US20180087518A1 - Turbocharger thrust bearing and manufacturing method - Google Patents

Turbocharger thrust bearing and manufacturing method Download PDF

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Publication number
US20180087518A1
US20180087518A1 US15/275,392 US201615275392A US2018087518A1 US 20180087518 A1 US20180087518 A1 US 20180087518A1 US 201615275392 A US201615275392 A US 201615275392A US 2018087518 A1 US2018087518 A1 US 2018087518A1
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United States
Prior art keywords
thrust
thrust bearing
pads
set forth
fluid
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US15/275,392
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English (en)
Inventor
Kenneth Bischof
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BorgWarner Inc
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BorgWarner Inc
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Priority to US15/275,392 priority Critical patent/US20180087518A1/en
Assigned to BORGWARNER INC. reassignment BORGWARNER INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BISCHOF, Kenneth
Priority to US15/340,964 priority patent/US9938982B1/en
Priority to CN201780058725.8A priority patent/CN109831919A/zh
Priority to EP17772858.1A priority patent/EP3516244A1/fr
Priority to KR1020197009786A priority patent/KR20190054099A/ko
Priority to JP2019515492A priority patent/JP2019529832A/ja
Priority to PCT/US2017/052149 priority patent/WO2018057480A1/fr
Publication of US20180087518A1 publication Critical patent/US20180087518A1/en
Priority to US16/279,524 priority patent/US20190203731A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/16—Arrangement of bearings; Supporting or mounting bearings in casings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B33/00—Engines characterised by provision of pumps for charging or scavenging
    • F02B33/32—Engines with pumps other than of reciprocating-piston type
    • F02B33/34—Engines with pumps other than of reciprocating-piston type with rotary pumps
    • F02B33/40—Engines with pumps other than of reciprocating-piston type with rotary pumps of non-positive-displacement type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/05—Shafts or bearings, or assemblies thereof, specially adapted for elastic fluid pumps
    • F04D29/051—Axial thrust balancing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/05—Shafts or bearings, or assemblies thereof, specially adapted for elastic fluid pumps
    • F04D29/053—Shafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/05—Shafts or bearings, or assemblies thereof, specially adapted for elastic fluid pumps
    • F04D29/056—Bearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/32—Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C17/00—Sliding-contact bearings for exclusively rotary movement
    • F16C17/04—Sliding-contact bearings for exclusively rotary movement for axial load only
    • F16C17/045—Sliding-contact bearings for exclusively rotary movement for axial load only with grooves in the bearing surface to generate hydrodynamic pressure, e.g. spiral groove thrust bearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C17/00—Sliding-contact bearings for exclusively rotary movement
    • F16C17/04—Sliding-contact bearings for exclusively rotary movement for axial load only
    • F16C17/047—Sliding-contact bearings for exclusively rotary movement for axial load only with fixed wedges to generate hydrodynamic pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/02—Parts of sliding-contact bearings
    • F16C33/04—Brasses; Bushes; Linings
    • F16C33/06—Sliding surface mainly made of metal
    • F16C33/10—Construction relative to lubrication
    • F16C33/1025—Construction relative to lubrication with liquid, e.g. oil, as lubricant
    • F16C33/106—Details of distribution or circulation inside the bearings, e.g. details of the bearing surfaces to affect flow or pressure of the liquid
    • F16C33/1075—Wedges, e.g. ramps or lobes, for generating pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/02—Parts of sliding-contact bearings
    • F16C33/04—Brasses; Bushes; Linings
    • F16C33/06—Sliding surface mainly made of metal
    • F16C33/14—Special methods of manufacture; Running-in
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/40—Application in turbochargers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/10—Manufacture by removing material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/50—Bearings
    • F05D2240/52—Axial thrust bearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/60—Shafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2220/00—Shaping
    • F16C2220/60—Shaping by removing material, e.g. machining
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2360/00—Engines or pumps
    • F16C2360/23—Gas turbine engines
    • F16C2360/24—Turbochargers

Definitions

  • the present invention relates to thrust bearings, particularly for turbochargers, and to methods of manufacturing thrust bearings.
  • Thrust bearings are a particular type of rotary-element bearings and are designed to support axial loads. Thrust bearings are commonly used in automotive, marine, power generation and aerospace applications. One common use is in turbochargers, particularly for passenger and commercial vehicles.
  • Turbochargers are used to increase engine power output by providing higher charge-air density such that more fuel can be burned in each engine cycle.
