U.S. patent application number 14/858223 was filed with the patent office on 2017-03-23 for geometry for increasing torque capacity of riveted vane lever.
The applicant listed for this patent is BorgWarner Inc.. Invention is credited to Eli Morgan, Greg Williams, JOHN ZAGONE.
Application Number | 20170081975 14/858223 |
Document ID | / |
Family ID | 56979680 |
Filed Date | 2017-03-23 |
United States Patent
Application |
20170081975 |
Kind Code |
A1 |
ZAGONE; JOHN ; et
al. |
March 23, 2017 |
GEOMETRY FOR INCREASING TORQUE CAPACITY OF RIVETED VANE LEVER
Abstract
A number of variations may include a product comprising: a vane
lever comprising a first end; a second end; a top surface; and a
bottom surface; and an opening defined by an inner surface which
extends through the top surface and the bottom surface of the
second end, and wherein at least a portion of the inner surface
comprises a non-cylindrical, multi-lobed shape.
Inventors: |
ZAGONE; JOHN;
(Hendersonville, NC) ; Morgan; Eli; (Leicester,
NC) ; Williams; Greg; (Arden, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BorgWarner Inc. |
Auburn Hills |
MI |
US |
|
|
Family ID: |
56979680 |
Appl. No.: |
14/858223 |
Filed: |
September 18, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02C 9/20 20130101; F01D
17/16 20130101; F01D 9/041 20130101; F02C 6/12 20130101; F05D
2220/40 20130101; F05D 2230/60 20130101; F01D 17/165 20130101; F05D
2240/12 20130101 |
International
Class: |
F01D 17/16 20060101
F01D017/16; F01D 9/04 20060101 F01D009/04 |
Claims
1. A product comprising: a vane lever comprising a first end; a
second end; a top surface; and a bottom surface; and an opening
which extends through the top surface and the bottom surface of the
second end, wherein the opening is defined by an inner surface and
at least one intervening surface between the inner surface and the
top surface, wherein at least a portion of the opening comprises a
non-cylindrical, multi-lobed shape; and wherein the intervening
surface extends between the top surface and the inner wall at each
of the lobes only.
2. (canceled)
3. (canceled)
4. The product of claim 1 wherein the intervening surface is at
least one of rounded, chamfered, grooved, or a plurality of
ridges.
5. The product of claim 1 further comprising a vane component,
wherein the vane component comprises a vane rotatably mounted to a
vane shaft, wherein the vane shaft includes a stepped portion; and
wherein the stepped portion extends through the non-cylindrical,
multi-lobed opening of the vane lever and is attached to the vane
lever.
6. The product of claim 5 wherein the stepped portion is
cylindrical.
7. The product of claim 5 wherein the stepped portion is
non-cylindrical.
8. The product of claim 5 wherein the vane shaft is riveted to the
vane lever.
9. A vane pack assembly comprising: an upper vane ring; a lower
vane ring; a plurality of vane components each having a vane shaft
and a vane interposed between the upper vane ring and the lower
vane ring; an adjustment ring surrounding a portion of the upper
vane ring having a plurality of openings; and a plurality of vane
levers each having a non-cylindrical, multi-lobed opening which
extends between a top surface and a bottom surface at a second end
of the vane lever, wherein the non-cylindrical, multi-lobed opening
is defined by an inner surface and at least one intervening surface
between the inner surface and the top surface of the vane lever,
wherein the non-cylindrical, multi-lobed opening surrounds a
portion of the vane shaft and wherein a first end of the vane lever
attaches to the adjustment ring; and wherein a portion of the vane
shaft is riveted to the vane lever and conforms to an entire shape
of the non-cylindrical, multi-lobed opening.
10. (canceled)
11. The vane pack assembly of claim 9 wherein the non-cylindrical,
multi-lobed opening is at least one of a diamond shape, a square
shape, a triangular shape, or other polygon shape.
12. The vane pack assembly of claim 9 wherein the intervening
surface extends between an entire area between the top surface and
the inner surface and is at least one of rounded, chamfered,
ridged, or grooved.
