U.S. patent application number 15/114199 was filed with the patent office on 2016-12-15 for method of retaining a noise attenuation device in a compressor cover.
The applicant listed for this patent is BORGWARNER INC.. Invention is credited to Simon SLATER.
Application Number | 20160363136 15/114199 |
Document ID | / |
Family ID | 53757715 |
Filed Date | 2016-12-15 |
United States Patent
Application |
20160363136 |
Kind Code |
A1 |
SLATER; Simon |
December 15, 2016 |
METHOD OF RETAINING A NOISE ATTENUATION DEVICE IN A COMPRESSOR
COVER
Abstract
A compressor housing (12) and a method of retaining for use with
a turbocharger having a noise attenuation device (20) secured in a
compressor cover (14). A staking tool (40) deforms compressor cover
material to retain the noise attenuation device (20). The
compressor housing (12) includes the noise attenuation device (20)
seated on a first shoulder (24) in the cover (14), and a second
shoulder (26) is deformed securing the noise attenuation device
(20) in the cover (14). Retaining a noise attenuation device (20)
in the cover (14) may include mounting the cover (14) with the air
inlet section (16) upward; placing the noise attenuation device
(20) in the air inlet section (16) on the first shoulder (24); and
applying an impact load with a staking tool (40) to deform
compressor cover material around the noise attenuation device (20)
to secure it in the cover (14).
Inventors: |
SLATER; Simon; (Bradford,
West Yorks, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BORGWARNER INC. |
Auburn Hills |
MI |
US |
|
|
Family ID: |
53757715 |
Appl. No.: |
15/114199 |
Filed: |
January 29, 2015 |
PCT Filed: |
January 29, 2015 |
PCT NO: |
PCT/US2015/013463 |
371 Date: |
July 26, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61934057 |
Jan 31, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02M 35/10157 20130101;
F04D 29/663 20130101; Y02T 10/144 20130101; Y02T 10/12 20130101;
F04D 29/4206 20130101; F02M 35/10354 20130101; F04D 29/624
20130101; F02M 35/1211 20130101 |
International
Class: |
F04D 29/66 20060101
F04D029/66; F04D 29/62 20060101 F04D029/62; F04D 29/42 20060101
F04D029/42 |
Claims
1. A compressor housing (12) adapted for use with a turbocharger
having a noise attenuation device (20), the compressor housing (12)
comprising a first shoulder (24) in an air inlet section (16) of a
compressor cover (14) with the noise attenuation device (20) seated
on the first shoulder (24), and a second shoulder (26) in the
compressor cover (14) of a larger diameter that is deformed
securing the noise attenuation device (20) in the compressor cover
(14).
2. The compressor housing (12) of claim 1 wherein the noise
attenuation device (20) has a mounting face (30) that is seated on
the first shoulder (24).
3. The compressor housing (12) of claim 2 wherein the noise
attenuation device (20) is pressed steel.
4. The compressor housing (12) of claim 2, wherein the second
shoulder (26) includes localized deformations that engage the
mounting face (30).
5. A method of retaining a noise attenuation device (20) in a
compressor cover (14) having a first shoulder (24) and second
shoulder (26) at an air inlet section (16), adapted for use with a
turbocharger, comprising the steps of mounting the compressor cover
(14) with the air inlet section (16); placing the noise attenuation
device (20) against the first shoulder (24); applying a specific
impact load on the second shoulder (26) with a staking tool (40);
and deforming compressor cover material of the second shoulder (26)
around the noise attenuation device (20) with impact of the staking
tool (40) to secure the noise attenuation device (20) in place in
the compressor cover (14).
6. The method of claim 5 wherein the staking tool (40) is
vertically mounted.
7. The method of claim 5 wherein the step of placing the noise
attenuation device (20) on the first shoulder (24) includes placing
a mounting face (30) of the noise attenuation device (20) on the
first shoulder (24).
8. The method of claim 5, wherein the staking tool (40) includes
protruding indenters configured to provide regions of localized
deformation upon impact.
