Turbocharger For An Internal Combustion Engine

Abstract

A turbocharger for an internal combustion engine has a bearing housing, in which a rotor shaft is mounted in a rotatable manner. A compressor having a compressor wheel is arranged for conjoint rotation on the rotor shaft. A fresh air supply channel conducts a fresh air mass flow to the compressor wheel. The fresh air supply channel has a first flow cross section upstream of the compressor wheel. A flow control device is provided and is adjustable between an open position, in which the first flow cross section is opened up, and a closed position, in which the first flow cross section is reduced to a second flow cross section. The flow control device is fluidically coupled to a compressor channel of the compressor downstream of the compressor wheel, such that the flow control device is adjusted in a manner dependent on a pressure prevailing in the compressor channel.

Claims

1-13 (canceled)

14. A turbocharger for a combustion machine, the turbocharger comprising: a rotor shaft; a bearing housing mounting said rotor shaft in a rotatable manner; a compressor having a compressor wheel disposed for conjoint rotation on said rotor shaft, said compressor further having a compressor channel; a fresh air supply channel for conducting a fresh air mass flow to said compressor wheel, said fresh air supply channel having a first flow cross section upstream of said compressor wheel; and a flow control device being adjustable between an open position, in which said first flow cross section is opened up, and a closed position, in which said first flow cross section is reduced to a second flow cross section, said flow control device is fluidically coupled to said compressor channel of said compressor downstream of said compressor wheel, such that said flow control device is adjusted in a manner dependent on a pressure prevailing in said compressor channel.

15. The turbocharger according to claim 14, wherein said flow control device has a control cylinder which, for purposes of adjusting said flow control device, is mounted so as to be displaceable axially with respect to a rotor axis of rotation of said rotor shaft, and which is fluidically coupled to said compressor channel of said compressor downstream of said compressor wheel.

16. The turbocharger according to claim 15, wherein said control cylinder is displaceable between two axial end positions including a first axial end position which corresponds to the open position of said flow control device and a second axial end position which corresponds to the closed position of said flow control device.

17. The turbocharger according to claim 15, wherein: a compressor housing has a piston cavity formed therein; and said control cylinder has an encircling piston ring, which is guided in an axially displaceable fashion in said piston cavity which corresponds to said piston ring.

18. The turbocharger according to claim 17, further comprising at least one seal element configured for sealing off said piston ring with respect to said piston cavity.

19. The turbocharger according to claim 17, further comprising at least one channel, said piston cavity is connected by means of said at least one channel to said compressor channel of said compressor.

20. The turbocharger according to claim 17, wherein said flow control device has an axial spring element which is disposed so as to exert a spring force on said control cylinder in an axial direction with respect to the rotor axis of rotation counter to a pressure force exerted on said control cylinder by pressure prevailing in said compressor channel, such that said control cylinder is axially displaceable in a manner dependent on the spring force and the pressure force.

21. The turbocharger according to claim 17, wherein said flow control device has multiple guide vanes which are mounted rotatably on said control cylinder, wherein said guide vanes are adjustable between an open position and a closed position by displacement of said control cylinder.

22. The turbocharger according to claim 21, wherein said guide vanes, in the open position, are disposed such that said guide vanes open up the first flow cross section, and wherein, with axial displacement of said control cylinder, said guide vanes are displaced in a direction of said compressor wheel and interact with said compressor housing such that said guide vanes are rotated in order to reduce the first flow cross section.

23. The turbocharger according to claim 21, wherein, in the closed position, said guide vanes are displaced axially in a direction of said compressor wheel and are rotated such that said guide vanes form a substantially closed conical ring with the second flow cross section.

24. The turbocharger according to claim 21, wherein said guide vanes are shaped so as to have a tapering front end, which faces toward said compressor wheel.

25. The turbocharger according to claim 22, wherein said flow control device has a radial spring element which is disposed so as to impart a spring force to in each case a rear end of said guide vanes in a direction of the rotor axis of rotation, such that a front end of said guide vanes is pressed against said compressor housing.

26. The turbocharger according to claim 14, wherein: said compressor housing has two parts including a first part fastened to said bearing housing and surrounds said compressor wheel, and a second part fastened to said first part; and said flow control device is disposed between said first and second parts.