13. The vane pack assembly of claim 9 wherein the intervening
surface extends between the inner surface and the top surface at
each of the lobes only.
14. The vane pack assembly of claim 9 wherein the intervening
surface is a plurality of ridges.
15. The vane pack assembly of claim 9 where the vane shaft includes
a stepped portion which is constructed and arranged to extend
within the vane lever opening.
16. The vane pack assembly of claim 15 wherein the stepped portion
is cylindrical.
17. The vane pack assembly of claim 15 wherein the stepped portion
is non-cylindrical.
18. A method of joining a vane lever and a vane shaft of a vane
pack assembly together comprising: providing a vane lever having a
non-cylindrical, multi-lobed opening defined by an inner surface,
wherein a top edge of the inner surface is at least one of rounded
or grooved; fitting the vane lever onto a vane shaft; and riveting
the vane shaft to the vane lever causing the vane shaft to conform
to the top edge of the inner surface when riveted.
19. The method of claim 18 wherein the vane shaft further comprises
a stepped portion having a non-cylindrical multi-lobed shape to
match the non-cylindrical, multi-lobed opening for orienting the
vane lever during assembly.
20. (canceled)
21. A product comprising: a vane lever comprising a first end; a
second end; a top surface; and a bottom surface; and an opening
which extends through the top surface and the bottom surface of the
second end, wherein the opening is defined by an inner surface and
at least one intervening surface between the inner surface and the
top surface, wherein at least a portion of the opening comprises a
non-cylindrical, multi-lobed shape; and wherein the opening
transitions from a cylindrical shape at the bottom surface to the
non-cylindrical, multi-lobed shape at the top surface.
Description
TECHNICAL FIELD
[0001] The field to which the disclosure generally relates to
includes vane levers and vane shafts for a turbine.
BACKGROUND
[0002] A turbocharger may include variable turbine geometry using
vanes in front of a turbine wheel.
SUMMARY OF ILLUSTRATIVE VARIATIONS
[0003] A number of variations may include a product comprising: a
vane lever comprising a first end; a second end; a top surface; and
a bottom surface; and an opening defined by an inner surface which
extends through the top surface and the bottom surface of the
second end, and wherein at least a portion of the inner surface
comprises a non-cylindrical, multi-lobed shape.
[0004] A number of variations may include a vane pack assembly
comprising: an upper vane ring; a lower vane ring; a plurality of
vane components each having a vane shaft and a vane interposed
between the upper vane ring and the lower vane ring; an adjustment
ring surrounding a portion of the upper vane ring having a
plurality of openings; and a plurality of vane levers each having a
non-cylindrical, multi-lobed opening defined by an inner surface at
a second end of the vane lever, wherein the non-cylindrical,
multi-lobed opening surrounds a portion of the vane shaft and
wherein the first end of the vane lever attaches to the adjustment
ring.
[0005] A number of variations may include a method of joining a
vane lever and a vane shaft of a vane pack assembly together
comprising: providing a vane lever having a non-cylindrical,
multi-lobed opening defined by an inner surface; fitting the vane
lever onto a vane shaft; and riveting the vane shaft to the vane
lever.
[0006] Other illustrative variations within the scope of the
invention will become apparent from the detailed description
provided hereinafter. It should be understood that the detailed
description and specific examples, while disclosing variations
within the scope of the invention, are intended for purposes of
illustration only and are not intended to limit the scope of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Select examples of variations within the scope of the
invention will become more fully understood from the detailed
description and the accompanying drawings, wherein:
[0008] FIG. 1 illustrates a perspective view of a vane lever
according to a number of variations.
[0009] FIG. 2 illustrates a perspective view of a vane lever
according to a number of variations.
[0010] FIG. 3 illustrates a top view of a vane lever according to a
number of variations.
[0011] FIG. 4 illustrates a perspective view of a vane lever
according to a number of variations.
[0012] FIG. 5 illustrates a top view of a vane lever according to a
number of variations.
