U.S. patent application number 10/728907 was filed with the patent office on 2005-06-09 for turbocharger assembly and method.
This patent application is currently assigned to Caterpillar Inc.. Invention is credited to DelVecchio, Kerry Alan, Gerke, Frank George, Hopmann, Ulrich, Reisdorf, Paul William.
Application Number | 20050123417 10/728907 |
Document ID | / |
Family ID | 34633810 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050123417 |
Kind Code |
A1 |
DelVecchio, Kerry Alan ; et
al. |
June 9, 2005 |
Turbocharger assembly and method
Abstract
A turbine assembly is provided. The turbine assembly includes a
turbocharger drive having a first threaded portion and a turbine
wheel assembly. The turbine wheel assembly includes a turbine wheel
and a second threaded portion adapted to engage the first threaded
portion of the turbocharger drive. The turbine assembly may be
utilized in a turbocharger assembly, wherein a compressor is
connected to a second end of the turbocharger drive.
Inventors: |
DelVecchio, Kerry Alan;
(Dunlap, IL) ; Reisdorf, Paul William; (Dunlap,
IL) ; Hopmann, Ulrich; (Peoria, IL) ; Gerke,
Frank George; (Chillicothe, IL) |
Correspondence
Address: |
Finnegan, Henderson, Farabow,
Garrett & Dunner, L.L.P.
1300 I Street, N.W.
Washington
DC
20005-3315
US
|
Assignee: |
Caterpillar Inc.
|
Family ID: |
34633810 |
Appl. No.: |
10/728907 |
Filed: |
December 8, 2003 |
Current U.S.
Class: |
417/407 |
Current CPC
Class: |
Y02T 10/144 20130101;
F05D 2220/40 20130101; F02B 37/10 20130101; F02B 39/00 20130101;
F01D 5/025 20130101; F01D 15/10 20130101; Y02T 10/12 20130101; F01D
5/026 20130101; F02B 39/10 20130101 |
Class at
Publication: |
417/407 |
International
Class: |
F04B 017/00 |
Goverment Interests
[0001] This invention was made with government support under the
terms of Contract No. DE-SC05-00OR-22810 awarded by the Department
of Energy. The government may have certain rights in this
invention.
Claims
What is claimed is:
1. A turbine assembly, comprising: a turbocharger drive having a
first threaded portion; and a turbine wheel assembly having a
turbine wheel and a second threaded portion adapted to engage the
first threaded portion of the turbocharger drive.
2. The turbine assembly of claim 1, wherein the turbine wheel
assembly includes a turbine shaft having a first end and a second
end, the first end of the turbine shaft having the second threaded
portion and the second end of the turbine shaft being connected to
the turbine wheel.
3. The turbine assembly of claim 1, wherein the second threaded
portion of the turbine wheel assembly has male threads.
4. The turbine assembly of claim 1, wherein the second threaded
portion of the turbine wheel assembly has female threads.
5. The turbine assembly of claim 1, further including a turbine
housing enclosing the turbine wheel assembly.
6. The turbine assembly of claim 5, further including at least one
bearing operatively connecting the turbocharger drive to the
housing.
7. The turbine assembly of claim 2, wherein the second end of the
turbine shaft is inertia welded to the turbine wheel.
8. The turbine assembly of claim 1, further including: a turbine
wheel base; and a plurality of turbine blades disposed around the
outer periphery of the turbine wheel base.
9. A method of assembling a turbocharger comprising: inserting a
turbocharger drive into a main housing, wherein the turbocharger
drive includes a first end having a first threaded portion and a
second end; engaging a second threaded portion of a turbine wheel
assembly with the first threaded portion of the turbocharger drive;
and connecting a compressor to the second end of the turbocharger
drive.
10. The method of claim 9, further including: pre-assembling the
turbocharger drive before inserting the turbocharger drive into the
main housing, wherein pre-assembling the turbocharger drive
includes: installing a shaft through a rotor; and balancing the
rotor.
11. The method of claim 9, further including: attaching a turbine
housing to the main housing thereby enclosing the turbine wheel
assembly; and attaching a compressor housing to the main housing
thereby enclosing the compressor.
12. A turbocharger, comprising: a housing assembly; a turbocharger
drive rotatingly disposed in the housing assembly, the turbocharger
drive including a first end having a first threaded portion and a
second end; a turbine wheel assembly having a turbine wheel and a
second threaded portion adapted to engage the first threaded
portion on the turbocharger drive; and a compressor connected to
the second end of the turbocharger drive.