Description

[0032] In the figures:

[0033] FIG. 1 shows a schematic sectional view of a turbocharger,

[0034] FIG. 2 shows a schematic partially sectional view of a turbocharger with a flow control device in a closed position as per an exemplary embodiment of the invention,

[0035] FIG. 3 shows a schematic plan view of a guide vane of the flow control device,

[0036] FIG. 4 shows a schematic partially sectional view of the turbocharger with the flow control device in an open position, and

[0037] FIGS. 5 and 6 show schematic views of a ring-shaped channel of the compressor of the turbocharger.

[0038] FIG. 1 schematically shows a sectional illustration of an example of an exhaust-gas turbocharger 1, which has an exhaust-gas turbine 20, a fresh-air compressor 30 and a rotor bearing 40. The exhaust-gas turbine 20 is equipped with a wastegate valve 29 and an exhaust-gas mass flow AM is indicated by arrows. The fresh-air compressor 30 has an overrun air recirculation valve 39 and a fresh-air mass flow FM is likewise indicated by arrows. A turbocharger rotor 10, as it is known, of the exhaust-gas turbocharger 1 has a turbine impeller 12 (also referred to as turbine wheel), a compressor impeller 13 (also referred to as compressor wheel) and a rotor shaft 14 (also referred to as shaft). The turbocharger rotor 10 rotates about a rotor axis of rotation 15 of the rotor shaft 14 during operation. The rotor axis of rotation 15 and at the same time the turbocharger axis 2 (also referred to as longitudinal axis) are illustrated by the indicated centerline and identify the axial orientation of the exhaust-gas turbocharger 1. The turbocharger rotor 10 is supported with its rotor shaft 14 by means of two radial bearings 42 and one axial bearing disk 43. Both the radial bearings 42 and the axial bearing disk 43 are supplied with lubricant via oil supply channels 44 of an oil connection 45.

[0039] In general, a conventional exhaust-gas turbocharger 1, as illustrated in FIG. 1, has a multi-part construction. Here, a turbine housing 21 in the exhaust tract of the internal combustion engine, a compressor housing 31 that is arrangeable in the intake tract of the internal combustion engine, and, between the turbine housing 21 and compressor housing 31, a bearing housing 41, are arranged adjacent to one another with respect to the common turbocharger axis 2 and connected together in terms of assembly.

[0040] A further structural unit of the exhaust-gas turbocharger 1 is represented by the turbocharger rotor 10, which has the rotor shaft 14, the turbine rotor 12, which is arranged in the turbine housing 21 and which has an impeller blade arrangement 121, and the compressor impeller 13, which is arranged in the compressor housing 31 and which has an impeller blade arrangement 131. The turbine impeller 12 and the compressor impeller 13 are arranged on the opposite ends of the common rotor shaft 14 and connected for conjoint rotation thereto. The rotor shaft 14 extends in the direction of the turbocharger axis 2 axially through the bearing housing 41 and is mounted axially and radially therein so as to be rotatable about its longitudinal axis, the rotor axis of rotation 15, wherein the rotor axis of rotation 15 coincides with the turbocharger axis 2.

[0041] The compressor housing 31 has a fresh-air supply channel 36, which has an intake pipe connector piece 37 for connection to the fresh-air intake system (not illustrated) of the internal combustion engine and which runs in the direction of the turbocharger axis 2 toward the axial end of the compressor wheel 13. Via this fresh-air supply channel 36, the fresh-air mass flow FM is drawn in from the fresh-air intake system by the compressor impeller 13.

[0042] Furthermore, the compressor housing 31 generally has a ring-shaped channel which is arranged in ring-shaped fashion around the turbocharger axis 2 and the compressor impeller 13 and which widens in spiral fashion away from the compressor impeller 13, and which is referred to as a so-called fresh-air volute 32 or compressor channel. Said fresh-air volute 32 has a gap opening which runs at least over a part of the inner circumference and which has a defined gap width, the so-called diffuser 35, which, directed in a radial direction away from the outer circumference of the compressor wheel 13, runs into the fresh-air volute 32 and through which the fresh-air mass flow FM flows away from the compressor impeller 13 at elevated pressure into the fresh-air volute 32.

[0043] The fresh-air volute 32 furthermore has a tangentially out-wardly directed fresh-air discharge channel 33 with a manifold connector piece 34 for connection to a fresh-air manifold (not illustrated) of an internal combustion engine. Through the fresh-air discharge channel 33, the fresh-air mass flow FM is conducted at elevated pressure, the compressor or boost pressure, into the fresh-air manifold of the internal combustion engine.