  • the use of turbochargers permits use of smaller engines and still maintain similar power and performance as larger engines. This also leads to the design and production of smaller and lighter vehicles, with resultant savings in weight and increased fuel economy.
  • Thrust bearings which are utilized in turbochargers are fixed profile fluid-film thrust bearings which provide increased bearing life and reduced cost. Thrust bearings contain a plurality of thrust pads arranged on one or both sides of the thrust bearing disc, and have central openings for placement on or around a shaft. These thrust bearings create regions of oil between the thrust pads and rotating disc members, such as collar washers, which support the applied thrust and eliminate metal-on-metal contact.
  • fluid-film thrust bearings and thrust pads can be manufactured with more precision in shape and geometry, as well as reduced manufacture cycling time. Associated benefits include increased load capacity and/or reduced bearing size and reduced oil film losses.
  • the thrust bearings have a plurality of thrust pads on one or both sides of the thrust bearing disc.
  • the thrust pads are preferably wedge-shaped with adjacent oil grooves and reservoirs.
  • the outer surfaces of the thrust pads are profiled with non-linear geometric or free formed configurations.
  • the profiles have single or compound shapes, with or without a flat land portion.
  • the free-formed profiles can be defined by power law equations.
  • the thrust pads are machined to their final profile and configuration using a high frequency high load capacity linear actuator machining assembly. Geometric or free-formed shape configuring thrust pads are formed by dimensionally varying radial and axial trajectories of a cutting tool on the actuator assembly. Once the thrust bearing disc is created with oversized thrust pads, the disc is rotated by a controller synchronized motion relative to the linear actuated cutting tool. The cutting tool tip trajectory generates the desired final profiles for the thrust pads.
  • FIG. 1 is a schematic depiction of a turbocharger.
  • FIGS. 2 and 3 depict known thrust bearings.
  • FIGS. 4 and 5 are cross-sections taken along lines 4 - 4 and 5 - 5 , respectively, in FIG. 3 .
  • FIGS. 6-10 depict known configurations for thrust pad faces.
  • FIGS. 11 and 12 depict another known thrust bearing.
  • FIG. 13 depicts an additional type of known thrust bearing.
  • FIGS. 14-19 depict configurations for thrust pad faces for thrust bearings in accordance with the present invention.
  • FIGS. 20-21 schematically depict an embodiment of an inventive process for forming configurations and profiles on thrust pad faces.
  • FIG. 22 depicts a flow chart for utilizing an inventive process.
  • Turbochargers have three main components, a turbine, a compressor and a center housing/hub assembly.
  • the center hub rotating assembly houses the shaft that connects the compressor impeller and turbine.
  • the assembly includes a bearing system to suspend the shaft, allowing it to rotate at high speeds with minimal friction.
  • Turbocharger shafts and turbine wheel assemblies can rotate in excess of 300,000 rpm.
  • bearing systems typically include a thrust bearing lubricated by a constant supply of pressurized engine oil. These bearings are commonly called fluid-film bearings.
  • FIG. 1 is a schematic illustration of a generic representative turbocharger 20 .
  • the turbocharger includes a compressor wheel 22 , a turbine wheel 24 , a rotating shaft member 26 and a housing member 28 .
  • Other components include a thrust bearing 30 , a thrust ring washer (also called a collar disc) 32 , a flinger ring or sleeve 34 and a compressor nut 36 .
  • the compressor wheel and turbine wheel are connected to the shaft member 26 .
  • the thrust bearing 30 is attached to the housing and does not rotate.
  • the thrust ring washer 32 and flinger ring sleeve 34 are attached to the shaft member and rotate with it.
  • the compressor nut 36 is screwed onto the end of the shaft member 26 and compresses together the compressor wheel 22 , the flinger ring 34 and the ring washer 32 .
  • Other bearings (not shown) are used to facilitate rotation of the shaft member inside the housing, and often other bushings, such as radial bushings, or bearings, are utilized in combination with the thrust bearing.
  • the thrust bearing pads extend axially, i.e. parallel to the axis of the shaft and rotating collar, and have thrust pad surfaces (also called faces) that are perpendicular to the axis of the shaft.
  • the rotating collar is also called a washer and has flat sides or surfaces that act on the fluid-film between it and the thrust bearing pads.
  • the flinger sleeve also has a flat face that acts on the fluid film between it and any thrust bearing pads on the adjacent side of the thrust bearing disc.
  • Passages 38 are provided or machined into the bearing housing to pass oil to the shaft member 26 and thrust bearing 30 .
  • the oil is used to lubricate these components, as well as to cool and maintain the components within desired operation temperature limits.
