Nozzled turbocharger turbine and associated engine and method

• US 8,857,178 B2
• Filed: 06/28/2011
• Issued: 10/14/2014
• Est. Priority Date: 06/28/2011
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: O'Hara, Steve
• Primary Examiner(s): Trieu, Thai Ba
• Application Number:
  US13/171,133
• Publication Number:
  US 20130000300A1
• Time in Patent Office: 1,204 Days
• Field of Search: 606/02, 606/052, 415203-205, 415/208.2, 415/208.4, 415/150, 415157-159, 415/184, 415/186, 415/182.1, 415/212.1, 415/214.1, 415/211.2, 417406-407, 416/187, 416/186.R, 416/185, 298/892
• US Class Current: 60/602
• CPC Class Codes: F01D 9/026 Scrolls for radial machines or engines
• CPC Class Codes: F01D 9/045 for radial flow machines or engines
• CPC Class Codes: F02B 37/025 Multiple scrolls or multiple gas passages guiding the gas to the pump drive
• CPC Class Codes: F02B 37/22 by varying cross-section of exhaust passages or air passages , e.g. by throttling turbine inlets or outlets or by varying effective number of guide conduits F02B37/24 takes precedence
• CPC Class Codes: F02B 37/24 by using pumps or turbines with adjustable guide vanes
• CPC Class Codes: F02M 26/05 High pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust system upstream of the turbine and reintroduced into the intake system downstream of the compressor
• CPC Class Codes: F05D 2220/40 in turbochargers
• CPC Class Codes: F05D 2230/53 by integrally manufacturing a component, e.g. by milling from a billet or one piece construction
• CPC Class Codes: F05D 2250/232 conical
• CPC Class Codes: F05D 2250/52 Outlet
• CPC Class Codes: F05D 2260/606 Bypassing the fluid
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 29/4932 Turbomachine making

Abstract

A turbocharger for an internal combustion engine includes a center housing, a shaft rotatably supported in the center housing, and a turbine wheel connected at one end of the shaft. A turbine housing is connected to the center housing and disposed around the turbine wheel. A bore formed in the turbine housing extends from a gas outlet end of the turbine housing to an annular stop surface of the turbine housing disposed adjacent the turbine wheel. A nozzle ring disposed in the bore surrounds a portion of the turbine wheel. An outlet cone is disposed at least partially in the bore and surrounds a remaining portion of the turbine wheel. The outlet cone is connected to the gas outlet end of the turbine housing.

Claims

1. A method for assembling a turbocharger, comprising:

providing a center housing;

installing a turbine housing onto the center housing, the turbine housing including a bore extending from a gas outlet end of the turbine housing to a stop surface, the bore having a generally cylindrical shape and disposed concentrically around a turbine wheel of the turbocharger when the turbocharger is fully assembled, the bore having an inner diameter along an entire length thereof;

providing a nozzle ring including an inner ring and first and second outer rings, the inner, first and second outer rings having an outer diameter that is configured to fit within the inner diameter of the bore with a clearance fit;

inserting the nozzle ring into the turbine housing through the bore after the turbine housing has been installed onto the center housing, the nozzle ring being disposed circumferentially around at least a portion of the turbine wheel;

inserting and locating an outlet cone having a generally hollow tubular shape into the bore such that an inner portion of the outlet cone is positioned around a remaining portion of the turbine wheel and in abutting relation with the nozzle ring; and

connecting the outlet cone to the turbine housing to thus secure the nozzle ring within the bore of the turbine housing.

2. The method of claim 1, further comprising inserting a turbine wheel connected to a shaft into the center housing through the bore before installing the outlet cone such that the turbine wheel is disposed within the turbine housing and the shaft is rotatably mounted to the center housing.

3. The method of claim 1, further comprising connecting a compressor wheel to a free end of the shaft, and connecting a compressor housing to the center housing such that the compressor housing is disposed around the compressor wheel.

4. The method of claim 1, wherein the nozzle ring and outlet cone are integrated into a single component such that the step of installing the nozzle ring and inserting and locating the outlet cone are accomplished in a single operation.

5. The method of claim 1, wherein the bore has an inner surface, and wherein the step of locating the outlet cone includes slidably engaging the inner surface of the bore with a generally cylindrical outer surface of the outlet cone that extends axially relative to a centerline of the outlet cone.