[0013] FIG. 6 illustrates a perspective view of a vane lever
according to a number of variations.
[0014] FIG. 7 illustrates a perspective view of vane lever
according to a number of variations.
[0015] FIG. 8 illustrated a perspective bottom view of a vane lever
according to a number of variations.
[0016] FIG. 9 illustrates a perspective view of a vane lever
according to a number of variations.
[0017] FIG. 10 illustrates a perspective view of a vane component
according to a number of variations.
[0018] FIG. 11 illustrates a perspective view of a vane component
according to a number of variations.
[0019] FIG. 12 illustrates a top view of a vane lever positioned
onto a vane shaft according to a number of variations.
[0020] FIG. 13 illustrates an exploded view of a vane pack assembly
according to a number of variations.
[0021] FIG. 14 illustrates a perspective view of a vane pack
according to a number of variations.
[0022] FIG. 15 illustrates a close-up perspective view of a vane
pack assembly according to a number of variations.
[0023] FIG. 16 illustrates a close-up perspective view of a vane
pack assembly according to a number of variations.
[0024] FIG. 17 illustrates a close-up perspective view of a vane
pack assembly according to a number of variations.
[0025] FIG. 18 illustrates a close-up perspective view of a vane
pack assembly according to a number of variations.
[0026] FIG. 19 illustrates a section view of a vane pack assembly
according to a number of variations.
[0027] FIG. 20 illustrates a perspective view of a vane component
according to a number of variations.
[0028] FIG. 21 illustrates a perspective view of a vane component
according to a number of variations.
DETAILED DESCRIPTION OF ILLUSTRATIVE VARIATIONS
[0029] The following description of the variations is merely
illustrative in nature and is in no way intended to limit the scope
of the invention, its application, or uses.
[0030] A variable turbine geometry (VTG) turbocharger may be used
to expand the usable flow rate range of an engine while at the same
time maintaining a high level of efficiency. A VTG turbocharger may
regulate the turbine output by changing the inflow angle and the
inflow speed at the turbine inlet. The change in the inflow angle
and inflow speed at the turbine inlet may be done using a vane pack
assembly 30, a variation of which is illustrated in FIG. 14. As
temperatures and aero loads of the VTG turbocharger are increased,
the torque transfer capability through the vane levers 32 and the
vane shafts 64 of the vane pack assembly 30 may need to be
increased. In a number of variations, a cylindrical (or
non-cylindrical) vane shaft and non-circular, multi-lobed lever
opening may be joined together using a riveting process which may
form a high torque capacity joint which may withstand the
temperatures and aero loads of the VTG turbocharger, as will be
discussed below.
[0031] Referring to FIGS. 1-9, in a number of variations, a vane
lever 32 may include a first end 34, a second end 36, a top surface
38, and a bottom surface 40. The vane lever 32 may also include an
opening 44 which may extend through the top surface 38 and the
bottom surface 40 at the second end 36 of the vane lever 32, and
which may be defined by an inner surface 52 of the vane lever 32.
The inner surface 52 may be constructed and arranged to accommodate
a portion of the outer perimeter of the vane shaft 64. The vane
lever opening 44 may be any number of non-cylindrical multi-lobed
shapes. In one variation, the vane lever opening 44 may include a
four sided multi-lobe interface 46 including, but not limited to, a
diamond-like or square shape, through the entire interface from the
top surface 38 to the bottom surface 40, a variation of which is
illustrated in FIG. 1. In another variation, the vane lever opening
44 may be a three sided multi-lobe interface 48 including, but not
limited to, a triangular or trilobe shape, through the entire
interface from the top surface 38 to the bottom surface 40, a
variation of which is illustrated in FIG. 2. In a number of
variations, the vane lever opening 44 may transition from
cylindrical 49 at the bottom surface 40 to non-cylindrical shapes
46, 48 described above and hereafter at the top surface 38,
variations of which are illustrated in FIGS. 3-7 and 9. In one
variation, the vane lever opening 44 may include a four sided
multi-lobe interface 46 at the top surface 38, transitioning to a
circular interface 49 at the bottom surface 40, variations of which
are illustrated in FIGS. 3, 4, and 9. In another variation, the
vane lever opening 44 may include a three sided multi-lobe
interface 48 on the top surface 38, transitioning to a circular
interface 49 at the bottom surface 40, variations of which are
illustrated in FIGS. 5 and 6. In another variation, the vane lever
opening 44 may include a knurled four sided multi-lobe interface 46
at the top surface 38, transitioning to a circular interface 49 at
the bottom surface 40, a variation of which is illustrated in FIG.
