Patent Description:
In diesel engines used for ships or the like, for example, a turbocharger for supplying combustion air is used (see <CIT>). There is a demand for improved performance of turbochargers due to introduction of stricter environmental restrictions.

<CIT> relates to a thrust bearing assembly including lined bearing surfaces. A turbocharger includes compressor and turbine wheels and a shaft that connects the compressor wheel to the turbine wheel. The shaft is supported by a thrust bearing assembly that includes a pair of thrust washers mounted on the shaft, a hollow, cylindrical spacer disposed on the shaft between and abutting first faces of the thrust washers, and a thrust bearing supported on the spacer between the thrust washers.

<CIT> relates to a supercharger. In this supercharger, an impeller is provided on a distal end of a rotary shaft extending from a turbine, the rotary shaft is rotatably supported by a bearing housing, the turbine is stored in a turbine housing, and the impeller is stored in a compressor housing. A fitting shaft part and a screw part are formed at the distal end of the rotary shaft. The fitting shaft part is fitted in the impeller, and the screw part is screwed to the impeller to connect the rotary shaft and the impeller.

<CIT> relates to a supercharger. The supercharger comprises a central casing, and a turbine shaft is provided in a bearing hole of the central casing via a journal bearing. Rings are formed at both ends of the bearing hole, and a snap ring is engaged with the ring groove so that the journal bearing is kept by the snap ring so as not to move to the blower. A thrust collar, a spacer and a further thrust collar are mounted at an end of the turbine shaft, and a pro-impeller is mounted at a portion of the shaft. The thrust bearings are inserted into the thrust collars.

<CIT> concerns a turbocharger bearing system. A shaft sleeve rotates with a turbocharger shaft. An end cap includes a radially extending flange portion and carries axial rotor thrust in the direction toward a thrust flange. A combination bearing element comprises thrust bearing surfaces and axially spaced journal bearings in one member and rotates in a bearing house bore.

The turbocharger disclosed in <CIT> has a journal bearing and a thrust bearing as separate bearings that support a rotary shaft used for rotating an impeller.

However, the configuration having the separate journal bearing and thrust bearing requires an increased number of components, which prevents reduction in size.

The present disclosure has been made in view of such circumstances and intends to provide a turbocharger having a bearing structure that can support a rotary shaft with a small number of components, and to provide an assembly method of the turbocharger.

The turbocharger of the present invention is defined in claim <NUM> and includes: an impeller; a rotary shaft to which the impeller is attached; and a bearing structure that supports the rotary shaft, wherein the rotary shaft comprises a small diameter portion, a large diameter portion, and a step part connecting the small diameter portion to the large diameter portion. The bearing structure comprises a sleeve provided so as to surround an outer circumference of the rotary shaft that rotates about a center axis line and configured to rotate together with the rotary shaft; collars provided so as to abut against both ends in the center axis line direction of the sleeve, respectively, having a larger diameter than the sleeve, and configured to rotate together with the rotary shaft; and a bearing arranged on an outer circumference side of the sleeve and between the collars.

The bearing is suitable for functioning as a journal bearing that supports the rotary shaft in a radial direction via the sleeve and is suitable for functioning as a thrust bearing that supports the rotary shaft in a thrust direction via the collars, wherein the sleeve and the collars are provided on the small diameter portion, and one of the collars on the large diameter portion side is provided so as to abut against the step part.

The turbocharger further comprises a fastener that is attached to an end of the rotary shaft on the small diameter portion side and presses the collars and the sleeve toward the step part side; and a journal bearing provided on the large diameter portion.

The sleeve has substantially the same outer diameter as the large diameter portion.

The sleeve that rotates together with the rotary shaft and the collars that rotate together with the rotary shaft so as to abut against both ends of the sleeve are provided. Further, the bearing is provided on an outer circumference side of the sleeve in a manner interposed between the collars. Accordingly, the bearing can support the rotary shaft in the radial direction via the sleeve and support the rotary shaft in the thrust direction via the collars. Since this allows a single bearing to function as a journal bearing and a thrust bearing, the number of components can be reduced, and a reduction in size can be realized.

Further, since the distance between the collars is defined by the sleeve, it is possible to suitably manage the thrust gap in the center axis line direction between the bearing and the collars.

The collars and the sleeve are pressed toward the step part side of the rotary shaft by using a fastener attached to the small diameter portion of the rotary shaft. Accordingly, the collars and the sleeve are fixed so as to rotate with the rotary shaft in an integrated manner.

Further, tension is applied to the small diameter portion of the rotary shaft between the fastener and the step part. Since the small diameter portion has larger extension due to elastic deformation than the large diameter portion, a tightening margin (extension margin) can be increased for the collars and the sleeve, and the tightening robustness can be improved.

Because the outer diameter of the sleeve is substantially the same as that of the large diameter portion, the bearing and the journal bearing can have substantially the same inner diameter. It is thus possible to manage the inner diameters of the bearing and the journal bearing together.

Furthermore, in the turbocharger according to the present invention, oil grooves may be formed at both ends in the center axis line direction of the bearing.