[0044] Over a particular region, between fresh-air supply channel 33 and diffuser 35, the radial inner contour of the compressor housing 31 follows the outer contour of the compressor impeller 13 accommodated therein. This region of the inner contour of the compressor housing 31 is referred to as compressor sealing contour 38 and has the effect that the fresh-air mass flow FM flows as completely as possible through the impeller blade arrangement 131 of the compressor impeller 13, and not past said impeller blade arrangement. In this respect, it is necessary for as small a gap as possible to be ensured between the compressor sealing contour 38 of the compressor housing 31 and outer contour of the compressor impeller 13 during operation, which gap duly permits a free rotation of the compressor impeller 13 but restricts the bypass flow losses to a minimum.

[0045] Further details of the turbocharger 1 will not be discussed any more specifically.

[0046] A turbocharger 1 according to an exemplary embodiment of the invention will be discussed below. Said turbocharger has, by contrast to FIG. 1, been modified at the compressor side and supplemented by a flow control device 50.

[0047] FIGS. 2 and 4 show schematic partially sectional views of the turbocharger 1 in two different operating states of the flow control device 50. The flow control device 50 serves for the variable adjustability of a flow cross section for the fresh-air mass flow FM in front of the compressor wheel 13, in order to improve a compressor characteristic map. The flow control device 50 will be discussed in detail below.

[0048] The compressor housing 31 is in two parts, and comprises a first part 31a, which is mounted on the bearing housing 41. The second part 31b is mounted on, for example screwed onto, the first part 31a. Between the two parts 31a and 31b of the compressor housing 31, the flow control device 50 is installed in the inlet region of the compressor 30.

[0049] The flow control device 50 has a control cylinder 51, which is of ring-shaped design and arranged around the rotor axis of rotation 15. The control cylinder 51 has a piston ring 52, which is of encircling design. By means of the piston ring 52, the control cylinder 51 is guided, so as to be displaceable axially with respect to the rotor axis of rotation 15, in a piston cavity 53. The piston cavity 53 is formed in the first part 31a of the compressor housing 31 as a ring-shaped encircling recess. In the piston cavity 53, there are arranged sealing elements 54 which seal off the piston ring 52 with respect to the piston cavity 53.

[0050] The piston cavity 53 is fluidically connected via at least one channel, in the exemplary embodiment a bore 55, to the fresh-air volute 32.

[0051] The flow control device 50 furthermore has an axial spring element 56. The axial spring element 56 is supported in the second part 31b of the compressor housing 31 and interacts with the control cylinder 51. The axial spring element 56 exerts an axial spring force directly on the control cylinder 51 in the direction of the compressor wheel 13 (indicated in FIG. 2).

[0052] Furthermore, multiple guide vanes 57 are mounted, rotatably with respect to axes of rotation 58, on the control cylinder 51. Whereas FIG. 2 shows only one guide vane 57 in section, multiple guide vanes 57 are indicated in FIG. 4. The guide vanes 57 are rotatably mounted on the control cylinder 51 via in each case one bearing bracket 59. The axes of rotation 58 run perpendicular to the rotor axis of rotation 15. For the installation of the guide vanes 57, the control cylinder 51 may be formed as one piece and slotted, for example crenellated, or else formed in two pieces.

[0053] As shown in FIG. 3 in a plan view, the guide vanes 57 are of wedge-shaped form. With respect to the rotor axis of rotation 15, the guide vanes 57 have a rear end 60, a central portion 61 with the bearing bracket and the axis of rotation 58, and a front end 62 which tapers. An inner surface 63, facing toward the rotor axis of rotation 15 in the installed state, of the guide vanes 57 is substantially planar. In other words, the guide vanes 57 taper with respect to the axial direction, and have oblique flanks. An outer surface 64, which is averted from the rotor axis of rotation 15 in the installed state, is adapted with regard to a shaping, at least in the region of the front end 62, to a facing housing wall 65 of the first part 31a of the compressor housing 31.

[0054] Furthermore, a radial spring element 66 in the form of a spring ring is provided, which is arranged around the rear ends 60 of the guide vanes 57 and which exerts a spring force on the guide vanes 57 with respect to the rotor axis of rotation 15. In this way, the guide vanes 57 are rotated counterclockwise, such that the front ends 62 are pressed against the housing wall 65.

[0055] Alternatively, it is also possible for multiple axial and radial spring elements to be provided.