9. A method of retaining a noise attenuation device (20) in a
compressor cover (14) having a first shoulder (24) and second
shoulder (26) at an air inlet section (16) comprising the steps of
mounting the compressor cover (14) with the air inlet section 16
facing upwardly; dropping the noise attenuation device (20) in the
air inlet section (16) to rest on the first shoulder (24); applying
an impact load on the second shoulder (26) with a vertically
mounted staking tool (40); and deforming compressor cover material
of the second shoulder (26) around the noise attenuation device
(20) with impact of indenters (42) of the staking tool (40) to
secure the noise attenuation device (20) in place in the compressor
cover (14).
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and all the benefits of
U.S. Provisional Application No. 61/934,057, filed on Jan. 31,
2014, and entitled "Method of Retaining A Noise Attenuation Device
In A Compressor Cover," which is incorporated herein by
reference.
BACKGROUND
[0002] Field of the Disclosure
[0003] This disclosure relates to a method of retaining a noise
attenuation device in a compressor cover air inlet of a
turbocharger. More particularly, this disclosure relates to a
compressor housing, a method, and a device regarding using a
staking tool that deforms compressor cover material to retain the
noise attenuation device.
[0004] Description of Related Art
[0005] Advantages of turbocharging include increased power output,
lower fuel consumption and reduced pollutant emissions. The
turbocharging of engines is no longer primarily seen from a
high-power performance perspective, but is rather viewed as a means
of reducing fuel consumption and environmental pollution on account
of lower carbon dioxide (CO.sub.2) emissions. Currently, a primary
reason for turbocharging is using exhaust gas energy to reduce fuel
consumption and emissions. In turbocharged engines, combustion air
is pre-compressed before being supplied to the engine. The engine
aspirates the same volume of air-fuel mixture as a naturally
aspirated engine, but due to the higher pressure, thus higher
density, more air and fuel mass is supplied into a combustion
chamber in a controlled manner. Consequently, more fuel can be
burned, so that the engine's power output increases relative to the
speed and swept volume.
[0006] In exhaust gas turbocharging, some of the exhaust gas
energy, which would normally be wasted, is used to drive a turbine.
The turbine includes a turbine wheel that is mounted on a rotatable
shaft and is rotatably driven by exhaust gas flow. The turbocharger
returns some of this normally wasted exhaust gas energy back into
the engine, contributing to the engine's efficiency and saving
fuel. A compressor, which is driven by the turbine, draws in
filtered ambient air, compresses it, and then supplies it to the
engine. The compressor includes a compressor impeller that is
mounted on the same rotatable shaft so that rotation of the turbine
wheel causes rotation of the compressor impeller.
[0007] Turbochargers typically include a turbine housing connected
to the engine's exhaust manifold, a compressor housing connected to
the engine's intake manifold, and a bearing housing coupling the
turbine and compressor housings together.
[0008] This disclosure focuses on the compressor end of a
turbocharger. The compressor is designed to help increase the
pressure and density of air in the engine air intake manifold to
allow the engine cylinders to ingest a greater mass of air during
each intake stroke. The compressor includes a tubular air inlet
that allows airflow to the compressor wheel. Usually, the inner
wall of the inlet is tapered, which may be molded as an integral
inner wall or provided as a wall of an insert in the inlet.
[0009] An annular baffle is one type of insert. UK Patent 2,256,460
shows an example with a portion of the inlet defined by an annular
baffle mounted on the compressor housing. The frustoconical baffle
may be mounted by fixing screws or bolts, by press fitting into the
housing or by snap fitting engagement. Noise can be reduced due to
changes in the direction of the path of the airstream. This baffle
attenuates noise.
SUMMARY
[0010] This disclosure relates to a method of retaining a noise
attenuation device in a compressor cover air inlet diameter of a
turbocharger. A method and a device include using a staking tool
that deforms compressor cover material, such as metal, to retain a
noise attenuation device.
[0011] The staking tool and an impact pedestal (press) can deform
the compressor cover material (i.e. metal) around the noise
attenuation device and secure the noise attenuation device in
place. The staking tool includes indenters extending from an
end.
[0012] A compressor housing with a secured noise attenuation device
may have a first shoulder in an air inlet section of a compressor
cover with the noise attenuation device seated on the first
shoulder and a second shoulder in the compressor cover of a larger
diameter than the first shoulder that is deformed to secure the
noise attenuation device in the compressor cover.
