Method for manufacturing a turbocharger with variable turbine geometry

• US 9,308,576 B2
• Filed: 09/22/2011
• Issued: 04/12/2016
• Est. Priority Date: 09/27/2010
• Status: Active Grant

• Current Assignee: BorgWarner Incorporated
• Original Assignee: BorgWarner Incorporated
• Inventors: Ramb, Thomas, Knauer, Uwe, Heidingsfelder, Leif, Radke, Urban
• Primary Examiner(s): Walters, Ryan J
• Application Number:
  US13/825,021
• Publication Number:
  US 20130180106A1
• Time in Patent Office: 1,664 Days
• US Class Current: 1/1
• CPC Class Codes: B21K 3/00 Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like
• CPC Class Codes: F01D 17/165 for radial flow, i.e. the vanes turning around axes which are essentially parallel to the rotor centre line F01D17/167 takes precedence
• CPC Class Codes: F02B 37/24 by using pumps or turbines with adjustable guide vanes
• CPC Class Codes: F05D 2220/40 in turbochargers
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49243 Centrifugal type

Abstract

A method for manufacturing a turbocharger (1) with variable turbine geometry (VTG), having a turbine housing (2) with a feed duct (9) for exhaust gases; a turbine rotor (4) which is rotatably mounted in the turbine housing (2); and a guide grate (18) which surrounds the turbine rotor (4) radially at the outside, which has a blade bearing ring (6), which has a multiplicity of guide blades (7) which have in each case one blade shaft (8) mounted in the blade bearing ring (6), which has an adjusting ring (5) operatively connected to the guide blades (7) via associated blade levers (20) fastened to the blade shafts (8) at one of the ends thereof, each blade lever (20) having at the other end a lever head (23) which can be placed in engagement with an associated engagement recess (24) of the adjusting ring (5), and which has a stop (25) at least for setting the minimum throughflow through the nozzle cross sections formed by the guide blades (7). The stop (25) is formed as a setting pin which is fastened by means of an automated butt welding process, the position of the setting pin being determined from a previously carried out throughflow measurement with similar guide grates.

Claims

1. A method for manufacturing a turbocharger (1) with variable turbine geometry (VTG), the method comprising:

manufacturing the turbocharger comprising;

a turbine housing (2) with a feed duct (9) for exhaust gases;

a turbine rotor (4) rotatably mounted in the turbine housing (2); and

a guide grate (18) which radially surrounds the turbine rotor (4), the guide grate comprising;

a blade bearing ring (6), a multiplicity of guide blades (7) each having a blade shaft (8) mounted in the blade bearing ring (6), an adjusting ring (5) operatively connected to the guide blades (7) via associated blade levers (20) fastened to the blade shafts (8) at one of the ends thereof, each blade lever (20) having at the other end a lever head (23) which can be placed in engagement with an associated engagement recess (24) of the adjusting ring (5), and a stop (25) for setting a minimum throughflow through nozzle cross sections formed by the guide blades (7),

wherein the stop (25) is a setting pin which is fastened by means of an automated butt welding process, a position of the setting pin being determined from iterative throughflow measurements.

2. The method as claimed in claim 1, wherein the setting pin (25) is provided with a cylindrical stop shank (26) which is adjoined by a support plate (27).

3. The method as claimed in claim 2, wherein the support plate (27) is manufactured with a diameter (D1) which is greater than or equal to the diameter (D2) of the stop shank (26).

4. The method as claimed in claim 2, wherein the support plate (27) is provided, on its support surface (28), with a latching peg (32).

5. The method as claimed in claim 1, wherein the setting pin (25) is formed as a welded pin.

6. The method as claimed in claim 5, wherein the setting pin (25) is butt-welded to the blade bearing ring (6).

7. The method as claimed in claim 1, wherein two setting pins (25, 25′

) are provided, one (25) of which serves to set the maximum position and the other (25′

) of which serves to set the minimum position of the guide grate (18).

8. A method for manufacturing a guide grate (18) for a turbocharger (1) with variable turbine geometry (VTG), which guide grate (18) radially surrounds a turbine rotor (4) of the turbocharger (1) the method comprising:

manufacturing the guide grate comprising;

a blade bearing ring (6),

a multiplicity of guide blades (7) each having a blade shaft (8) mounted in the blade bearing ring (6),

an adjusting ring (5) operatively connected to the guide blades (7) via associated blade levers (20) fastened to the blade shafts (8) at one of the ends thereof, each blade lever (20) having at the other end a lever head (23) which can be placed in engagement with an associated engagement recess (24) of the adjusting ring (5), and

a stop (25) for setting a minimum throughflow through nozzle cross sections formed by the guide blades (7),

wherein the stop (25) is formed as a setting pin which is fastened by means of an automated butt welding process, a position of the setting pin being determined from iterative throughflow measurements.

9. The method as claimed in claim 8, wherein the setting pin (25) is provided with a cylindrical stop shank (26) which is adjoined by a support plate (27).

10. The method as claimed in claim 9, wherein the support plate (27) is manufactured with a diameter (D1) which is greater than or equal to a diameter (D2) of the stop shank (26).

11. The method as claimed in claim 9, wherein the support plate (27) is provided, on a support surface (28), with a latching peg (32).

12. The method as claimed in claim 8, wherein the setting pin (25) is formed as a welded pin.

13. The method as claimed in claim 12, wherein the setting pin (25) is butt-welded to the blade bearing ring (6).

14. The method as claimed in claim 8, wherein two setting pins (25, 25′

) are provided, one (25) of which serves to set the maximum position and the other (25′

) of which serves to set the minimum position of the guide grate (18).

15. A method for manufacturing a stop of a guide grate (18) for a turbocharger (1) with variable turbine geometry (VTG), which guide grate (18) radially surrounds a turbine rotor (4) of the turbocharger (1)

the guide grate comprising:

a blade bearing ring (6),

a multiplicity of guide blades (7) each having a blade shaft (8) mounted in the blade bearing ring (6),

an adjusting ring (5) operatively connected to the guide blades (7) via associated blade levers (20) fastened to the blade shafts (8) at one of the ends thereof, each blade lever (20) having at the other end a lever head (23) which can be placed in engagement with an associated engagement recess (24) of the adjusting ring (5),

the method comprising;

forming the stop (25) as a setting pin which is fastened by means of an automated butt welding process, wherein a position of the setting pin is determined from iterative throughflow measurements.