Abstract:
By relieving the shaft of an electronically-controlled turbocharger (ECT) in a central region of where a rotor of an electric machine couples with the shaft eases assembly of the electric machine onto the shaft. On either side of the relieved section, the fit between the shaft and the rotor may be a slip fit or an interference fit. Alternatively, the rotor is relieved in a central section. In some embodiments, the shaft is welded to the rotor. In yet other embodiments, the outside of the shaft and the inside of the rotor are threaded with a nut or a pin to secure the shaft to the rotor or the rotor itself has threads to engage with threads on the shaft. Such arrangements ease assembly and allow adjustment of dynamic characteristics of the rotor system.

Description:
FIELD 
       [0001]    The present disclosure relates to fitting a rotor of an electric motor onto a shaft of a turbomachine. 
       BACKGROUND 
       [0002]    The tightness of the fit between a shaft of an electronically-controlled turbocharger (ECT) and a rotor of the electric motor has competing demands. The fit should be tight enough that there is no relative motion between the two at the most demanding operating conditions anticipated. That is, operating conditions in which the torques applied to the shaft and rotor act to present the highest difference in torque urging them to rotate separately and elevated temperature conditions that can affect the fit by unequal thermal expansion. The fit must also resist separation at high rotational speeds due to centrifugal forces acting on the masses causing expansion as well as maintain connection over the entire operating range including extreme cold and hot conditions which can cause unequal thermal expansion. The fit should not be so tight such that stresses set up in the mated parts develop cracks. Furthermore, the fit should be as easy to assemble as possible. In some cases, it may be found useful to heat the rotor or to cool the shaft to facilitate assembly of an interference fit. If such thermal preparation can be avoided or the error rate of the assembly can be reduced, assembly cost is reduced. In prior ECTs, the rotor is fit over the shaft with a slip fit or an interference fit along the majority of the length over which the two are mated. In both the slip and interference fits the inside diameter of the rotor substantially equals the outside diameter of the shaft. With the former, there is a slight clearance and in the latter, there is a slight overlap meaning that the shaft diameter exceeds the rotor inside diameter so that when mated there is an interference. One of the problems of such a large surface area of engagement is that if there is any imperfection in the surface finish or concentricity, the two may become stuck at an intermediate position, i.e., not fully assembled. In addition, due to the minute tolerance ranges used for turbomachinery, cylindricity and roundness further complicate the fit. In the event of deviation in any of the above-described factors, the shaft and the rotor are non compliant. 
       SUMMARY 
       [0003]    To overcome at least one problem identified in the prior art, an electronically-controlled turbomachine is disclosed that includes a shaft having a turbine wheel coupled to a first end of the shaft, a turbine housing section disposed over the turbine wheel, a compressor wheel secured to a second end of the shaft, a compressor housing section disposed over the compressor wheel, and an electric machine disposed on the shaft. The rotor is located between the turbine and the compressor sections. The electric machine comprises a rotor and a stator. The rotor is fixed onto a portion of the shaft. The portion of the shaft has first, second, and third axial sections. The inside diameter of the rotor is greater than the diameter of the second axial section. The second axial section is located between the first and third axial sections. 
         [0004]    In some embodiments, the inside diameter of the rotor is substantially equal to an outside diameter of the shaft along the first and third axial sections. Alternatively, the inside diameter of the rotor is slightly smaller than an outside diameter of the shaft along the third axial section so that an interference fit is formed along the third axial section and the third axial section is located closer to the turbine wheel than the first and second axial sections. In some embodiments, the inside diameter of the rotor is substantially equal to the outside diameter of the shaft along the first axial section. In the present disclosure, a slip fit is a fit in which inside diameter of the rotor is substantially equal to the outside diameter of the shaft but with a minimal clearance between the two. The two parts are engaged by hand or with a modest amount of pressure. In an interference fit the two diameters are substantially equal but with the inside diameter of the rotor slightly smaller than the outside diameter of the shaft. Furthermore, in the present disclosure, the term interference fit is also used to refer to what might be called an expansion fit and a shrink fit, e.g., when the rotor is heated to fit over the shaft and/or the shaft is cooled to allow insertion into the rotor. When the two parts come to the same temperature, the interference occurs. 
         [0005]    In one embodiment, an end of the rotor proximate the first axial section of the shaft is welded to the shaft. The weld is by one of electron beam, laser, and tungsten inert gas welding. Alternatively, the shaft and the rotor are ultrasonically or friction welded. 