[0013] A method of retaining a noise attenuation device in a
compressor cover having a first shoulder and second shoulder at an
air inlet section may include the steps of mounting the compressor
cover, with the air inlet section preferably facing upwardly;
placing or dropping the noise attenuation device into the air inlet
section against the first shoulder; applying an impact load with a
staking tool; and deforming compressor cover material of the second
shoulder around the noise attenuation device with impact of
indenters of the staking tool securing the noise attenuation device
in place in the compressor cover.
[0014] This method of retaining a noise attenuation device to a
compressor cover negates the use of additional operations, such as
machining screw threads, drilling and pinning, and applying
adhesive, which are all current methods of retaining noise
attenuation devices.
[0015] Advantages of retaining a noise attenuation device with a
staking tool to deform compressor cover material include simplicity
of design, less machining, speed of assembly, fewer parts, and no
cure time for adhesives. Parts cannot work loose, and there are
fewer parts that can vibrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Advantages of the present disclosure will be readily
appreciated as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0017] FIG. 1 is a perspective view of a noise attenuation device
secured in a compressor cover of a compressor housing of a
turbocharger;
[0018] FIG. 2 is a perspective view of a noise attenuation
device;
[0019] FIG. 3 is a cross section of the perspective view of the
noise attenuation device of FIG. 2;
[0020] FIG. 4 shows cross-sectional view of a compressor cover with
two shoulders;
[0021] FIG. 5 shows an expanded side view of a staking tool moving
toward a noise attenuation device to be seated in a compressor
cover on a compressor housing;
[0022] FIG. 6 is a cross-sectional view of a portion of a noise
attenuation device moving toward a compressor cover of a compressor
housing;
[0023] FIG. 7 is a cross-sectional view of a mounting face of a
noise attenuation device seated on a shoulder of compressor
cover;
[0024] FIG. 8 is a perspective view of a staking tool with an
indenter moving toward a noise attenuation device seated on a
shoulder;
[0025] FIG. 9 shows a cross-sectional view of an indenter of a
staking tool being pressed into a shoulder adjacent to a noise
attenuation device;
[0026] FIG. 10 is a cross-sectional view of the deformation of the
compressor cover securing the noise attenuation device;
[0027] FIG. 11 shows a perspective view of staking tool with
indenters; and
[0028] FIG. 12 shows a perspective view of an indenter on the
staking tool.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] A turbocharger is generally known and includes a turbine and
a compressor, wherein a compressor impeller is rotatably driven via
a rotatable shaft by a turbine wheel. The rotatable shaft is
supported in a bearing housing between a turbine housing connected
to an engine's exhaust manifold and a compressor housing 12
connected to the engine's intake manifold.
[0030] The term compressor housing 12, as generally understood and
used herein, broadly means the component that houses the compressor
impeller and includes the compressor cover 14 with an air inlet
section 16. FIG. 1 shows a noise attenuation device 20 secured in a
compressor cover 14 of a compressor housing 12. FIG. 4 shows a
compressor cover 14 with a hollow, cylindrical air inlet section 16
at the outermost portion of the cover 14 where air flows in. As
shown in FIGS. 4 and 6 through 10, the air inlet section 16 has an
outer wall 22 with a first shoulder 24 and a second shoulder 26
formed on an inner surface of the outer wall 22.
[0031] The compressor housing 12 has a compressor cover 14 with the
first shoulder 24 as an inner diameter of the air inlet section 16
of the outer wall 22 where the noise attenuation device 20 is
seated and the second shoulder 26 in the compressor cover 14 of a
larger diameter that is deformed to secure the noise attenuation
device 20 in the compressor cover 14. The second shoulder is
located axially outward (e.g., further away from the compressor
wheel) relative to the first shoulder 24. The noise attenuation
device 20 has an annular mounting face 30 that seats on the first
shoulder 24. When the second shoulder 26 is deformed, the mounting
face 30 is contacted and engaged by the deformed portions of the
second shoulder 26. The noise attenuation device 20 is preferably
pressed steel that tapers inward or funnels inward from the
mounting face 30 to complement the inner wall 32 of the compressor
cover 14.
[0032] A method of retaining a noise attenuation device 20 in a
compressor cover air inlet diameter of a turbocharger includes
using a staking tool 40 (FIGS. 11 and 12) that deforms compressor
cover material (i.e. metal) to retain the noise attenuation device
20 within the air inlet 16. The noise attenuation device 20 is
preferably a simple pressed steel design having mounting face 30 as
shown in FIGS. 2 and 3, which can locate on a complementary
compressor cover shoulder 24 as shown in FIG. 7.