13. The turbocharger of claim 12, wherein the turbine wheel
assembly includes a shaft having a first end and a second end, the
first end of the shaft having the second threaded portion and the
second end of the shaft being connected to the turbine wheel.
14. The turbocharger of claim 12, wherein the second threaded
portion of the turbine wheel assembly has male threads.
15. The turbocharger of claim 12, wherein the second threaded
portion of the turbine wheel assembly has female threads.
16. The turbocharger of claim 12, wherein the compressor includes a
third threaded portion adapted to engage a fourth threaded portion
disposed on the second end of the turbocharger drive.
17. The turbocharger of claim 13, wherein the compressor includes a
shaft having a first end and a second end, the first end of the
shaft having the third threaded portion and the second end
connected to the compressor.
18. The turbocharger of claim 12, wherein the housing assembly
includes: a main housing enclosing the turbocharger drive; a
compressor housing enclosing the compressor; and a turbine housing
enclosing the turbine assembly.
19. The turbocharger of claim 12, wherein the turbocharger drive
includes: a shaft; and a rotor operably connected to the shaft.
20. A turbocharger, comprising: a housing assembly; a turbocharger
drive rotatingly disposed in the housing assembly; a turbine wheel
assembly having a turbine wheel and a means for removably
connecting the turbine wheel to the turbocharger drive; and a
compressor connected to the second end.
21. The turbocharger of claim 20, wherein the turbine wheel
assembly includes a shaft having a first end and a second end, the
first end of the shaft having the connecting means and the second
end of the shaft being connected to the turbine wheel.
Description
TECHNICAL FIELD
[0002] The present invention is directed to a turbocharger assembly
and, more particularly, to a turbocharger assembly that provides
for removably connecting a turbine wheel assembly to a turbocharger
drive.
BACKGROUND
[0003] Internal combustion engines such as, for example, diesel
engines, gasoline engines, or natural gas engines may be operated
to generate a power output. In order to maximize the power
generated by the internal combustion engine, the engine may be
equipped with a turbocharged air induction system.
[0004] A turbocharged air induction system may include a
turbocharger that compresses the air flowing into the engine to
thereby force more air into a combustion chamber. The increased
supply of air allows for increased fuelling, which may result in
increased power. A turbocharged engine typically produces more
power than the same engine without turbocharging.
[0005] A turbocharger may include a turbine wheel that is connected
to a compressor. The expansion of hot exhaust gases over the
turbine wheel drives the compressor wheel to force compressed air
into a combustion chamber. A typical turbocharger includes a
housing, a shaft, a turbine wheel attached to one end of the shaft,
and a compressor connected by threaded fastening to the other end
of the shaft. The turbine, shaft, and compressor may be assembled
into the housing as described in U.S. Pat. No. 5,193,989 issued to
Fleury et al. on Mar. 16, 1993. The '989 patent to Fleury et al.
describes assembly of a turbocharger having the turbine wheel
permanently attached to the shaft. The shaft and turbine wheel may
be inserted from one side of the housing and the compressor wheel
may be fastened to the other end of the shaft.
[0006] However, the turbocharger of Fleury et al. does not allow
for the design flexibility required for more complex turbocharging
systems that require additional components. Adding the additional
components to the turbocharger systems of Fluery et al. may be
difficult because the turbocharger components may only be assembled
from one end of the turbocharger shaft. Additionally, the
turbocharger of Fleury et al. may be too expensive to maintain when
combined with more complex air induction systems because the
turbine wheel and shaft are inseparable.
[0007] The turbocharger assembly of the present invention solves
one or more of the problems set forth above.
SUMMARY OF THE INVENTION
[0008] A first aspect of the present disclosure is directed to a
turbine assembly. The turbine assembly includes a turbocharger
drive having a first threaded portion and a turbine wheel assembly.
The turbine wheel assembly includes a turbine wheel and a second
threaded portion adapted to engage the first threaded portion of
the turbocharger drive.
[0009] A second aspect of the present disclosure is directed to a
method of assembling a turbocharger. The method includes inserting
a drive into a main housing, wherein the turbocharger drive
includes a first end having a first threaded portion and a second
end. A second threaded portion of a turbine wheel assembly is
engaged with the first threaded portion of the turbocharger drive.
A compressor is connected to the second end of the turbocharger
drive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a cross-sectional illustration of a turbine
assembly in accordance with an exemplary embodiment of the present
invention.