6. A turbocharger for an internal combustion engine, comprising:

a center housing;

a shaft rotatably supported in the center housing;

a turbine wheel connected at one end of the shaft;

a turbine housing connected to the center housing and disposed around the turbine wheel;

a nozzle ring surrounding a portion of the turbine wheel, the nozzle ring including an inner ring and first and second outer rings connected to one another by vanes;

a bore having a generally cylindrical shape formed in the turbine housing, the bore disposed concentrically around the turbine wheel and extending between an exhaust gas outlet end of the turbine housing and an annular stop surface of the turbine housing disposed adjacent the turbine wheel, the bore having an inner diameter along an entire length of the bore that is at least large enough to accommodate the nozzle ring therein with a clearance fit;

wherein the nozzle ring is disposed within the bore, and

an outlet cone that is integrated with the nozzle ring, the outlet cone disposed at least partially in the bore and surrounding a remaining portion of the turbine wheel, the outlet cone connected to the turbine housing at the gas outlet end thereof to thus secure the nozzle ring within the bore of the turbine housing;

wherein the outlet cone and nozzle ring are configured to be removed from the bore through an exhaust gas outlet opening at the gas outlet end of the turbine housing.

7. The turbocharger of claim 6, wherein the outlet cone and the nozzle ring are connected along the first outer ring of the nozzle ring.

8. The turbocharger of claim 6, wherein the outlet cone includes an annular surface extending radially relative to a centerline of the outlet cone, the annular surface being in abutting relationship to the annular stop surface.

9. The turbocharger of claim 6, wherein the outlet cone includes a generally cylindrical surface extending axially relative to a centerline of the outlet cone, the generally cylindrical surface slidably engaging an inner cylindrical surface of the bore.

10. The turbocharger of claim 6, wherein the outlet cone has a generally hollow tubular shape defining an inner surface, the inner surface comprising a contoured surface disposed radially around an outlet portion of the turbine wheel.

11. The turbocharger of claim 10, wherein the inner surface of the outlet cone further includes a generally frusto-conical inner surface that is disposed generally tangentially relative to the contoured surface.

12. The turbocharger of claim 6, further comprising a compressor connected to the center housing, the compressor including a compressor wheel connected to the shaft.

13. An internal combustion engine comprising a plurality of cylinders fluidly connectable to an intake manifold and to at least one exhaust collector, comprising:

a turbocharger including a turbine and a compressor, the turbine including a turbine housing connected to a center housing and having a gas outlet end and a gas inlet, the gas inlet being in fluid communication with the at least one exhaust collector, and a turbine wheel connected to a shaft that is rotatably mounted within the center housing such that the turbine wheel is enclosed within the turbine housing;

a nozzle ring surrounding a portion of the turbine wheel, the nozzle ring including an inner ring and first and second outer rings connected to one another by vanes;

a bore having a stepped cylindrical shape formed in the turbine housing, the bore disposed concentrically around the turbine wheel and extending between an exhaust gas outlet end of the turbine housing and an annular stop surface of the turbine housing disposed adjacent the turbine wheel, the bore including a first internal diameter portion having a first internal diameter, which accommodates therein an outer diameter of the inner ring with a clearance fit, and the bore forming a second internal diameter portion having a second internal diameter, which second internal diameter is larger than the first internal diameter, and which accommodates therein the first outer ring with a clearance fit,

wherein the nozzle ring is disposed within the bore, and

an outlet cone disposed at least partially in the bore and surrounding a remaining portion of the turbine wheel, the outlet cone connected to the turbine housing at the gas outlet end thereof,

wherein the outlet cone and the nozzle ring are configured to be removed from the bore through an exhaust gas outlet opening at the gas outlet end of the turbine housing.

14. The internal combustion engine of claim 13, wherein the outlet cone and the nozzle ring are integrated into a single component.

15. The internal combustion engine of claim 13, wherein the outlet cone includes an annular surface extending radially relative to a centerline of the outlet cone, the annular surface being in abutting relationship to the annular stop surface.

16. The internal combustion engine of claim 13, wherein the outlet cone includes a generally cylindrical surface extending axially relative to a centerline of the outlet cone, the generally cylindrical surface slidably engaging an inner cylindrical surface of the bore.

17. The internal combustion engine of claim 13, wherein the outlet cone has a generally hollow tubular shape defining an inner surface, the inner surface comprising a contoured surface disposed radially around an outlet portion of the turbine wheel.

18. The internal combustion engine of claim 17, wherein the inner surface of the outlet cone further includes a generally frusto-conical inner surface that is disposed generally tangentially relative to the contoured surface.

19. The internal combustion engine of claim 13, further comprising a compressor connected to the center housing, the compressor including a compressor wheel connected to the shaft, and a compressor housing fluidly connected to the intake manifold and surrounding the compressor wheel.

20. The internal combustion engine of claim 13, further comprising an exhaust gas recirculation (EGR) system fluidly interconnected between the intake manifold and the at least one exhaust collector.