WO2015159189A1

WO2015159189A1 - Method for coupling an actuator to a turbocharger

Info

Publication number: WO2015159189A1
Application number: PCT/IB2015/052583
Authority: WO
Inventors: Karsten HECK; Reiner KOEHNE
Original assignee: Woco Industrietechnik Gmbh
Priority date: 2014-04-17
Filing date: 2015-04-09
Publication date: 2015-10-22
Also published as: DE102014109216A1

Abstract

The invention relates to a method (1700) for coupling an actuator (202) to a turbocharger, characterized by the steps: mounting (1701) of an adjusting rod (201) on a base plate (203) of the actuator (202); fixing (1702) of a coupling point (305) at a free end of the adjusting rod (201) in relation to the base plate (203) of the actuator (202); actuating (1703) the actuator (202) until the coupling point (305) at the free end of the adjusting rod (201) reaches a predetermined distance (408) from the base plate (203) of the actuator (202); and welding (1704) of a coupling bolt (406) for coupling the adjusting rod (201) to the turbocharger with the adjusting rod (201) at the coupling point (305) at the predetermined distance (408).

Description

Method of coupling a control box to a turbocharger

description

The present invention relates to a method for coupling a control box to a turbocharger, in particular with a welding of a coupling pin of the turbocharger with an actuating rod of the control box. The present invention further relates to a welded connection of the coupling bolt to the control rod, to a turbocharger made according to such a method having such a welded connection, and to a quality monitoring system for monitoring the quality of such a welded connection.

A turbocharger is used to increase the performance of piston engines. The exhaust gas turbine drives the compressor and increases the air flow rate of the piston. The turbocharger draws its energy from the residual pressure of the exhaust gases. Turbochargers can use the pressure and kinetic energy of the exhaust gases to build up a higher working pressure at the same temperature in the cylinder.

In non-supercharged piston engines, the pistons generate a negative pressure in the intake tract of the engine, in which flows in the air under atmospheric pressure. With increasing speed, however, this negative pressure is no longer sufficient to convey the maximum possible amount of air or fuel-air mixture into the combustion chamber of the engine, so that the achievable performance of the engine is limited. Measures to counteract this may be the enlargement of the Ansaugquerschnitts at its narrowest point, the valve opening. The valve opening can be increased there, for example, by a second valve. To the cylinders more combustion air These can also be filled with overpressure. The purpose of this is to charge the cylinders by means of a turbocharger.

1 shows a representation of a conventional turbocharger 100 with a turbine housing 101, in which a valve 106 is mounted, via which more air can be supplied to the turbocharger 100. The valve mechanism is controlled via a control box 102. At the control box 102, a control rod 103 is fixed, which in response to a control signal, in particular compressed air with an overpressure or a negative pressure, is axially deflected. Due to the deflection, the control rod 103 actuates a lever 107, which further opens or closes the valve 106. For example, a deflection of the actuating rod 103 in the direction of the control can 102, a stronger opening of the valve 106 and a deflection in the opposite direction cause a stronger closure of the valve 106. Of course, a reverse control characteristic is conceivable, so that upon deflection of the actuating rod 103 in the direction of the control box 102, a smaller opening of the valve 106 is achieved. The lever 107 is connected via a coupling pin 104 with the actuating rod 103, which conducts the force from the control rod 103 of the control box 102 via the lever 107 to the valve 106. Coupling pin 104 and actuating rod 103 are connected to each other by means of a screw connection 105.

Both the mounting of the lever 107 via the coupling pin 104 to the actuating rod 103 by means of the screw 105 and the adjustment of the control box 102 via the adjustment of the screw 105 is very expensive. For example, a replaced control box on the turbocharger must be readjusted during servicing. In addition, the setting can be subsequently changed so that, for example, an owner of a motor vehicle can make a change to the turbocharger setting with the aim of achieving an increase in output, which, however, could overstress the engine.

It is the object of the present invention to make the coupling of the control box to the turbocharger safer. This object is solved by the features of the independent claims. Advantageous forms of further education are the subject of the dependent claims.

The object is achieved by a method for coupling a control box to a turbocharger, comprising the steps of: mounting an actuating rod to an actuator of the control box; Fixing a coupling point at an open end of the control rod with respect to a base plate of the control box; Driving the control box until the coupling point at the open end of the control rod to the base plate of the control box occupies a predetermined distance; and welding a coupling bolt for coupling the adjusting rod to the turbocharger with the adjusting rod at the coupling point at the predetermined distance.

Such a method makes the assembly of the control cans to the turbocharger safer, because a once set distance from the base plate of the control rod to the coupling point to which the coupling pin is attached, can not be changed in retrospect due to the welding of the coupling pin with the control rod. Thus, the owner of a motor vehicle is no longer possible to make a change to the turbocharger setting in order to increase performance and thus to claim the engine outside the permitted range. Also, the exhaust gas values can not be changed adversely, in particular not so that a so-called emission standard is not met. The service technician can make replacement of the control box and / or the turbocharger easier and safer, since the entire weld joint of coupling pin and control rod can be removed as a unit and after replacing the control box with exactly the same setting, ie the same distance between the base plate of the control box and Coupling bolt, can be reinstalled. The base plate is in particular at least partially formed by and / or comprises of a housing bottom of the control box. The actuator is in particular a membrane, a diaphragm plate and / or at least one element which is in operative connection with a diaphragm plate and / or a membrane. According to a first embodiment, the method further comprises: forming, in particular by flattening, an at least partially planar surface in the axial direction at the coupling point of the control rod. This has the advantage that the welding of the control rod with the coupling bolt on a flat surface of the control rod is easier. The welded joint thus obtained is more durable and of higher quality.