[0011] FIG. 2 is a cross-sectional illustration of a turbine
assembly in accordance with an exemplary embodiment of the present
invention.
[0012] FIG. 3 is a cross-sectional illustration of a turbocharger
in accordance with an exemplary embodiment of the present
invention.
[0013] FIG. 4 is a diagrammatic and schematic illustration of an
engine system in accordance with an exemplary embodiment of the
present invention.
DETAILED DESCRIPTION
[0014] An exemplary embodiment of a turbine wheel assembly 10 is
illustrated in FIG. 1. The turbine wheel assembly 10 includes a
turbine wheel 11 having a turbine wheel base 12 and a plurality of
turbine blades 13. The plurality of turbine blades 13 may be
disposed on the outer periphery of the turbine wheel base 12 and
may be adapted to rotate the turbine wheel base 12 when driven by
the expansion of hot exhaust gases. The plurality of turbine blades
13 may be rigidly fixed to the turbine wheel base 12 using
conventional means or they may be movable with respect to the
turbine wheel base 12 such as, for example, by providing variable
pitch turbine blades or variable geometry turbine blades. The
plurality of turbine blades 13 may also be integral with the
turbine wheel base 12.
[0015] The turbine wheel assembly 10 may also include a connecting
means such as for example, a threaded portion 14. The threaded
portion 14 may be integral to turbine wheel base 12 or may be
connected to the base through any means known in the art such as,
for example, inertia welding. The threaded portion 14 may be
adapted to transmit power from the turbine wheel assembly 10 to a
corresponding connecting member.
[0016] In the embodiment of FIG. 1, the threaded portion 14 of the
turbine wheel assembly 10 is adapted to engage a corresponding
connecting means of a turbocharger drive 18. In this embodiment,
the connecting means is a threaded portion 16. When the threaded
portion 14 of the turbine wheel assembly 10 is engaged with the
threaded portion 16 of the turbocharger drive 18, the turbine wheel
assembly 10 is connected to the turbocharger drive 18 so that a
rotation of the turbine wheel assembly 10 will cause a
corresponding rotation of the turbocharger drive 18.
[0017] In the exemplary embodiment of FIG. 1, the threaded portion
14 of turbine wheel assembly 10 has male threads and the threaded
portion 16 of the turbocharger drive 18 has female threads. The
male threads of the turbine wheel assembly 10 may be engaged with
the female threads to connect the turbine wheel assembly 10 to the
turbocharger drive 18. The turbine wheel assembly 10 may
alternatively have a female threaded portion adapted to engage a
male threaded portion of the turbocharger drive 18.
[0018] Another exemplary embodiment of a turbine wheel assembly 10
is illustrated in FIG. 2. The turbine wheel assembly 10 of this
embodiment includes a turbine wheel 11 and a stub shaft 20 having a
threaded portion 22. The stub shaft 20 may be integral to turbine
wheel base 12 or may be connected to turbine wheel base 12 by any
manner known in the art such as, for example, inertia welding. The
stub shaft 20 may include a female threaded portion 22 adapted to
engage a male threaded portion 16 located on the turbocharger drive
18 (referring to FIG. 1), thereby connecting the turbine wheel
assembly 10 to the turbocharger drive 18. Alternatively, the stub
shaft 20 may include a male threaded portion adapted to engage a
female threaded portion located on the turbocharger drive 18.
[0019] It is contemplated that the turbine wheel assembly 10 may be
incorporated in a turbocharger assembly. An exemplary embodiment of
a turbocharger 23 is illustrated in FIG. 3. In this embodiment, the
turbocharger 23 includes a stator housing 24 in which a
pre-assembled drive assembly 26 may be inserted.
[0020] The pre-assembled drive assembly 26 may have a stator 28 and
a rotor 29 held by end plate retainers 34 between bearings 30. The
stator 28, rotor 29, end plate retainers 34, and bearings 30 are
assembled to the turbocharger drive 18. The pre-assembled drive
assembly 26 may be adapted to generate power when the turbocharger
drive 18 is rotated and direct the power to a crankshaft of an
engine 46 (referring to FIG. 4) to which the turbocharger 23 is
attached.
[0021] A turbine housing 40 is assembled to stator housing 24 to
enclose turbine wheel assembly 10. The turbine housing 40 is
adapted to direct hot expanding exhaust gases through a turbine
exhaust inlet 41 to the plurality of turbine blades 13 disposed on
the turbine wheel base 12 to cause the turbine wheel assembly 10
and associated turbocharger drive 18 to rotate. After passing
through the turbine wheel assembly 10, the exhaust gases are
released to the atmosphere through a turbine exhaust outlet 42.