[0033] The compressor cover 14 has the first shoulder 24 that
locates the noise attenuation device 20 (a loose tolerance is
initially acceptable) and the second shoulder 26 that forms a
diameter as a shelf for the indenters 42 of the staking tool 40 to
locate and press. These shoulders 24 and 26 are preferably machined
as inner diameters of the air inlet 16 as part of the outer wall 22
of the compressor cover 14. No other special machining of the
compressor cover 14 is required to retain the noise attenuation
device 20.
[0034] The staking tool 40 and an impactor (i.e. pedestal and/or
press) can cause deformation of the compressor cover material
around the noise attenuation device 20 and secure the noise
attenuation device 20 in place. As shown in FIGS. 11 and 12, the
staking tool 40 may be a hardened steel cylindrical tube with
axially-protruding indenters 42 located at one end of the tube
around the diameter of the tube. The indenters 42 can vary in
number, shape, and pitch, wherein more indenters 42 are preferred
for a larger diameter. In the illustrated embodiment, eight
indenters 42 are equidistantly spaced around the circumference of
the tube end. The indenters 42 are shaped to obtain the correct
geometry in the compressor cover 14. For example, each indenter 42
has an outer surface 42a that forms an extension of the tube outer
surface, and a concavely curved inner surface 42b. The indenter
outer surface 42a and inner surface 42b intersect at a line edge
42c.
[0035] The staking tool 40 is preferably mounted vertically on a
support shaft mechanism, such as a spindle. The spindle can be
connected to a pedestal-type impactor, such as a lever operated,
spring-loaded device for applying a specific impact load to the
staking tool 40. Easy placement of the compressor cover 14 and the
noise attenuation device 20 into the compressor cover 14 and then
operating a lever, manually or automated, to actuate the staking
tool 40 allow for speedy assembly.
[0036] FIG. 5 shows the staking tool 40 moving toward a noise
attenuation device 20 to be seated and retained in a compressor
cover 14 of a compressor housing 12. The staking process preferably
includes mounting the compressor cover 14 with the air inlet
section 16 facing upwardly so the noise attenuation device 20 can
be simply dropped into the air inlet section 16.
[0037] FIG. 6 shows a portion of a noise attenuation device 20
being moved toward a first shoulder 24 of a compressor cover 14.
The noise attenuation device 20 can be placed adjacent to the first
shoulder 24 for assembly, such as by dropping the noise attenuation
device 20 into place on the first shoulder 24 of the compressor
cover 14 in the air inlet section 16, which is preferably facing
upwardly as shown in FIGS. 5 through 10.
[0038] FIG. 7 shows a mounting face 30 of a noise attenuation
device 20 being seated on a first shoulder 24 of compressor cover
14. The staking tool 40 moves toward the second shoulder 26 with
the seated noise attenuation device 20 as shown in FIG. 8. The
indenters 42 align with the second shoulder 26.
[0039] FIG. 9 shows an indenter 42 of a staking tool 40 being
pressed into the second shoulder 26 adjacent to a noise attenuation
device 20. The impact on the staking tool 40 forces the indenters
42 into the compressor cover material, and the staking tool 40
locally deforms the compressor cover material in a radially inward
direction. The deformed material engages the mounting surface 30 to
secure the noise attenuation device 20 in place in the compressor
cover air inlet diameter.
[0040] FIG. 10 shows the resulting deformation of the compressor
cover 14 at the second shoulder 26 securing the noise attenuation
device 20 to the outer wall 22 of the compressor cover 14.
[0041] Minimal load is applied on the noise attenuation device 20
away from the indenters 42 with this method of retention. When the
material of the compressor cover 14 is deformed by the staking tool
40, the noise attenuation device 20 is securely fixed to the
compressor cover 14 as only two parts without need for other
operations, such as using adhesives.
[0042] The invention has been described in an illustrative manner,
and it is to be understood that the terminology used is intended to
be in the nature of words of description rather than limitation.
Many modifications and variations of the present invention are
possible in light of the above teachings. It is, therefore, to be
understood that within the scope of the appended claims, the
invention may be practiced other than as specifically
described.
* * * * *