According to a second embodiment of the method, the control rod is mounted on the actuator of the control box before or after the forming of the at least partially planar surface on the control rod. This has the advantage that the fixing of the coupling point at the open end of the control rod with respect to the base plate of the control box can be executed more precisely, otherwise there is no reference coordinate system to the control box when not mounted control rod.

According to a third embodiment of the method, the control of the control box comprises the supply and / or discharge, preferably introduction or discharge of a fluid, in particular pneumatic fluid, such as compressed air, preferably under pressure or negative pressure, into or out of the control box. This has the advantage that the control box can be adjusted very accurately and thus the predetermined distance can be precisely met. Since the predetermined distance from the base plate of the control box to the coupling point specifies the lever arm, with which the valve is actuated to open and close the turbocharger, a precise adjustment of this distance is responsible for a precise operation of the turbocharger valve.

According to a fourth embodiment of the method, the fixing of the coupling point is based on a type length of the control rod. This has the advantage that with the method control cans can be coupled to turbocharger, which are used in various vehicles. The type length of the control rod indicates the type of engine or turbocharger for which the control rod is suitable. For example, the same control box can be used in different vehicles, if the length of the control rod is chosen differently depending on the type of vehicle. That's it Method used in a variety of different vehicles and leads to a reduction in production costs.

According to a fifth embodiment of the method, the predetermined distance of the coupling point of the control rod to the base plate of the control box based on a predetermined setting of the turbocharger. This has the advantage that the predetermined setting of the turbocharger, for example a maximum and / or minimum opening of the valve flap and an achievable performance increase and / or predetermined exhaust gas values can be precisely maintained, so that precise manufacturing tolerances can be ensured in the production process.

According to a sixth embodiment of the method, the predetermined distance of the coupling point of the control rod to the base plate of the control box comprises a predetermined tolerance range. This has the advantage that a tolerance compensation between turbocharger and control box is possible, which simplifies the manufacturing process.

According to a seventh embodiment of the method, the coupling bolt on a surface to be welded on, in particular at least partially encircling, survey. The circumferential survey has the advantage that when welding the contact with the coupling point on the survey, so that a material removal of the material of this survey takes place. Thus, there are no irregularities of the weld, this is uniform and of high quality.

According to an eighth embodiment of the method, the surface to be welded of the coupling bolt in addition to, in particular at least partially encircling, elevation on, preferably at least partially encircling, depression. This has the advantage that the material removed from the elevation during welding can collect in the depression, so that the weld is uniformly shaped and has a high breaking strength.

According to a ninth embodiment of the method, the welding comprises a capacitor welding. This has the advantage that the welding process over the Charging of the capacitor can be controlled very precisely and all welded joints are of the same high quality. In addition, this welding process offers the advantage of lower heat input into the welded elements. Thus, a partial heat input is achieved and pre-damage adjacent components and / or changes in the basic properties of the materials avoided.

According to a tenth embodiment, the method further comprises: detecting welding parameters of the welding, in particular at least one of the following parameters: welding energy, welding force, peak currents, time integral over the welding current, height before welding, welding adjustment and / or welding compression. This has the advantage that statements about the course and the quality of the weld can be derived via the welding parameters. In the case of parameters deviating from the standard, for example adjustable threshold values, the welding process can be readjusted immediately. A defect can be immediately recognized and corrected.

According to an eleventh embodiment, the method further comprises determining a quality of the welded coupling bolt based on maintaining a tolerance range of the detected welding parameters, in particular based on a tolerance range of about 1 percent with respect to predetermined maximum values of the welding parameters. This has the advantage that the welded joint can always be produced with consistent high quality.

In addition, the object is achieved by a welded connection of a coupling pin of a turbocharger with an actuating rod of a control box, wherein the welded connection is produced by the method described above or one of its embodiments. Such a welded joint, used in a turbocharger, makes the assembly of the control box to the turbocharger safer, because a predetermined distance from the base plate of the control rod to the coupling point to which the coupling pin is mounted, can not anymore due to the welded to the control rod coupling pin be changed in retrospect. This is It is no longer possible for the owner of a motor vehicle to make a change to the turbocharger setting in order to increase performance and thus to claim the engine outside the permitted range.

The object is further achieved by a turbocharger comprising: a control box for controlling the turbocharger, an actuator rod mounted to the control box; and a coupling bolt for coupling the control rod to a valve means of the turbocharger, wherein the coupling of the control can to the turbocharger according to the method described above or one of its embodiments is made and in particular has a welded connection of the coupling pin with the control rod as described above. Such a turbocharger is traffic safer, because a predetermined distance from the base plate of the control rod to the coupling point can always be guaranteed, so that a performance of the turbocharger is within the manufacturer tolerances, even if it comes to the service to replace the control box.

The object is further achieved by a quality monitoring system for monitoring a quality of a weld joint of a coupling bolt of a turbocharger with a control rod of a control box, comprising: a processor adapted to detect the welding parameters of the welding according to the above-described tenth embodiment of the method and a quality of the welded coupling bolt according to the above-described eleventh embodiment of the method. Such a quality monitoring system has the advantage that a consistently consistent quality of the welded joint of the control rod and the coupling bolt can be maintained.

The object is further achieved by an engine, in particular an internal combustion engine, comprising a turbocharger according to the above description, in particular a turbocharger comprising a welded connection of the coupling bolt to the control rod as described above. Such an engine meets higher safety requirements than an engine with a conventional turbocharger equipped, because with the welded joint of control rod and coupling bolt can always be the same operation of the turbocharger valve guaranteed.

The object is further achieved by a vehicle, in particular a motor vehicle or a ship, comprising an engine or internal combustion engine as described above. Such a vehicle meets higher safety requirements than a vehicle equipped with a conventional turbocharger, because with the welded joint of control rod and coupling pin can always be the same operation of the turbocharger valve guaranteed.