[0022] A compressor assembly 37 may be connected to the other end
of the turbocharger drive 18 and be adapted to rotate with the
turbocharger drive 18. The compressor assembly 37 may include a
compressor wheel base 38 and a plurality of compressor blades 39
disposed around the outer periphery of the compressor wheel base
38. Compressor assembly 37 may also include a stub shaft (not
shown) having a fastening means such as for example, threads,
similar to stub shaft 20 connected to turbine wheel 11. The stub
shaft of compressor assembly 37 may be adapted to connect the
compressor assembly 37 to the turbocharger drive 18.
[0023] A compressor housing 43 may be assembled to the stator
housing 24 that encloses compressor assembly 37. Compressor housing
43 is adapted to direct ambient air from a compressor air inlet 44
to the plurality of compressor blades 39 attached to the rotating
compressor wheel base 38. The plurality of compressor blades 39 may
be operable to compress the air and force the compressed air out of
the turbocharger 23 through a compressor air outlet 45 (referring
to FIG. 4).
[0024] As illustrated in FIG. 4, the turbocharger 23 of the present
disclosure may be used with an engine 46 in an engine assembly 48.
The engine 46 may be a diesel engine, a gasoline engine, a natural
gas engine, or any other engine known in the art. Hot exhaust gases
from the engine 46 are directed into the turbine exhaust inlet 41
where the gases drive the rotation of the turbine assembly 10
resulting in a corresponding rotation of compressor assembly 37.
The rotation of compressor assembly 37 compresses inlet air and
forces the compressed air into the engine 46 through compressor air
outlet 45.
[0025] Industrial Applicability
[0026] As will be apparent from the foregoing description, the
present disclosure provides a system and method that allows for
design flexibility and low cost maintenance of a turbocharger
23.
[0027] The turbocharger 23 of the present disclosure may be
assembled from both ends of the turbocharger drive 18. The
pre-assembled drive assembly 26 (having stator 28, rotor 29, end
plate retainers 34, bearings 30, and turbocharger drive 18) is
balanced and then inserted into stator housing 24. Turbine wheel
assembly 10 is connected to one end of the turbocharger drive 18 by
engaging threaded portion 14 of the turbine wheel assembly 10 with
threaded portion 16 of the turbocharger drive 18. Turbine housing
40 is assembled to one side of the stator housing 24 and encloses
the turbine wheel assembly 10. Compressor assembly 37 may be
connected to the other end of the turbocharger drive 18 and
enclosed by compressor housing 43 assembled to the other side of
the stator housing 24.
[0028] Because the turbocharger 23 can be assembled from both sides
of the turbocharger drive 18, design flexibility is expanded.
Design is no longer limited to components capable of assembly from
only one direction. Likewise, methods of assembly are no longer
limited to only one direction of assembly.
[0029] In addition to increased design flexibility, maintenance
costs of the turbocharger 23 may be reduced by the ability to
remove both the turbine wheel assembly 10 and the compressor
assembly 37 from the turbocharger drive 18. For example, when
maintaining a turbocharger having a turbine wheel permanently
secured to a turbocharger drive, replacement of a damaged turbine
wheel required the entire turbocharger be taken apart. Both turbine
and compressor housings had to be removed and the compressor
assembly had to be disconnected from the turbocharger drive. The
pre-assembled drive assembly had to be removed from the stator
housing along with the turbine wheel and the turbocharger drive.
The pre-assembled drive assembly had to be separated from the
turbocharger drive. Finally the turbine wheel and turbocharger
drive could be replaced.
[0030] With the turbine wheel assembly 10 detachable from the
turbocharger drive 18 as described in the present disclosure, the
maintenance process is simplified. For example, when replacing a
broken or damaged turbine wheel assembly 10, the turbine housing 40
is removed and the turbine wheel assembly 10 is detached. Not only
is the process simplified saving time and labor cost, but part cost
is also reduced.
[0031] It will be apparent to those skilled in the art that various
modifications and variations can be made in the turbine wheel
assembly 10 of the present disclosure without departing from the
scope of the invention. Other embodiments of the invention will be
apparent to those skilled in the art from consideration of the
specification and practice of the invention disclosed herein. It is
intended that the specification and examples be considered as
exemplary only, with a true scope of the invention being indicated
by the following claims and their equivalents.
* * * * *