device (12) forms a section of the second passage section (32).
4. Method for producing a turbocharger housing (10) with a valve device (12) formed in the turbocharger housing, according to Claim 1, wherein the method features the steps:

   - making available a pressure diecasting mold (14) for forming the turbocharger housing (10),

   - providing a mold slide element (16) formed free of an undercut in the pressure diecasting mold (14) for forming the valve device (12) in the turbocharger housing (10), wherein the mold slide element (16) has a first passage section projection (34), which forms the first passage section (30), and a second passage section projection (36), which forms the second passage section (32), wherein the first passage section projection (34) and the second passage section projection (36) are arranged with their longitudinal axes (42) parallel to one another, and wherein the mold slide element furthermore has a valve chamber section (44) and a valve seat section (46),

   - introducing a pressure diecasting material into the pressure diecasting mold (14) and forming the turbocharger housing (10) with the valve device (12) formed in the turbocharger housing (10) as a pressure diecasting part.
5. Method according to Claim 4,
   characterized in that
   the mold slide element (16) is formed so as to form the valve seat (28), the valve chamber (26), the first passage section (30) and the second passage section (32) of the valve device (12) of an overrun air recirculation valve in a compressor housing.
6. Method according to Claim 4 or 5,
   characterized in that
   the pressure diecasting mold (14) has a first mold half (18) and a second mold half (20), wherein the mold slide element (16) can be connected to at least one mold half (18, 20) or can be brought into engagement therewith.

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