7. In one variation, the top edge 50 of the inner surface 52 may be
rounded or chamfered 54, variations of which are illustrated in
FIGS. 1-2. In another variation, the top edge 50 of the inner
surface 52 may include a groove 56 at each of the lobes 58,
variations of which are illustrated in FIGS. 3-6 and 9. In yet
another variation, the top edge 50 of the inner surface 52 may
include a plurality of ridges or grooves 60 which may extend around
the perimeter of the top edge 50, a variation of which is
illustrated in FIG. 7. Referring to FIG. 8, in a number of
variations, the bottom edge 51 of the inner surface 52 may also be
rounded or may include a chamfer.
[0032] Referring to FIGS. 1-8, in one variation, the vane lever 32
may also include a tab 42 which may extend downward from the first
end 34 and may be constructed and arranged to mate with an
opening/cutout 90 in an adjustment ring 88, as will be discussed
hereafter. In a number of variations, the tab 42 may include a
cutout or grooved surface 43, a variation of which is illustrated
in FIG. 8. The bottom surface 40 may include a standoff 100 which
may be located between the first end 34 and the second end 36, a
variation of which is also illustrated in FIG. 8. The standoff 100
may be constructed and arranged so that it may sit on the top
surface 89 of the adjustment ring 88, variations of which are
illustrated in FIGS. 15 and 19.
[0033] Referring to FIG. 9, in another variation, the first end 34
of the vane lever 32 may be constructed and arranged as a fork end
91 having a first and second protrusion 93. The fork end 91 of the
vane lever 32 may be constructed and arranged to attach to an
adjustment ring 88, as will be discussed hereafter.
[0034] It is noted that any number of vane lever configurations may
include any of the above vane lever opening 44 configurations
without departing from the spirit and scope of the invention.
[0035] Referring to FIGS. 10-11, in a number of variations, a vane
component 62 may include a vane 66 and a vane shaft 64. Any number
of vane 66 configurations may be used. The vane shaft 64 may extend
through the vane 66 so that the vane 66 may rotate around the vane
shaft 64. A first portion 68 of the vane shaft 64 may be
constructed and arranged to extend within an opening 81 in a lower
vane ring 80, as will be discussed hereafter. A second portion 70
of the vane shaft 64 may be constructed and arranged to extend
through an opening 83 in an upper vane ring 82, as will be
discussed hereafter. In a number of variations, the vane shaft 64
may be cylindrical and may include a shouldered step 72 which may
be constructed and arranged to fit within the vane lever opening
44, as will be discussed hereafter. In one variation, the
shouldered step 72 may be cylindrical 74, a variation of which is
illustrated in FIG. 10, and may be subsequently deformed to conform
to a non-circular vane lever opening 44 interface, variations of
which are illustrated in FIGS. 20-21. In another variation, the
shouldered step 72 may be non-cylindrical 76 to mate with the
non-cylindrical shape of the vane lever opening 44, a variation of
which is illustrated in FIG. 11, and may be subsequently deformed
to conform to the non-circular lever interface.
[0036] Referring to FIGS. 13-14, in a number of variations, a
plurality of vane components 62 may be spaced circumferentially
between the lower vane ring 80 and the upper vane ring 82 so that
the vanes 66 are positioned between the lower vane ring 80 and the
upper vane ring 82 and so that the shouldered step 72 extends above
the upper vane ring 82. In a number of variations, the upper vane
ring 82 may include a stepped portion 84 which may extend around
the outer perimeter 86 of the upper vane ring 82 and may be
constructed and arranged to accommodate a portion of an adjustment
ring 88.