The object is further achieved by a welding method for welding a coupling bolt of a turbocharger to an actuating rod of a control box, comprising the following steps: detecting welding parameters, in particular at least one of the following parameters: welding energy, welding force, peak currents, time integral via the welding current, height before Welding, welding adjustment, welding compression; and welding the coupling bolt to the control rod based on the welding parameters. Such a welding method has the advantage that a higher quality of the welded joint between the control rod and the coupling bolt can be achieved. Thus, the weld is more resistant to breakage and a turbocharger with such a welded joint between the control rod and coupling bolt has a longer life.

The object is further achieved by a control socket connection to a turbocharger, in particular the connection of the actuator of a control box to a connecting bolt. By means of the connecting bolt, the connection is made to an actuator of the turbocharger. Thus, the hitherto known connection via threaded rods and nuts, which is however subsequently manipulated, to be replaced. The Steuerdosenanbindung now provides on the actuator formed as an actuator to provide at least a partially flat surface forming portion to which a mounting surface of the connecting bolt in particular by welding, preferably capacitor welding (CD welding), can be fixed. In particular, it is provided on the mounting surface of the connecting bolt at least one weld hump in shape at least one projection to be provided, wherein further at least one adjacent to the weld hump depression is provided in the form of a return trough, which is designed to receive liquefied during the welding process material, in particular of the one or more Schweißbuckel.

The object is further achieved by a method for connecting an actuator of a control box to a terminal bolt. In this case, the method provides the step of providing the at least one partially flat surface on the actuator in an axial region of the actuator. In this case, an axial extension of the flat surface has a greater extension than an axial extent of the attachment surface of the connecting bolt. A further step consists in a positioning of the actuator by actuating the control box, in particular by acting on the control box with compressed air and / or negative pressure. Finally, the further step of fixing the connecting bolt to the actuator by welding, in particular CD welding, is provided in a desired position. This leads in particular to a permanent fixing of the connecting bolt with respect to the actuator, wherein advantageously tolerances in the positioning of the actuator can be compensated by the attachment of the connecting bolt when the actuating box is actuated. Thus, a substantially permanent connection between the connecting bolt and adjusting rod is achieved, in particular a tearing force of at least 12 kN. The method can be used in particular for substantially any surfaces or surface finishes of the control rod or the connecting bolt and various or any connection geometries between the connecting bolt and valve.

Furthermore, the method does not allow any additional components, such as a linkplate, to connect the control can to the turbocharger or valve, or any machined machining, such as holes for a rivet connection, particularly on the control rod, the control can or the actuator , must be provided.

Further embodiments will be explained with reference to the accompanying drawings. Show it: a schematic representation of a conventional turbocharger 100, in which the coupling pin 104 and the actuating rod 103 are connected to each other by means of a screw 105; a schematic representation of a control box 202 with mounted

A control rod 201 for a turbocharger according to an embodiment; a schematic representation of the control box 202 with mounted

Control rod 201 of Figure 2, in which the control rod 201 has at its open end a coupling point 305 with a flat surface according to an embodiment. a schematic representation of the control box 202 with mounted

Control rod 201 of FIG. 3, in which a coupling pin 406 at the

Coupling point 305 is welded at a distance 408 to the control rod 201 according to an embodiment; a perspective view of a welded connection of a control rod 201 with a coupling pin 406 according to an embodiment in a lateral plan view; a perspective view of the welded joint of Fig. 5a in

Side view; a schematic representation of a coupling bolt 406 for a turbocharger according to an embodiment in plan view; a schematic representation of the coupling pin 406 of Figure 6a in side view. a schematic representation of a welded joint of a

Coupling pin 406 for a turbocharger with a coupling point 305 of a control rod 201 according to an embodiment in side view; a schematic representation of the welded joint of Figure 7 showing the maximum tolerable travel path. a schematic representation of a coupling bolt 406 for a turbocharger according to an embodiment in plan view 900a; a schematic representation of the coupling pin 406 of Figure 9a in side view 900b. a perspective view of an assembly of the coupling pin 406 of Fig. 9a, 9b at the coupling point 305 of a control rod 201 before welding according to an embodiment in side view 900c; an enlarged view of the area shown in Figure 9b X; an enlarged view of the area shown in Fig. 9b Y; an enlarged view of the area shown in Figure 9b Z; a schematic representation of a coupling bolt 406b for a turbocharger according to an embodiment in plan view; a schematic representation of a nitriding portion of the coupling pin 406b of Figure 1 la in side view. a sectional view of the coupling pin 406b of Figure 1 la with respect to the plane BB. a sectional view of the coupling pin 406b of Fig. I Ia with respect to the plane AA; an enlarged view of the area shown in Figure 1 ld Y; an enlarged view of the area shown in Figure 1 ld Z; an enlarged view of the area X shown in Figure 1 ld. a schematic representation of an arrangement 1300 for producing a welded connection of a coupling bolt 406, 406b with a

Coupling point 305 of a control rod at the beginning of the welding operation according to an embodiment; a schematic representation of the assembly 1300 for producing the welded joint of Figure 13 at the end of the welding process. a graph 1500 of the welding current I over the time t when welding a coupling pin 406, 406b with a

Coupling point 305 of a control rod using the arrangement 1300 of Figures 13 and 14 according to one embodiment. a graphical representation of the welding energy W over the time t of a welding monitoring system using the assembly 1300 of FIGS. 13 and 14 according to one embodiment; and a schematic representation of a method 1700 of coupling a control can to a turbocharger in accordance with a

Embodiment.