         [0006]    The weld may be located along the interface between the shaft and the rotor in one or both of the first and third axial sections. In another embodiment, the shaft has a fourth axial section located between the third axial section and the turbine wheel. The fourth axial section includes a surface extending outwardly in a substantially radial direction which mates with a surface of the rotor that extends in a substantially radial direction. The mating surfaces are friction welded. 
         [0007]    In one embodiment, the shaft has a threaded axial section between the rotor and the compressor axial section. A nut engages with the threads on the shaft to cause the rotor to abut against the stop. 
         [0008]    In yet another alternative, the shaft is threaded for at least a fraction of the length of the first portion. 
         [0009]    The inside diameter of the rotor is substantially uniform along the length of the rotor and the shaft of the turbomachine is cutback along the second axial section. Alternatively, the rotor is cutback along the length that mates with the second axial section of the shaft. 
         [0010]    The shaft may include a stop section that is located between the third axial section and the turbine wheel. The stop section of the shaft has a greater diameter than the third axial section; and the stop section locates the rotor onto the shaft in an axial direction. 
         [0011]    The length and diameter of the first, second, and third axial sections are selected to provide the desired vibrational characteristics within the speed range of the turbomachine. 
         [0012]    The turbomachine further includes a motor housing disposed over the electric machine and first and second bearings are disposed on the shaft. The first bearing is located between the compressor section and the rotor. The second bearing is located between the turbine section and the rotor. 
         [0013]    Also disclosed is an electronically-controlled turbomachine that includes a rotor of an electric machine and a shaft having a wheel coupled to a first end of the shaft. The wheel is a turbine wheel or a compressor wheel. The shaft has an axial portion adapted to mate with the rotor. The axial portion has a first axial section having a first diameter, a second axial section having a second diameter, and a third axial section having a third diameter. The second axial section is located between the first and third axial sections and the second diameter is smaller than the first and third diameters. 
         [0014]    In one alternative, the first and third diameters are substantially equal and an inside diameter of the rotor is slightly smaller than the first diameter so as to form an interference fit between the rotor and the shaft along the first and third axial sections. In another alternative, the first axial section is farther from the turbine wheel than the third axial section and the third diameter is greater than the first diameter. The inside diameter of the rotor is substantially equal to the first diameter to form a slip fit and an interference fit is formed between the rotor and the shaft along the third axial section. 
         [0015]    In some embodiments, a fourth axial section is disposed between the third axial section and the turbine wheel. The fourth axial section has a fourth diameter that is larger than the third diameter. The rotor has an inside diameter less than the fourth diameter. The fourth axial section serves as a stop to the rotor. 
         [0016]    In one alternative, the shaft has a threaded section proximate the first axial section. A nut is engaged with the threads on the shaft to cause the rotor to abut the stop. Alternatively, the inside surface of the rotor has a threaded section engaged with the threaded section associated with the shaft. In some embodiments, the third diameter associated with the shaft is greater than the inside diameter of the unthreaded inner surface section of the rotor. 
         [0017]    In some embodiments, the length of the second axial section is longer than the first axial section and the second axial section is longer than the third axial section. Alternatively, the first, second, and third axial sections are roughly the same length. 
         [0018]    The rotor is part of an electric machine, a pneumatic machine, or a hydraulic machine. 
         [0019]    In one embodiment in which the wheel is a turbine wheel, the turbomachine may further include a compressor wheel coupled to a second end of the shaft with the rotor located between the turbine wheel and the compressor wheel. 
         [0020]    An advantage according to some embodiments is that the length of the interference fit between the rotor and the turbocharger shaft is less than the entire length over which they couple. This eases assembly and reduces the potential for the rotor to stick onto the shaft during assembly prior to full engagement, thereby reducing the number of parts that are scrapped. 
         [0021]    Turbocharger speeds can be into the range of 350,000 rpm. Bending of the shaft is to be avoided. It has been found that by having a slip fit and/or press fit between the turbocharger shaft and the electric rotor over less than the length of the interface can lead to less bending during installation and/or during operation. The relative lengths of the axial sections of the various fit types can be tuned based on the dynamics of the system to yield the desired vibrational characteristics over the turbomachine&#39;s speed range. 
         [0022]    An electronically-controlled turbomachine is disclosed that has a rotor and a shaft having a wheel coupled to a first end of the shaft. The shaft has an axial portion that mates with the rotor. The axial portion has: a first axial section having a first diameter, a second axial section having a second diameter, and a third axial section having a third diameter. The second axial section is located between the first and third axial sections. The second diameter is small than the first and third diameters. The wheel is a turbine wheel or a compressor wheel. In some embodiments, the first axial section is farther from the wheel than the third axial section and the third diameter is substantially equal to the first diameter. In one embodiment, the first and third axial sections form a slip fit with the rotor. In another embodiment, the first and third axial sections form an interference fit with the rotor. In yet another embodiment, the first axial section forms a slip fit and the third axial section forms an interference fit between the rotor and the shaft. 