[0037] Referring to FIGS. 15-17, in a number of variations, the
first end 34 of the vane lever 32 may be attached to the adjustment
ring 88. In one variation, the adjustment ring 88 may include a
plurality of cutouts/openings 90 which may be constructed and
arranged to accommodate a tab 42 on the vane lever 32, a variation
of which is illustrated in FIG. 15, or a block 102 which may be
located within the cutout/opening 90 and which may be constructed
and arranged to accommodate the tab 42, a variation of which is
illustrated in FIG. 17, which may secure the adjustment ring 88 to
the upper vane ring 82. In this variation, the vane levers 32 may
be positioned onto the vane shafts 64 so that the vane shaft 64
extends through the vane lever openings 44 and so that the lever
tabs 42 extend through the cutouts/openings 90 (or blocks 102) on
the adjustment ring 88, variations of which are illustrated in
FIGS. 15 and 17. In another variation, a vane lever 32 having a
fork end 91 may be positioned between the adjustment ring 88 and
the upper vane ring 82 so that the first and second protrusions 93
surround a pin 104 which may be riveted or welded to the adjustment
ring 88 to attach the vane lever 32 to the adjustment ring 88, a
variation of which is illustrated in FIG. 16. In another variation,
a combination of pins and rotating blocks may be used to secure the
vane lever 32 to the adjustment ring 88. It is noted that any
number of attachment methods between the vane lever 32 and the
adjustment ring 88 may be used.
[0038] In one variation, a press-fit may be used for accurate
positioning if desired, a variation of which is illustrated in FIG.
12. Press-fitting the vane lever 32 onto the vane shaft 64 may
cause irregular radial material deformation at the top edge 50 of
the inner surface 52 which may further increase torque capacity
before riveting. In a number of variations, external fixturing may
be used to accomplish vane lever 32 to vane shaft 64 orientation
for assemblies using vane shafts 64 having a cylindrical 74
shouldered step 72. In another variation, vane lever 32 to vane
shaft 64 orientation may be accomplished using similar
non-cylindrical shapes 46, 76 on the inner surface 52 and the
shouldered step 72 of the vane shaft 64, variations of which are
illustrated in FIGS. 1 and 11.
[0039] Referring to FIGS. 18-21, in a number of variations, the
vane shafts 64 may be riveted 92 to the vane levers 32 to secure
the vane shafts 64 in place. The riveting of the vane shafts 64 may
cause the material of the vane shaft 64 to form into the shape of
the inner surface 52 so that the vane shaft 64 contours the shape
of the inner surface 52, variations of which are illustrated in
FIGS. 20 and 21. The interface between the non-cylindrical inner
surface 52 and the dilated vane shaft 78 material may provide
additional grip between the vane lever 32 and the vane shaft 64
which may increase the torque capacity of the joint.
[0040] Any number of combinations of the above geometries and
differing edge conditions at the top of the rivet interface may be
used to accommodate the riveting process. It is noted that more
irregular or aggressive geometries may be used with advanced
riveting processes capable of exaggerated deformations of the vane
shaft material.
[0041] The following description of variants is only illustrative
of components, elements, acts, products and methods considered to
be within the scope of the invention and are not in any way
intended to limit such scope by what is specifically disclosed or
not expressly set forth. The components, elements, acts, products
and methods as described herein may be combined and rearranged
other than as expressly described herein and still are considered
to be within the scope of the invention.
[0042] Variation 1 may include a product comprising: a vane lever
comprising a first end; a second end; a top surface; and a bottom
surface; and an opening defined by an inner surface which extends
through the top surface and the bottom surface of the second end,
and wherein at least a portion of the inner surface comprises a
non-cylindrical, multi-lobed shape.