FIG. 2 shows a schematic illustration 200 of a control box 202 with a mounted control rod 201 for a turbocharger according to an embodiment. The control box 202 includes a base plate 203. Through the base plate 203, the control rod 201 passes. The control rod 201 is connected by means of a connection, not shown, at least indirectly with a fluidly activated actuator inside the control box 202. For this purpose, the control rod 201 on the side, which is connected to the actuator, have a thread which can engage in a mating thread of the actuator. The control box 202 includes a port 204, can be passed through the compressed air and / or negative pressure in the control box, with which the actuator of the control box 202 and thus the mounted control rod 201 can be deflected. The actuator rod 201 may be mounted in type length on the actuator of the control box 202, so that adjusting rods of different vehicle or turbocharger types can be mounted on the same control box 202.

FIG. 3 shows a schematic representation 300 of the control box 202 with mounted control rod 201 from FIG. 2, in which the control rod 201 has at its open end a coupling point 305 with a planar surface according to one embodiment. The coupling point 305 may be determined with respect to the coordinates of a base plate 203. The coupling point 305 can be set with mounted control rod without introducing compressed air into the control box via the compressed air connection 204. As a reference system, the base plate 203 can serve, over which a distance to the coupling point 305 can be determined, for example, depending on a type length of the control rod 201.

The coupling point 305 can, as shown in FIG. 3, be defined as an axial part of the control rod 201, which at least partially has a flat surface. The planar surface may be formed by flattening, but other fabrication techniques may be used such as, for example, abrading, etching, planing, thinning, or other deformation techniques in which material is removed or not removed. The coupling point 305 may be formed as an approximately rectangular flat surface, it may also be formed as an approximately circular or oval surface. As a reference point for determining the distance from the coupling point 305 to the base plate 203 may serve a center of the formed, for example flattened flat surface, for example, the intersection of the two straight lines passing through the corners of the flattened surface when the surface is approximately plate-shaped is formed rectangular or the center of the circle or the ellipse, if the flat surface is formed circular or elliptical. The planar surface of the control rod can be formed on the coupling point 305 on both sides of the rod, as shown in Fig. 3, but it can also be formed only on one side of the control rod, for example, if it is produced by Materialabtragungstechniken such as grinding. The planar surface may be formed on four, six or more sides of the bar, for example when the bar is deformed by flattening at coupling point 305 into a square, hex or polygon.

4 shows a schematic illustration 400 of the control box 202 with mounted control rod 201 from FIG. 3, in which a coupling bolt 406 at the coupling point 305 is welded at a distance 408 to the control rod 201 according to an embodiment.

For producing the welded connection of control rod 201 and coupling bolt 406 shown in FIG. 4, the control box can be driven so far, for example by filling compressed air 407 by and / or applying a negative pressure to the compressed air connection 204 to the coupling point 305 at the open end of the control rod 201 to the base plate 203 of the control box 202 occupies a predetermined distance 408. The positioning can be done in the tool, for example in the flattening tool, with which the flat surface is produced at the coupling point 305. Due to the clamping in the tool, the coupling point 305 can be set in a simple manner as a reference point from which can be measured to the bottom plate. The control box can be controlled with compressed air until the predetermined distance between coupling point 305 and base plate 203 is reached. The predetermined distance 408 may be defined depending on a desired setting of the turbocharger, for example, determined so that the turbocharger can operate within a certain power range. After setting the control box 202 and reaching the predetermined distance 408 of the coupling pin 406 can be welded to the control rod 201 at the coupling point 305 at the predetermined distance 408. Thus, the welded connection shown in Fig. 4 can be produced, which has all the advantages described in the introductory part above. For welding, a capacitor (CD) welding application may apply, as described below to Figures 13 to 16. The mounting of the coupling bolt 406 on the control rod 201 can be done by means of ZSB assembly, ie using documents such as a technical drawing on which the individual components are specified and possibly other mounting dimensions and additional information such as mounting order or forces and / or or torques for the assembly as well as a parts list.

The weld joint of actuator rod 201 and coupling bolt 406 may also be made without first forming a flat surface at the interface 305. For example, the coupling bolt 406 can be placed directly on the control rod 201 at the coupling point and welded to the control rod 201 at this coupling point 305. If the surface of the control rod 201 at the coupling point 305 is not flat, then a stable weld can be generated for a sufficiently long time by appropriate support of the two parts to be welded by applying a corresponding force and a corresponding current flow.

5a shows a perspective view of a welded connection 500 of an actuating rod 201 with a coupling bolt 406 according to an embodiment in a lateral plan view. In the representation of the coupling pin 406 can be seen, which is welded to the coupling point 305 with the control rod 201. The control rod 201 is shown in the illustration of FIG. 5a in the unassembled state, that is not mounted with control box 202. At one end of the control rod 201, which can be mounted on the actuator of the control box 202, the control rod 201 has a thread 509. Fig. 5b shows a perspective view of the welded joint 500 of Fig. 5a in side view. The predetermined distance 408 (in particular in the activated state of the control box 202) between the base plate 203, the control box 202 and coupling point 305 is marked with an arrow. The threaded portion 509 of the control rod 201 is not part of this distance 408. FIG. 6 a shows a schematic representation 600 a of a coupling bolt 406 for a turbocharger according to one embodiment in plan view. The bolt 406 is circular and comprises two cylinders arranged one above the other, ie an upper cylinder part 612 and a lower cylinder part 611 with different radii, as can be seen from the two central axis 613 circles shown in the figure.