         [0023]    In some embodiments, the turbomachine is an electronically-controlled turbocharger in which the wheel on the first end is a turbine wheel. A compressor wheel is coupled to a second end of the shaft. In some alternatives, an interference fit exists between the shaft and the rotor along the third axial section. 
         [0024]    Also disclosed is an electronically-controlled turbomachine having a rotor with a first axial rotor section, a second axial rotor section and a third axial rotor section. The turbomachine also has a wheel (compressor wheel or turbine wheel) coupled to a first end of the shaft. The shaft has an axial portion adapted to engage with the rotor. The axial portion has a first axial shaft section that engages with the first axial rotor section, a second axial shaft section within the second axial rotor section, and a third axial shaft section that engages with the third axial rotor section. The second axial shaft section is located between the first and third axial shaft sections. A difference between an inner diameter of the second axial rotor section and an outer diameter of the second axial shaft section is greater than a difference between an inner diameter of the third axial rotor section and an outer diameter of the third axial shaft section. The wheel may be a compressor wheel or a turbine wheel. 
         [0025]    In some alternatives, an outer diameter of the first axial shaft section equals the outer diameters of the second and third axial shaft sections. The inner diameter of the first axial rotor section is substantially equal to the first outer diameter of the first axial shaft section. In some embodiments, the outer diameter of the second axial shaft section is less than the outer diameter of the first axial shaft section to provide a cutback shaft. 
         [0026]    The first axial shaft section is farther from the wheel than the third axial shaft section and an outer diameter of the third axial shaft section is substantially equal to an outer diameter of the first axial shaft section such that the third axial shaft section and the third axial rotor section form a slip fit or an interference fit and the first axial shaft section and the first axial rotor section form a slip fit or an interference fit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  is an cross-sectional view of an electronically-controlled turbocharger; 
           [0028]      FIG. 2  is a cross-sectional view of a rotor and turbocharger shaft assembly; 
           [0029]      FIGS. 3 ,  5 ,  6 ,  7 , and  8  are cross-sectional views of embodiments of a rotor and a portion of a turbocharger shaft as assembled; and 
           [0030]      FIG. 4  is an exaggerated view of a portion of a turbocharger shaft. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    As those of ordinary skill in the art will understand, various features of the embodiments illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce alternative embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations. Those of ordinary skill in the art may recognize similar applications or implementations whether or not explicitly described or illustrated. 
         [0032]    In  FIG. 1 , an ECT is shown in cross section. The ECT has a compressor section  10 , an electric machine section  12 , and a turbine section  14 . A shaft  16  passes through sections  10 ,  12 , and  14 . A turbine wheel  18  is affixed to shaft  16  by welding, or by mechanical fasteners, or any other suitable manner of coupling two members. 
         [0033]    Electric machine section  12  includes an electric machine that includes a rotor  20  and a stator  22  enclosed within two housing portions: a turbine side housing portion  24  and a compressor side housing portion  26 . The electric machine can be operated as either a motor, in which electrical energy is applied to the motor to cause the shaft to rotate faster than it would otherwise, or as a generator, in which an electrical load is applied to the motor to cause the shaft to rotate slower than it would otherwise. The terms electric machine, motor, and generator are used herein interchangeably with the understanding that depending on the embodiment, the electric machine may be operated as a motor, generator, or neither if no electric current is applied to windings associated with the rotor. In some embodiments, the electric machine may be adapted to operate only as a motor or only as a generator. Bearings  28  and  30  are disposed in housing portions  26  and  24 , respectively, to support shaft  16 . Considered axially, bearing  30  is located between rotor  20  and turbine section  14  and bearing  28  is located between rotor  20  and compressor section  10 . 
         [0034]    Rotor  20  of the electric machine is pressed onto shaft  16  such that rotor  20  rotates with shaft  16 . Thus, the tightness of the fit and the length over which the two are fit are selected to ensure no relative rotation of the two. 
         [0035]    A compressor wheel  32  is provided on the end of shaft  16  distal from turbine wheel  18 . Compressor wheel  32  is held onto shaft  16  via a nut  34  in the embodiment of  FIG. 1 . The compressor wheel  32  is typically manufactured from a light alloy dissimilar from the turbo shaft  16  preventing a weldment. Compressor wheel  32  is typically clamped the shaft via a fastener or threaded feature. 