[0043] Variation 2 may include a product as set forth in Variation
1 wherein the inner surface transitions from a cylindrical shape at
the bottom surface to the non-cylindrical, multi-lobed shape at the
top surface.
[0044] Variation 3 may include a product as set forth in Variation
1 wherein a top edge of the inner surface is at least one of
rounded or includes a groove at each of the lobes
[0045] Variation 4 may include a product as set forth in Variation
1 wherein a top edge of the inner surface includes a plurality of
ridges.
[0046] Variation 5 may include a product as set forth in any of
Variations 1-4 further comprising a vane component, wherein the
vane component comprises a vane rotatably mounted to a vane shaft,
wherein the vane shaft includes a stepped portion; and wherein the
stepped portion extends through the non-cylindrical, multi-lobed
opening of the vane lever and is attached to the vane lever.
[0047] Variation 6 may include a product as set forth in Variation
5 wherein the stepped portion is cylindrical.
[0048] Variation 7 may include a product as set forth in Variation
5 wherein the stepped portion is non-cylindrical.
[0049] Variation 8 may include a product as set forth in any of
Variations 5-7 wherein the vane shaft is riveted to the vane
lever.
[0050] Variation 9 may include a vane pack assembly comprising: an
upper vane ring; a lower vane ring; a plurality of vane components
each having a vane shaft and a vane interposed between the upper
vane ring and the lower vane ring; an adjustment ring surrounding a
portion of the upper vane ring having a plurality of openings; and
a plurality of vane levers each having a non-cylindrical,
multi-lobed opening defined by an inner surface at a second end of
the vane lever, wherein the non-cylindrical, multi-lobed opening
surrounds a portion of the vane shaft and wherein the first end of
the vane lever attaches to the adjustment ring.
[0051] Variation 10 may include a vane pack assembly as set forth
in Variation 9 wherein a portion of the vane shaft is riveted to
the vane lever and conforms to the shape of the inner surface.
[0052] Variation 11 may include a vane pack assembly as set forth
in any of Variations 9-10 wherein the non-cylindrical, multi-lobed
opening is at least one of a diamond shape, a square shape, a
triangular shape, or other polygon shape.
[0053] Variation 12 may include a vane pack assembly as set forth
in any of Variations 9-11 wherein the inner surface has at least
one of a rounded or a chamfered top edge.
[0054] Variation 13 may include a vane pack assembly as set forth
in any of Variations 9-11 wherein the inner surface includes a top
edge having a groove at each lobe.
[0055] Variation 14 may include a vane pack assembly as set forth
in any of Variations 9-11 wherein the inner surface includes a top
edge having a plurality of ridges.
[0056] Variation 15 may include a vane pack assembly as set forth
in any of Variations 9-14 where the vane shaft includes a stepped
portion which is constructed and arranged to extend within the vane
lever opening.
[0057] Variation 16 may include a vane pack assembly as set forth
in Variation 15 wherein the stepped portion is cylindrical.
[0058] Variation 17 may include a vane pack assembly as set forth
in Variation 15 wherein the stepped portion is non-cylindrical.
[0059] Variation 18 may include a method of joining a vane lever
and a vane shaft of a vane pack assembly together comprising:
providing a vane lever having a non-cylindrical, multi-lobed
opening defined by an inner surface; fitting the vane lever onto a
vane shaft; and riveting the vane shaft to the vane lever.
[0060] Variation 19 may include a method as set forth in Variation
18 wherein the vane shaft further comprises a stepped portion
having a non-cylindrical multi-lobed shape to match the
non-cylindrical, multi-lobed opening for orienting the vane lever
during assembly.
[0061] Variation 20 may include a method as set forth in any of
Variations 18-19 wherein a top edge of the inner surface is at
least one of rounded or grooved causing the vane shaft to conform
to the shape of the inner surface when riveted.
[0062] The above description of select variations within the scope
of the invention is merely illustrative in nature and, thus,
variations or variants thereof are not to be regarded as a
departure from the spirit and scope of the invention.
* * * * *