FIG. 6b shows a schematic illustration 600b of the coupling bolt 406 from FIG. 6a in side view. On the underside of the lower cylinder part 611, i. On the surface of the coupling pin 406, which is the surface to be welded, a circumferential projection 610 is mounted, which runs centrally about a central axis 613 of the lower cylinder part 611. A height of this elevation 610 is indicated by Ay, a width of this elevation 610 is denoted by Ax. In one embodiment, Ay and Ax may each be 3 mm. However, other values are also possible, for example within a range of 1 mm to 20 mm, and the width may also be different from the height of the elevation 610. In one embodiment, the peripheral elevation may be serrated. The bump 610 does not necessarily have to run on a circle around the central axis 613, it may also run elliptically about the central axis 613 or form another geometric shape. The bump 610 need not be continuously the same height Ay. It may have a height Ay at some circumferential points and may not be present at other circumferential points, i. have the height 0. In this case, continuous or discontinuous transitions between the height Ay and the height 0 can be formed. The bump 610 can also run on several different circles or in other geometric shapes about the central axis 613.

7 shows a schematic illustration 700 of a welded connection of a coupling bolt 406 for a turbocharger with a coupling point 305 of an actuating rod 201 according to an embodiment, for example according to FIGS. 6a and 6b in side view. The lower cylinder part 611 of the coupling bolt 406 may have a diameter of Aa or a radius of Ac = Aa / 2. The Plättlange or the length of the flat surface at the coupling point is denoted by Ad. This results in a possible travel path Ab during assembly of the coupling bolt 406 to the The travel path Ab extends in the radial direction from the axis 613 of the lower cylinder part 611, which is also the axis 613 of the upper cylinder part 612 and the axis of the coupling bolt 406 at the same time. The travel distance Ab can thus be determined as

Ab = Ad-Aa. In one embodiment, the described parameters have the following values: Aa = 12mm; Ad = 20mm; Ab = 8mm; Ac = 6mm.

FIG. 8 shows a schematic representation 800 of the welded connection from FIG. 7, showing the maximum tolerable travel path. In the left-hand position of the coupling bolt 406, the bolt 406 is mounted on the left boundary of the coupling point 305, while in the position of the coupling bolt 406 shown on the right, it is mounted on the right boundary of the coupling point 305. With appropriate dimensions as described above for Fig. 8, the travel can be denoted by Ab. The lower surface of the lower cylinder part 611 of the coupling bolt 406, which at the same time corresponds to the surface to be welded of the coupling bolt 406, may have a diameter of Aa, as already shown above in FIG. The Plättlange or the length of the flat surface at the coupling point is denoted by Ad. According to FIG. 7, these values may, for example, assume the following values: Aa = 12 mm; Ad = 20mm; Ab = 8mm; Ac = 6mm.

FIG. 9 a shows a schematic representation 900 a of a coupling bolt 406 for a turbocharger according to an embodiment in plan view 900 a. The coupling bolt 406 may be formed as described above with reference to FIGS. 6 to 8. The bolt 406 is circular and comprises two superimposed cylinders, i. an upper cylinder part 612 and a lower cylinder part 611 with different radii, as can be seen from the two circles shown in the figure with common central axis 613 or center point. Through the central axis 613, the section A-A, which is shown in more detail in Fig. 9b.

FIG. 9b shows a schematic illustration 900b of the coupling bolt 406 from FIG. 9a in a side view 900b according to the section AA. The lower surface of the lower cylinder part 611 of the coupling bolt 406, which at the same time to be welded Surface of the coupling pin 406, may have a circumferential projection 610, as already described above to Fig. 6a and 6b. In addition to the circumferential elevation 610, a circumferential depression 911 may be formed, for which the mutatis mutandis same properties apply as already described above for Fig. 6b with respect to the circumferential survey. The circumferential recess 911 may be disposed inside or outside the circumferential projection 610. The circumferential projection 610 and the circumferential recess 911 are shown in greater detail in the enlarged view of the area X in Fig. 10a. The upper cylinder part 612 may have at its upper end a peripheral edge 912, which is shown in greater detail in the enlarged view of the area Z in Fig. 10c. The lower cylinder portion 611 may have at its lower end a circumferential notch 913, which is shown in greater detail in the enlarged view of the area Y in Fig. 10b. The dimensions given in FIG. 9b are only to be regarded as exemplary. Any other embodiment of a coupling bolt 406 of other dimensions is possible.

9c shows a perspective illustration 900c of an assembly of the coupling bolt 406 from FIGS. 9a, 9b at the coupling point 305 of an actuating rod 201 prior to welding according to an embodiment in side view 900c. The bolt 406 may be attached to the lower surface of the lower cylinder part 611, which at the same time corresponds to the surface of the coupling bolt 406 to be welded, at the coupling point 305 of the adjusting rod 201. The central axis 613 of the coupling pin 406 can run centrally with respect to the coupling point 305. Before welding, the circumferential elevation 610 of the lower cylinder part 611 rests on the flat surface of the coupling point 305, as shown in FIG. 9c. The height of the circumferential elevation 610 thus corresponds to a weld hump height, as shown in FIG. 9c.

Fig. 10a shows an enlarged view 1000a of the area X shown in Fig. 9b. Fig. 10b shows an enlarged view 1000b of the area Y shown in Fig. 9b. Fig. 10c shows an enlarged view 1000c of the area Z shown in Fig. 9b ,

The welding parameters for CD welding of the arrangement shown in FIG. 9c can be determined, for example, according to the following method: In a first step For example, a pin contour may be machined as shown in the drawings of FIGS. 9a, 9b and 9c. In this case, for example, a hump height in 1.5 mm, 1.3 mm and 1.2 mm in 1.4923 or 1.4307 material can be formed. In a second step, rods and flattening, for example in 1.4301 material, can be made in the standard tool and measured. In a third step, pins and rods can be measured with statistical evaluation. The tolerances can be defined with regard to machine capability and confirmed by further test runs. In a fourth step, the output process data from the determined welding tests can be used with respect to the micrographs and subsequently determined in accordance with the setting criteria and the start-up color of the pin on the metal strip. Subsequently, micro-grindings can be created and evaluated for the evaluation of welding quality.