  • the oil is distributed from the main oil feed system of the vehicle in which the turbocharger is located. The films of oil in the bearing reduce friction and extend the life of the bearing and the turbocharger.
  • Thrust bearings contain a plurality of thrust pads, generally arranged in a circular orientation around the shaft.
  • the size and shape of thrust pads and the number of pads can vary depending on the loads in which the bearing will be subjected.
  • the bearing pads form a 360° circular pattern, although bearings subjected to lighter load may not extend completely around the shaft.
  • the thrust bearings are preferably made of a brass or bronze material.
  • FIGS. 2-5 Representative thrust bearings are shown in FIGS. 2-5 .
  • the thrust bearing 50 is circular in shape with a central shaft opening 52 and a plurality of individual thrust pad members 54 .
  • the outer surfaces of each of the pad members have land portions 53 and tapered portions 55 .
  • a shaft member 26 (shown in dashed lines) is positioned in opening 52 and rotates in the direction of arrow 57 .
  • the clearance between the outer diameter of the shaft member 26 and inner diameter of opening 52 is enlarged for ease of illustration. The actual clearance is typically a few millimeters.
  • a plurality of oil grooves 58 are positioned on the thrust bearings, with a groove positioned between each of the thrust pads 54 . Openings 59 are positioned in each of the oil grooves to facilitate the entry and circulation of oil.
  • the outer edge or rim 56 of the thrust bearing is called a shroud or dam. Depending on the design intent, some thrust bearings may not have this feature.
  • thrust pads depicted in FIGS. 2 and 3 have a sector or wedge shape, this is not critical. Thrust pads used in thrust bearings can have a wide variety of shapes, such as circular, triangular, oval, segmented, or rectangular. Thrust pads with the largest footprint or area are preferred, regardless of their shape.
  • thrust bearings When thrust bearings are utilized in turbomachines in general, a pair of them can be positioned adjacent a thick rotating thrust collar ring (washer). Thus, thrust pads can be located on both sides of the washer. In other turbomachinery, a pair of thrust washers can be positioned on both sides of a thrust bearing which has thrust pads on both sides.
  • FIGS. 4 and 5 are cross-sections taken along lines 4 - 4 and 5 - 5 in FIG. 3 . These show that the thrust pads are formed or machined as part of the thrust bearing, i.e. they are not separate components or parts made elsewhere and attached to the thrust bearing disc, but instead are an integral part of a one-piece product.
  • the profile or configuration of the axial outer surface of the thrust pads in known fluid-film thrust bearings typically have from one or more linear tapers. This is shown in FIGS. 3 and 4 , as well as FIG. 6 , which is a side view of the thrust pads in FIGS. 3 and 4 , and in FIG. 7 , which is an end view of that thrust pad.
  • the thrust pad 54 has a linear land or flat section 53 and a linear flat tapered section 55 .
  • the ratio of the circumferential length of the land section relative to the tapered section is typically about 20% to 80%, but other ratios can be utilized.
  • FIGS. 8 and 9 A profile or shape of the axial outer edge 151 of the thrust pad 154 of another known fluid-film thrust bearing is shown in FIGS. 8 and 9 .
  • the axial outer surface has a compound taper shape.
  • the land or flat section 153 is the same as that of land or flat section 53 in FIGS. 6 and 7 , although the tapered section 155 has linear tapers in both the circumferential direction 151 and 155 and in the side radial cross direction 156 .
  • the tapered sections of the thrust pads are oriented relative to the spinning (rotating) thrust collar (washer) such that the oil flow proceeds “up” the tapered ramp. This is shown in FIG. 10 .
  • the oil flow is shown by arrows 65 relative to the thrust rotating collar 32 and the stationary thrush bearing 30 . ( FIG. 10 also shows other items which are referred to below.)
  • thrust bearings can have thrust pads on one or both sides of the disc.
  • the thrust pads preferably will have the same locations, orientations, sizes and shapes on both sides of two-sided thrust bearings, but this can be changed at the discretion of the skilled engineer.
  • the pads and oil grooves could be staggered from one side to the other side.
  • the oil grooves and reservoirs will be the same and located in the same positions on both sides of a double-sided thrust bearing.
  • FIG. 11 Another known thrust bearing 70 is shown in FIG. 11 .
  • the thrust pads 72 each have a stepped profile 74 , as shown in FIG. 12 .
  • a still further known thrust bearing 80 is shown in FIG. 13 .
  • the disc body surrounds only a portion of the shaft member 26 ′. It also has fewer thrust pads 82 and fewer oil grooves 84 .