         [0036]    In  FIG. 2 , a rotor and turbine shaft assembly is shown. Turbine wheel  38  having turbine blades  39  is welded to shaft  40  at weld joint  41 . Alternatively, turbine wheel  38  couples to shaft  40  via a nut or other suitable fastener or other suitable joining technique. Rotor  42  is slid over shaft  40  with rotor  42  moved in direction  44  with respect to shaft  40 . Shaft  40  is cutback in the center of the section onto which rotor  42  is affixed. Rotor  42  includes magnets  60  and end support sections  62  and  64 . 
         [0037]    A detail of a portion of a turbocharger shaft  50  is shown in  FIG. 3  with a rotor  52  placed over shaft  50 . Shaft  50  has different diameters along the length. Along a first length, shaft  50  has a diameter D 1 ; along a second length, shaft  50  has a diameter D 2 ; along a third length, shaft  50  has a diameter D 3 ; and along a fourth length, shaft  50  has a diameter D 4 , where D 4 &gt;D 3 ≧D 1 &gt;D 2 . Rotor  52  has an inner diameter of D. D 2  is less than D so that there is a slight gap between rotor  52  and shaft  50 . D 4  is greater than D by a sufficient amount so that D 4  acts as a stop to rotor  52 , i.e., the area where D 4  is located positions rotor  52  on shaft  50 . In one embodiment, D 1 =D 3 =D, i.e., the three are substantially equal. Rotor  52  is a slip or slide fit along the first and third lengths. In an alternative embodiment, D 1 &gt;D and D 3 &gt;D forming an interference fit in the shaft regions with diameters D 1  and D 3 . Such an interference fit can be, in one non-limiting example,  0 . 025  mm difference in diameter. Depending on the materials, rotor  52  may be press fit onto shaft  50  at room temperature, i.e., the material deforms sufficiently to allow an interference fit. With some materials, the temperature of rotor  52  is elevated compared to the temperature of shaft  50  to allow assembly. When the two reach a temperature equilibrium, the tensile and compressive forces due to the interference fit cause the two to be coupled together even in the presence of a relative torque force. In yet another embodiment, D 1 =D and D 3 &gt;D such that a slip or press fit is formed along the first length, i.e., the first portion of shaft  50  that couples with rotor  52  during assembly. Then, an interference fit is formed along the third length, the last portion over which rotor  52  slides over shaft  50 . 
         [0038]    An embodiment is described above in which rotor  52  is held onto shaft  50  by appropriate fitting of the shaft along first and third lengths. In an alternative embodiment, rotor  52  is welded to shaft  50 . A weld fillet  54  is provided at the left end of rotor  52 , as shown in  FIG. 3 . Any of electron beam, laser, or tungsten inert gas welding may be used. Or any suitable welding technique may also be used. 
         [0039]    In  FIG. 4 , an exaggerated version of a turbocharger shaft is shown in which a first, second, third, and fourth axial portions,  70 ,  72 ,  74 , and  76 , respectively, have diameters D 1 ′, D 2 ′, D 3 ′, and D 4 ′, respectively. And, D 4 ′&gt;D 3 ′&gt;D 1 ′&gt;D 2 ′. In  FIG. 4 , D 3 ′&gt;D 1 ′. However, in an alternative embodiment, D 3 ′ substantially equals D 1 ′. Between  74  and  76 , a fillet  78  to provided to relieve stress risers. Although not shown, chamfers or fillets are provided between the portions  70 ,  72 , and  74  for stress relief and to avoid burrs that would interfere during assembly of the rotor onto the shaft. 
         [0040]    In the embodiment in  FIG. 3 , shaft  50  is ultrasonically or friction welded to rotor  52 . In one alternative, the two are welded at one or both of first and third lengths, i.e., circumferentially at the shaft and rotor interface at which they are slip fit together. 
         [0041]    In another alternative, shaft  60 , of  FIG. 4  has a stop surface  80  that extends outwardly in a substantially radial direction. Stop surface  80  mates with an end surface  56  of rotor  52  (shown in  FIG. 3 ). The shaft may be rotated with respect to the rotor so that surfaces  80  and  56  are friction welded. Alternatively, high-frequency ultrasonic vibrations are applied to surfaces  80  and  56  to ultrasonically weld the rotor to the shaft. Surfaces  80  and  56  are shown in  FIGS. 3 and 4 , respectively, as being substantially perpendicular to a center axis of the shaft. However, the surfaces could be at other angles. 