1 a shows a schematic representation 1100 a of a coupling bolt 406 b for a turbocharger according to one embodiment in a plan view. The coupling pin 406b may be formed as described above with reference to FIGS. 6 to 10. The bolt 406b is circular and comprises two superimposed cylinders, i. an upper cylinder part 612b and a lower cylinder part 61b with different radii, as can be seen from the two central axis 613b circles shown in the figure. Through the central axis 613b, the sections B-B and A-A, which are shown in more detail in Figures 1 lc and 1 ld.

1 b shows a schematic representation 1100 b of a nitriding region of the coupling bolt 406 b from FIG. 1 a in a side view. The nitriding area comprises the three subareas B1, B2 and B3. At the upper edge of the region B l is a circumferential securing groove 1103. A nitriding or a process for surface hardening can be used, for example, to produce the peripheral edge 912b on the upper cylinder part 612b.

11c shows a sectional illustration 1100c of the coupling bolt 406b from FIG. 11a with respect to the plane BB. The lower surface of the lower cylinder part 611b of the coupling bolt 406b, which at the same time the surface to be welded of the Coupling pin 406b, may have a circumferential projection 610b, as already described above to Fig. 6a and 6b. In addition to the peripheral elevation 610b, a circumferential depression 911b may be formed, for which the mutatis mutandis same properties apply as already described above for Fig. 6b with respect to the circumferential survey. The circumferential recess 911b may be disposed inside or outside the circumferential projection 610b.

Fig. Id shows a sectional view HOOd of the coupling pin 406b of Fig. I Ia with respect to the plane A-A. The plane A-A represents the opposite side of the plane B-B shown in Fig. 11c. The circumferential projection 610b and the circumferential recess 911b are shown in greater detail in the enlarged representation of the region X in Fig. 12c on a scale of 10: 1. The upper cylinder part 612b may have at its upper end a circumferential edge 912b, which is shown in greater detail in the enlarged representation of the region Z in FIG. 12b in the scale 20: 1. The lower cylinder portion 611b may have at its lower end a circumferential notch 913b, which is shown in greater detail in the enlarged view of the area Y in Fig. 12a on a scale of 10: 1. The dimensions of the figures I Ia to I ld are to be considered as exemplary only. Any other design of a coupling bolt 406b of other dimensions is possible.

Fig. 12a shows an enlarged view 1200a of the area Y shown in Fig. 1d. Fig. 12b shows an enlarged view 1200b of the area Z shown in Fig. Id. Fig. 12c shows an enlarged view 1200c of the area shown in Fig. Id shown area X.

13 shows a schematic representation of an arrangement 1300 for producing a welded connection of a coupling bolt 406, 406b with a coupling point 305 of an actuating rod at the beginning of the welding process according to an embodiment. The assembly may comprise a capacitor welder 1320 which may be clamped by a clamp 1323a, 1323b into which the mounting assembly of coupling bolts 406, 406b and actuator rod correctly positioned at the interface 305 shown in FIG. 9c may be clamped under the action of a force F 1322 For example, corresponds to a contact pressure of 2200 kg, and a current flow I 1321, for example, between 55 kA and 60 kA, to a welding of the coupling pin 406, 406b with the control rod leads. The force F 1322 acts from both parts of the clamping 1323a, 1323b on the mounting arrangement of coupling bolts 406, 406b and control rod. At the contact point of the circumferential projection 610, 610b of the coupling pin 406b with the coupling point 305 of the control rod, which has a height h, the circuit of the capacitor welding can be closed. The contact point has the smallest cross-sectional area, so that it comes here to the strongest heating, so that the welding process can begin. The action of the force F 1322 on the clamping 1323a, 1323b ensures that there is no intervening opening of the circuit, which would mean an interruption of the welding process.

FIG. 14 shows a schematic representation of the arrangement 1300 for producing the welded joint from FIG. 13 at the end of the welding process. At the end of the welding process, the peripheral elevation 610, 610b has been removed and its material partially fused to the two surfaces of the coupling pin and the control rod and partially captured by the circumferential recess 911, 911b. Thus, a robust and unbreakable weld joint of coupling bolts 406, 406b and control rod 201 is made.

15 shows a plot 1500 of the welding current I over time t in welding a coupling bolt 406, 406b to a coupling point 305 of a control rod using the assembly 1300 of FIGS. 13 and 14 according to one embodiment. Shown in FIG. 15 is a discharge curve 1501 of the capacitors of the capacitor welding as well as a weld progression curve 1502. As parameters for the energy input W, the current intensity I and the welding time t at the welding machine can be documented. At the start of the welding operation at the time t = 0, coupling bolts 406, 406b and control rod contact the circumferential projection 610, 610b of the coupling bolt 406, 406b on a relatively small surface, as shown in region 1. The welding current assumes its maximum value at this time. After the start of the welding process after about one millisecond, from which also the effective welding time starts to run, the surface on which the coupling pins 406, 406b and the actuating rod touch is already substantially larger, as shown in region 2. The welding current has already dropped slightly at this time. Towards the end of the Welding process after about eight milliseconds, the peripheral elevation 610, 610b of the coupling pin 406, 406b is almost worn away or has merged with the welding surfaces of the coupling pin and control rod, as shown in section 3. The welding current has dropped even further at this time. The welding energy W corresponds to the integral of the welding current over the time t and can also be represented by the formula W = CU ^2/2 . The current rise time can be defined as the time from the area 1 to the area 2. The welding time can be defined as the time from the area 2 to the area 3. The decay time can be defined as the time from the area 3. The times shown in the diagram are only exemplary values, other values can also be configured.