  • This type of thrust bearing 80 is used in situations where the axial faces are less than would be encountered with some turbochargers that need a full 360° thrust bushing.
  • a typical thrust bearing of this type has a 230° shape.
  • the thrust pads are centered around the shaft or at least in a pitch circle configuration centered around the shaft.
  • the remaining portion of the thrust bearing acts as the support structure and typically only needs connection to the bearing housing at the top and sides.
  • the bottom portion of the bearing housing at the bottom of the thrust bearing is left open for oil drainage.
  • the profile of the axial extension of the thrust pad or thrust pad face, which is the active portion of the thrust pad, on the thrust bearings can have significantly different profiles and shapes.
  • the thrust pads Rather than having a flat surface, or a surface having a land and either a single or compound linear taper, the thrust pads have non-linear geometrically shaped or free-form shaped curved tapers.
  • the surfaces have varying radial and axial shapes, preferably compound formed shapes. For optimum effectiveness, the precise curve for the surfaces of the thrust pad is determined based on which creates the best flow of oil on its surface.
  • the “k” exponent used from the leading edge of the taper on the thrust pad to the trailing edge is optimized differently from the exponent to be used for the inside diameter edge to the outer diameter edge of the thrust pad in the case of compound non-linear tapers.
  • FIGS. 14 and 15 depict a thrust pad 90 in accordance with the invention with an axial outer surface 92 having a flat land section 94 and a non-linear geometric curved taper section 96 .
  • the flat land section is at the trailing edge of the thrust pad while the lowest end of the thrust pad is at the leading edge.
  • geometrically curved means that the profile or configuration follows a geometric equation and does not have a flat or linear shape.
  • FIGS. 16 and 17 depict a thrust pad 100 in accordance with the invention with a compound curved axial outer face surface 102 on the thrust pad.
  • the thrust pad has a flat land 104 and a geometrically non-linear curved tapered surface 106 which, from the leading edge view FIG. 17 has a compound geometric curve.
  • the nonlinear taper 107 is not the same as the 105 outer diameter.
  • nonlinear taper 108 is transitioning from 107 to 105 .
  • FIG. 18 depicts a leading edge view from an alternate thrust pad 110 with an alternate compound tapered shape or curve.
  • the axial outer shape 112 has a different geometric shape or curve 114 .
  • the geometric curve 118 begin at the trailing edge 119 of the thrust pad 120 and continuously curve longitudinally from one end to the other end 121 , thus eliminating a land or flat section entirely.
  • the curve of the tapered outer surface could be either a single curved taper or a compounded curved taper, either similar to or different from any of the above described compounded geometrically curved profiles.
  • free form means that the curvatures and tapers provided on the axial outer surface of the thrust pads cannot be expressed in a geometric equation. They are not equation based.
  • a unique process is provided relative to manufacturing the thrust bearings and for providing the curvature and/or configuration of the axial outer surfaces on the thrust pads.
  • the process can be utilized for forming free form or power equation based configurations on the thrust pad surfaces.
  • FIG. 20 A schematic depiction of an embodiment of the new process and system is depicted in FIG. 20 and identified generally by the reference numeral 150 .
  • the process allows for free-forming shape configured thrust pads formed by dimensionally varying radial and axial trajectories of a cutting tool on an actuator device relative to a rotating thrust bearing.
  • the thrust bearing 152 is held in place in a chuck or fixture member 154 which is rotating, such as in the direction of arrow 156 .
  • the thrust bearing is held in place by the jaws 158 of the fixture.
  • the upper outer axial surfaces of the thrust pads 160 are not finish machined and a thin layer or stock of excess material 161 is left on them.
  • a cutting tool 162 is coupled to a linear actuator mechanism 170 .
  • the mechanism 170 includes a high frequency linear actuator member 172 that is coupled to a linear-slide member 174 such that the actuator member 172 is moveable along an axis parallel with respect to the outer surface (or faces) of the thrust pads 160 on the thrust bearing 152 .
  • a linear slide motor 176 activates the liner slide member 174 .
  • a linear position encoder 178 is used to position and move the slide and cutting tool appropriately.
  • An electronic controller unit (ECU) 180 directs the linear actuator to allow the cutting tool to machine the thin layer of material remaining on the outer surface of the thrust pads and provide the final desired profile and face configuration. This can provide a free-form or any other linear or non-linear geometric configuration on the faces of the thrust pads.
  • the process provides a synchronized motion of the spinning workpiece relative to the linear activated cutting tool while using cutting tool trajectory to generate the desired configuration.