         [0042]    In  FIG. 5 , an alternative embodiment of a rotor  82  and a shaft  84  are shown. Along a first portion  90 , rotor  82  and shaft  84  are fit together in a slip or interference fit. Along a second portion  92 , there is a gap between the outside diameter of shaft  84  and an inside diameter of rotor  82 . Rotor  82  and shaft  84  are threaded along a fourth portion  94 . Fourth portion  96  of shaft  84  extends out of rotor  82 . The diameter of portion  96  is greater than the diameter of rotor  82  along first, second, and third portions,  90 ,  92 , and  94 , respectively, with an end of portion  96  acting as a stop for rotor  82 . In embodiments, in which torque between rotor  82  and shaft  84  is only in one sense, by appropriate selection of right handed or left handed threads allows the relative torque to push rotor  82  into the stop associated with portion  96 . In a situation in which the torque can be of either sense, a lock pin (not shown) can be applied to maintain a shoulder of rotor  82  pressed against the stop associated with portion  96 . 
         [0043]    In  FIG. 6 , yet another alternative of a rotor  102  and a shaft  104  has a first portion on which at least part of the length of shaft  104  is threaded. A nut  106  engages with threads  120  of shaft  104  and jams rotor  102  against a stop  122  located at an interface between a third axial portion  114  and a fourth axial portion  116 . A second axial portion  112  includes a cutback between rotor  102  and shaft  104 . In one embodiment, rotor  102  and shaft  104  have a slip fit along a third axial portion  114 . In an alternative embodiment, rotor  102  and shaft  104  have an interference fit along third axial portion  114 . 
         [0044]    As shown in  FIG. 6 , nut  106  is separate from rotor  102 . In an alternative embodiment, nut  106  is not a separate element, but instead integrated with the rotor. 
         [0045]    In the embodiments described with regard to  FIGS. 3-6 , the desired relative diameters between the rotor and the shaft are provided by cutting back the shaft. Alternatively, the rotor could be machined internally to provide the desired fit or gap along the length over which the two parts couple. 
         [0046]    In  FIG. 7 , an embodiment in which the diameter of the rotor is increased in the center section of the rotor. A shaft  140  engages with a rotor  160  in a first axial section  180 , a second axial section  182 , and a third axial section  184 . Shaft  140  has a first axial section  180  which has an outside diameter, D 1 S, that is substantially the same as an inside diameter, D 1 R, of rotor  160 . Also along first axial section  180 , there are threads  144  on shaft  140  and rotor  160 . Along second axial section  182 , shaft  140  has an outside diameter, D 2 S, which is less than inner diameter, D 2 R, of rotor  160 . Along third axial section  184 , an outside diameter, D 3 S, of the shaft substantially equals an inner diameter, D 3 R, of rotor  160 . In one embodiment, shaft  140  and rotor  160  are slip fit together along third axial section  184 . In another embodiment, shaft  140  and rotor  160  have an interference fit along third axial section  184 . Herein, both the slip fit and the interference fit are described as having the inner diameter of the rotor and the outer diameter of the shaft substantially equal because as known by one skilled in the art, the difference in dimension between a slip fit and an interference fit is small. Thus, the two diameters are substantially equal. 
         [0047]    In the embodiment shown in  FIG. 7 , D 1 S=D 2 S=D 3 S. Shaft  140  deviates from the same diameter at stop  142  which is used to located rotor  160  on shaft  140  in an axial direction. Also, rotor  140  has internal threads  144  along part of first axial section  180 . In other embodiments, the D 1 R diameter and D 1 S diameter exist along the entire first axial section. 
         [0048]    Rotor  160  is comprised of an end cap  164  that includes the portion that extends over shaft  140 , end cap  166  that includes threads  144  to engage with threads of shaft  140 , magnets  162 , and sleeve  168  to contain magnets  162 . These components other than the magnets may be welded together. In  FIG. 8 , an alternative rotor  190  is shown that has an end cap  194  that includes threads  198  to engage with threads on shaft  140 . In some embodiments with threads, stop  142  of  FIGS. 7 and 8  is not used. 
         [0049]    The type of fit to obtain the desired static and dynamic characteristics depends on at least: the materials of the rotor and the shaft, the temperatures that are expected during operation and during non-operational hot and cold soak periods, the maximum operating speeds, the torque to be transmitted through the shaft-to-rotor fit, the mass of the rotor, and the length of the fitted joint or joints. 
         [0050]    A turbocharger is a particular type of turbomachine. The two terms are not being used interchangeably in the present disclosure. A turbocharger includes a turbine and a compressor; whereas, a turbomachine includes at least one of a compressor and a turbine. 
         [0051]    While the best mode has been described in detail with respect to particular embodiments, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described herein that are characterized as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.