16 shows a plot 1600 of welding energy W versus time t of a weld monitoring system according to an embodiment using arrangement 1300 of FIGS. 13 and 14. The weld monitoring system may operate as follows: A monitor may provide an indication of the weld integrity of an HSPW (FIG. high speed pulse welding) provide a welding process that can be nearly equivalent to the information provided by a destructive testing method. For example, the compression of the projection used in welding may be measured during the welding cycle and compared to the maximum and minimum tolerances to determine if the welded part should be accepted or not accepted. By monitoring the welding parameters and welding characteristics, the welding monitoring system can be efficiently implemented to ensure high quality welds. For example, the welding monitoring system can measure and monitor the following parameters through the following parameters: welding energy, welding force, peak currents, welding time integral, welding pre-welding, welding or welding. For example, a progression of the welding process can only be allowed if the welding parameters are within the tolerance values of the respective welding process, for example less than one percent of the maximum tolerance values. All monitored values can be displayed and transferred to a data interface of a processor. In one embodiment, the quality monitoring system is for monitoring the quality of the weld joint of the coupling pin of a turbocharger with the control rod of a control box and includes a processor that can detect the welding parameters of the welding as described above and determine a quality of the welded coupling pin as described above.

17 shows a schematic representation of a method 1700 for coupling a control can to a turbocharger according to an embodiment.

The method 1700 includes mounting a control rod 201 to an actuator of the control box 202, for example as described above with reference to FIG. 2. The method 1700 further includes locating 1702 a coupling location at an open end of the actuator rod 201 relative to the base plate 203 of the control can 202, for example, as described above with reference to FIG. 3. The method 1700 further comprises driving the control box 1703 until the coupling point 305 at the open end of the control rod 201 to the base plate of the control box occupies a predetermined distance 408, for example as described above for Fig. 4. The method 1700 further comprises welding 1704 a coupling bolt 406 for coupling the control rod 201 to the turbocharger with the control rod 201 at the coupling point 305 at the predetermined distance 408, for example as described above for Fig. 4 and to Figures 5 to 16.

The method 1700 may further comprise forming, in particular by flattening, an at least partially planar surface in the axial direction at the coupling point of the control rod, for example as described above with reference to FIG. 3. The control rod may be mounted to the base plate of the control box prior to forming the at least partially planar surface on the control rod. The control of the control box may include introducing compressed air into the control box and / or applying a negative pressure to the control box. The setting of the coupling point may be based on a type length of the control rod. The predetermined distance 408 of the coupling point of the control rod to the base plate of the control box can be based on a predetermined setting of the turbocharger. The predetermined distance of the coupling point of the control rod to the base plate the control box may include a predetermined tolerance range. The coupling bolt may have an at least partially encircling elevation on a surface to be welded. The surface to be welded of the coupling bolt may have an at least partially circumferential recess in addition to the at least partially encircling elevation. The welding may include capacitor welding. The method may further comprise: detecting welding parameters of the welding, in particular at least one of the following parameters: welding energy, welding force, peak currents, time integral over the welding current, height before welding, welding adjustment, welding compression. The method may further comprise determining a quality of the welded coupling bolt based on maintaining a tolerance range of the detected welding parameters, in particular based on a tolerance range of about 1 percent with respect to predetermined maximum values of the welding parameters.

A weld joint of a coupling bolt of a turbocharger with an actuating rod of a control box, for example as described above with reference to FIGS. 5 to 8, can be produced by the method 1700. A turbocharger may include a control box for controlling the turbocharger, an actuator rod mounted to the control box; and a coupling bolt for coupling the control rod to a valve means of the turbocharger. The coupling of the control can to the turbocharger may be made in accordance with method 1700 and, in particular, may include the weld joint of the coupling bolt to the control rod described above.

Another aspect of the invention includes a computer program product that may be loaded directly into the internal memory of a digital computer and includes software code portions that enable method steps 1701, 1702, 1703, and 1704 of the method described in FIG. 17 to be performed when the product running on a computer. The computer program product may be stored on a computer-suitable medium and include: computer-readable program means for causing a computer to perform the method as described in Figure 17, and more particularly at step 1704 of welding. The computer may be part of the one described above with reference to FIGS. 13 to 16 Quality monitoring system. Overall, the claimed method leads to a high accuracy and reproducibility of the connection, there are heat distortion and post-treatment steps, as known from the prior art, avoided. Furthermore, a high strength or high tearing force, in particular compared to alternative bonding techniques, such as rivets, achieved. Finally, the welding operation can be well integrated into existing assembly processes.

It is to be understood that the features of the various embodiments described herein by way of example may be combined with each other except as specifically stated otherwise. As shown in the specification and drawings, individual elements that have been shown to be related need not communicate directly with each other; Intermediate elements may be provided between the connected elements. Further, it is to be understood that embodiments of the invention may be implemented in discrete circuits, partially integrated circuits, or fully integrated circuits or programming means. The dimensions of the coupling bolts shown in the figures may differ from the dimensions of the design drawings. The term "for example" is meant to be an example rather than the best or optimal, certain embodiments have been illustrated and described herein, but it will be apparent to those skilled in the art that a variety of alternative and / or similar implementations may be substituted for those shown and shown described embodiments can be realized without departing from the concept of the present invention.