  • the direction provided by the controller is determined by a user's selection of a particular thrust pad profile chosen from a data base of thrust pad profiles.
  • the process allows the thrust bearing pad geometry to be manufactured faster and with higher precision than prior processes. It also allows increased bearing load capacity and/or reduced bearing size due to the power equation or “free-form” profile. The profile also will reduce oil filling losses by eliminating over-designed thrust bearings.
  • FIG. 21 schematically depicts the positioning and movement of the cutting tool 162 on a thrust pad 160 by the linear actuator 170 .
  • the cutting tool has numerous movements in machining the thrust pads, such as providing the depth of the cut, the radial position of the tool, the angular position for each pass of the tool for each radius of the thrust pads as the thrust bearing rotates. This provides free-form shapes at low cycle times with high precision.
  • the actuator is software programmable by populating a look-up table that the high frequency actuator uses to determine the depth of cut for each specific location of the thrust pad(s).
  • the process can economically generate linear and curved (nonlinear) pad surfaces to optimize oil flow, load capacity and losses.
  • the process is also preferably a closed-loop process which profiles trajectories of the thrust pad surface and makes self-corrections and thus reduced errors. Sensors are provided to measure and profile the geometry in real-time and, with feedback, correct any profile trajectory errors.
  • FIG. 22 A representative flow diagram 200 for control of the profiling machine, and providing appropriate position signals is shown in FIG. 22 .
  • the flow diagram starts with a programmable look-up table 210 with desired free-form pad profiles.
  • This provides data and instructions to the computer controller 220 , which has a user interface and data acquisition system.
  • This step optimally could be closed-loop feedback for repetitive learning control (RLC).
  • the controller 220 provides input to the linear slide motor 230 to move which in turn provides generated signals to the linear slide position encoder. This data signal is then fed to the computer controller 220 .
  • the computer controller 220 is providing signals to the high frequency actuator 250 , which also controls the cutting tool machining process, rotating chuck and thrust bearing.
  • the chuck angular position encoder 240 sends position signals to the computer controller 220 .
  • a profile sensor real-time profile repetitive learning control (RLC) 260 could be utilized.
  • thrust pad faces and profiles can slightly deform profiles under the loads imposed on them during operation of the turbocharger or turbomachinery. This can be taken into account during the formation of the thrust pad faces. With the present invention, this factor can be taken into account in the computer program which is fed to the computer controller 220 . Thus, the final profiles on the thrust pads can be optimized for the actual use during operation for which the thrust bearings are designed.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Combustion & Propulsion (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Sliding-Contact Bearings (AREA)
  • Supercharger (AREA)
US15/275,392 2016-09-24 2016-09-24 Turbocharger thrust bearing and manufacturing method Abandoned US20180087518A1 (en)

Priority Applications (8)

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US15/275,392 US20180087518A1 (en) 2016-09-24 2016-09-24 Turbocharger thrust bearing and manufacturing method
US15/340,964 US9938982B1 (en) 2016-09-24 2016-11-01 Turbocharger thrust bearing and manufacturing method
CN201780058725.8A CN109831919A (zh) 2016-09-24 2017-09-19 涡轮增压器止推轴承和制造方法
EP17772858.1A EP3516244A1 (fr) 2016-09-24 2017-09-19 Palier de butée de turbocompresseur et procédé de fabrication
KR1020197009786A KR20190054099A (ko) 2016-09-24 2017-09-19 터보차저 스러스트 베어링 및 제조 방법
JP2019515492A JP2019529832A (ja) 2016-09-24 2017-09-19 ターボチャージャー・スラスト軸受および製造方法
PCT/US2017/052149 WO2018057480A1 (fr) 2016-09-24 2017-09-19 Palier de butée de turbocompresseur et procédé de fabrication
US16/279,524 US20190203731A1 (en) 2016-09-24 2019-02-19 Turbocharger thrust bearing and manufacturing method

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WO2024104529A1 (fr) * 2022-11-15 2024-05-23 Ihi Charging Systems International Gmbh Palier axial pour supporter un arbre rotatif et turbocompresseur à gaz d'échappement possédant un palier axial
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CN109831919A (zh) 2019-05-31
US9938982B1 (en) 2018-04-10
US20180087519A1 (en) 2018-03-29
EP3516244A1 (fr) 2019-07-31
KR20190054099A (ko) 2019-05-21
WO2018057480A1 (fr) 2018-03-29
US20190203731A1 (en) 2019-07-04

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