[0056] FIG. 2 shows a state of the flow control device 50 which may also be referred to as installation state or as non-operation state of the turbocharger 1. In this state, a first pressure p1, for example normal pressure, or no elevated compressor pressure, prevails in the fresh-air volute 32. In this state, the spring force of the axial spring element 56 is so great that the control cylinder 51 is displaced in the direction of the compressor wheel 13 into the piston cavity 53 as far as into a first axial end position. The axial spring element 56 may also transmit a spring force indirectly to the control cylinder 51, for example by interaction with the guide vanes 57 and/or with the radial spring element 66. In this way, owing to their direct mechanical coupling to the control cylinder 51, the guide vanes 57 are axially displaced and moved into the position shown. Here, the guide vanes 57 are supported on the housing wall 65, such that said guide vanes are, correspondingly to the arcuate shaping on the outer surface 64 in the region of the front ends 62, rotated inward about the axes of rotation 58. The rear ends 60 of the guide vanes are rotated radially outward counter to a spring force of the radial spring element 66. The spring element 66 is preloaded or is preloaded further. This spring force ensures that the guide vanes 57 are held with the front end 62 against the housing wall 65.

[0057] In the state shown in FIG. 2, the front ends 62, for example tips of the guide vanes 57, are moved close to the compressor wheel 13 or to the compressor wheel inlet. In this state, a maximum position, the guide vanes 57 form a substantially closed, cone-shaped ring. In this state, which is also referred to as closed position, the guide vanes constrict the first flow cross section A1 of the fresh-air supply channel 36 to a second flow cross section A2.

[0058] FIG. 4 shows an operating state of the turbocharger 1, wherein the fresh-air mass flow FM is present in the fresh-air volute 32 with a second pressure p2 which is elevated in relation to the first pressure p1. Owing to the bore 55 between the fresh-air volute 32 and piston cavity 53 and thus the control cylinder 51, the second pressure p2 reacts via the fresh-air volute 32 on the control cylinder 51, such that said control cylinder is, in a manner dependent on the second pressure p2, displaced axially in a direction away from the compressor wheel 13 counter to the spring force of the axial spring element 56. In this way, the guide vanes 57 are pulled away from the compressor wheel 13 in continuous fashion. Owing to the spring force of the radial spring element 66 on the rear ends 60 of the guide vanes 57, the guide vanes 57 rotate counterclockwise and bear closely against the housing wall 56. As a result, the guide vanes 57 move out of the flow of the fresh-air mass flow FM.

[0059] FIG. 4 shows a second axial end position of the control cylinder 51, wherein said control cylinder is in a position at a maximum distance from the compressor wheel 13. In this way, the guide vanes 57 are likewise in their end position, and have been pulled radially completely out of the flow. As a result, the first flow cross section A1 has been fully opened up. This is referred to as open position of the flow control device 50 or of the guide vanes 57. In this open position, the guide vanes 57 are situated with their inner surface 63 at a cylinder diameter of the fresh-air supply channel 36, for example the first flow cross section A1. Between the oblique flanks, the guide vanes 57 form gaps laterally with respect to one another.

[0060] FIG. 4 additionally shows an insertable rear wall 67 and a seal bushing 68. These are however not of relevance for the described principle.

[0061] Depending on the pressure prevailing in the fresh-air volute 32, the control cylinder 51 may assume other positions between the two axial end positions as per FIGS. 2 and 4. In a manner dependent on this position, it is also possible for the guide vanes 57 to assume correspondingly different (intermediate) positions.

[0062] The described turbocharger 1 thus permits the advantages and functions mentioned in the introduction, wherein, in a manner dependent on a pressure prevailing in the fresh-air volute 32, the flow cross section for the fresh-air mass flow FM for the impingement of flow on the compressor wheel 13 is adapted in continuous, self-controlling fashion. An adaptation with regard to the compressor characteristic map may be realized by way of the shape, number and size of the guide vanes 57, a cross-sectional area of the piston ring 52 which is exposed to the pressure from the fresh-air volute 32, and the spring elements 56, 66, for example the spring rates thereof. Furthermore, the compressor characteristic map and a response characteristic of the self-control may be adjusted by means of the connection of the piston cavity 53 to the fresh-air volute 32, as will be described below.

[0063] FIG. 5 schematically shows the fresh-air volute 32. Various positions P1 to P4 for the bore 55 are illustrated here. FIG. 6 furthermore shows that an orientation of the bore 55 may also vary. The advantages mentioned in the introduction can be achieved in this way.