The features disclosed in the foregoing description, the claims and the drawings may be essential to the invention in its various embodiments both individually and in any combination. LIST OF REFERENCE NUMBERS

100 turbochargers

101 turbine housing

102 control box

103 control rod

104 coupling bolts

105 screw connection

106 valve

107 levers

200 schematic representation of a control box with mounted control rod

201 control rod

202 control box

203 base plate

204 connection for compressed air

300 schematic representation of a control box with mounted control rod

305 coupling point

400 schematic representation of a control box with mounted control rod

406 coupling bolts

407 compressed air

408 predetermined distance

500 welded joint

509 thread

600a schematic representation of a coupling bolt

600b schematic representation of a coupling bolt

610 circumferential survey

61 1 lower cylinder part of the coupling bolt

612 upper cylinder part of the coupling bolt

613 center axis of the coupling bolt

Δχ width of the survey

Ay amount of the survey

700 schematic representation of a welded joint

Aa. Diameter of the lower cylinder part of the coupling bolt

From the travel path

Ac radius of the lower cylinder part of the coupling bolt

Ad length of the coupling site

800 schematic representation of a welded joint 00: schematic representation of a coupling bolt

00b schematic representation of a coupling bolt

00c schematic representation of an assembly of the coupling pin at the coupling point of an actuating rod

11 circumferential recess

12 peripheral edge

13 circumferential notch

1000a enlarged view of the area X.

1000b enlarged representation of the area Y

1000c enlarged view of the area Z

1100a schematic representation of a coupling bolt in plan view 1100b schematic representation of a coupling bolt in side view 1100c sectional view of the coupling bolt with respect to the plane B-B 1 lOOd sectional view of the coupling bolt with respect to the plane A-A 06b coupling bolt

61 Whether circumferential survey

611b lower cylinder part of the coupling bolt

612b upper cylinder part of the coupling bolt

613b center axis of the coupling bolt

911b circumferential recess

912b circumferential edge

913b circumferential notch

1200a enlarged view of the area Y

1200b enlarged view of the area Z

1200c enlarged view of the area X

1300 Arrangement for producing a welded joint

1320 capacitor welder

1321 Current flow I

1322 force F

1323a restraint, upper end

1323b restraint, lower end

1500 graphical representation of the welding current I over time t

1501 discharge curve

1502 sweat curve

1600 graphical representation of the welding energy W over time t

1700 Method of coupling a control box to a turbocharger

1701 mount (1st step) 1702 setting (2nd step)

1703 control (3rd step)

1704 welding (4th step)

Claims

claims

A method (1700) of coupling a control can (202) to a turbocharger, characterized by the steps of:

Mounting (1701) an actuator rod (201) to an actuator of the control can (202);

Defining (1702) a coupling site (305) at an open end of the

Adjusting rod (201) with respect to a base plate (203) of the control box (202);

Driving (1703) the control can (202) until the coupling point (305) at the open end of the control rod (201) to the base plate (203) of the control can (202) occupies a predetermined distance (408); and

Welding (1704) a coupling bolt (406) for coupling the

Control rod (201) to the turbocharger with the control rod (201) at the coupling point (305) at the predetermined distance (408).

The method (1700) of claim 1, characterized in that the method (1700) further comprises:

Forming, in particular by flattening, an at least partially planar surface in the axial direction at the coupling point (305) of the control rod (201), wherein preferably the control rod (201) on the actuator of the control can (202) before or after molding the at least partially planar Surface is mounted on the control rod (201).

3. The method (1700) according to any one of the preceding claims, characterized

marked that

the control (1703) of the control box (202), the supply and / or discharge, preferably introducing or discharging a fluid, in particular pneumatic fluid, such as compressed air (407), preferably under pressure or negative pressure, into or out of the control box (202 ) and / or characterized in that

setting (1702) the interface (305) on a type length of the

Control rod (201) based.

4. The method (1700) according to any one of the preceding claims, characterized

marked that

the predetermined distance (408) of the coupling point (305) of the control rod (201) to the base plate (203) of the control box (202) is based on a predetermined setting of the turbocharger and / or

the predetermined distance (408) of the coupling point (305) of the control rod (201) to the base plate (203) of the control box (202) comprises a predetermined tolerance range.

5. The method (1700) according to any one of the preceding claims, characterized

marked that

the coupling bolt (406) has an elevation (610, 610b) on a surface to be welded, in particular the surface of the coupling bolt (406) to be welded next to the elevation (610, 610b), in particular at least partially encircling, a, preferably at least partially encircling, recess (911, 911b).

6. The method (1700) according to any one of the preceding claims, characterized

marked that

the welding (1704) comprises capacitor welding.

7. The method (1700) according to any one of the preceding claims, characterized

characterized in that the method (1700) further comprises:

Detecting welding parameters of the welding, in particular at least one of the following parameters: welding energy, welding force, peak currents, time integral over the welding current, height before welding, welding adjustment and / or

Welding, wherein the method (1700) preferably further comprises:

Determining a quality of the welded coupling bolt (406) based on maintaining a tolerance range of the detected welding parameters, in particular based on a tolerance range of about 1 percent with respect to predetermined maximum values of the welding parameters.

8. welded connection (500) of a coupling pin (406) of a turbocharger with an actuating rod (201) of a control box (202), characterized in that

the welded connection (500) is produced by the method (1700) according to one of the preceding claims.

9. turbocharger, comprising:

a control box (202) for controlling the turbocharger,

an actuator rod (201) mounted to the control box (202); and

a coupling bolt (406) for coupling the control rod (201) to a

Valve means (101) of the turbocharger,

characterized in that

the coupling of the control box (202) to the turbocharger is made according to a method (1700) according to any one of claims 1 to 7, and in particular a

Welded connection (500) of the coupling bolt (406) with the control rod (201) according to claim 8.

10. Quality control system for monitoring a quality of a

A welded connection (500) of a coupling bolt (406) of a turbocharger with an actuating rod (201) of a control box (202), comprising:

a processor,

characterized in that

the processor is configured to sense the welding parameters of the welding of claim 7 and to determine a quality of the welded coupling bolt (406) of claim 7.