The oil grooves are formed at both ends of the bearing. Accordingly, the lubricant is guided to both ends of the bearing, and both the ends of the bearing can thus be used as thrust pads. Therefore, since it is not required to provide thrust pads as separate components from the bearing, the number of components can be reduced.

Furthermore, in the turbocharger according to the present invention, a lubricant supply hole with downstream side opened to an inner circumference side of the bearing may be formed in the bearing.

The lubricant supply hole with the downstream side opened to the inner circumference side of the bearing is formed. Thus, after flowing out to the inner circumference side of the bearing, the lubricant passes through the radial gap between the inner circumference of the bearing and the outer circumference of the sleeve and then flows in the thrust gap between each end of the bearing and each collar. In such a way, after heated by friction heat and reduced in viscosity while passing through the radial gap, the lubricant flows in the thrust gap. By reducing the viscosity of the lubricant with a rise in temperature in such a way, it is possible to reduce a mechanical loss occurring in the thrust gap.

Further, an assembly method of a turbocharger according to the present invention is defined in claim <NUM> and is an assembly method of a turbocharger including an impeller, a rotary shaft to which the impeller is attached and that rotates about a center axis line, and a bearing structure that pivotably supports the rotary shaft, the rotary shaft has a small diameter portion, a large diameter portion, and a step part connecting the small diameter portion to the large diameter portion, and the bearing structure has a sleeve surrounding an outer circumference of the rotary shaft, collars provided so as to abut against both ends in the center axis line direction of the sleeve, respectively, and having a larger diameter than the sleeve, and a bearing arranged on an outer circumference side of the sleeve and between the collars. The bearing functions as a journal bearing that supports the rotary shaft in a radial direction via the sleeve and functions as a thrust bearing that supports the rotary shaft in a thrust direction via the collars, wherein the turbocharger further comprises a journal bearing provided on the large diameter portion, and wherein the sleeve has substantially the same outer diameter as the large diameter portion. The assembly method includes: an arrangement step of inserting the collars and the sleeve to the small diameter portion and arranging the bearing between both the collars; an abutting step of abutting one of the collars against the step part; and a fixing step of pushing and fixing the impeller, the collars, and the sleeve against the step part by fixing a fastener to the small diameter portion.

Since both the radial and thrust loads are supported by a bearing, the number of components can be reduced.

One embodiment according to the present disclosure will be described below with reference to the drawings.

As illustrated in <FIG>, a turbocharger <NUM> that is an exhaust gas turbine turbocharger is used in a diesel engine that is a main engine of a ship, for example. The turbocharger <NUM> has a turbine <NUM>, a compressor <NUM>, a rotary shaft <NUM>, and a housing <NUM> accommodating these components. Note that the turbocharger <NUM> may be used in an auxiliary engine without being limited to the main engine.

The housing <NUM> has a hollow therein and has a turbine housing 5a accommodating the turbine <NUM>, a compressor housing 5b accommodating the compressor <NUM>, and a bearing housing 5c accommodating the rotary shaft <NUM>. The bearing housing 5c is located between the turbine housing 5a and the compressor housing 5b.

A turbine wheel <NUM> of the turbine <NUM> is fixed to one end (the right end in <FIG>) in the center axis line CL direction of the rotary shaft <NUM>. A plurality of turbine blades <NUM> are provided to the turbine wheel <NUM> circumferentially at predetermined intervals. A compressor impeller <NUM> of the compressor <NUM> is fixed to the other end (the left end in <FIG>) in the center axis line CL direction of the rotary shaft <NUM>. A plurality of blades <NUM> are provided to the compressor impeller <NUM> at predetermined intervals in the circumferential direction.

The rotary shaft <NUM> is supported rotatably about the center axis line CL by a turbine-side journal bearing <NUM> on the turbine <NUM> side and supported rotatably about the center axis line CL by a compressor-side journal bearing (bearing) <NUM> on the compressor <NUM> side. The compressor-side journal bearing <NUM> also functions as a thrust bearing as described later.

An inlet passage <NUM> for an exhaust gas to the turbine blades <NUM> and an outlet passage <NUM> for the exhaust gas therefrom are provided to the turbine housing 5a. When the exhaust gas of a diesel engine is guided from the inlet passage <NUM> and passes through the turbine blades <NUM>, the energy of the exhaust gas is converted into rotational energy of the turbine <NUM>, and the rotary shaft <NUM> is rotated about the center axis line CL.

An intake port <NUM> for an air to the compressor impeller <NUM> and a discharge port <NUM> that discharges a compressed air are provided to the compressor housing 5b. The compressor impeller <NUM> is rotated by the rotational power obtained by the turbine <NUM>, the air taken from the intake port <NUM> is compressed when passing through the blades <NUM> of the compressor impeller <NUM>. The compressed air compressed by the compressor <NUM> is guided from the discharge port <NUM> to the diesel engine as a combustion air.

A lubricant supply path <NUM> used for supplying a lubricant to respective components such as the bearings <NUM> and <NUM> is provided in the bearing housing 5c. A turbine-side lubricant supply path 30a of the lubricant supply path <NUM> is connected to the outer circumference side of the turbine-side journal bearing <NUM>. A compressor-side lubricant supply path 30b is connected to the outer circumference side of the compressor-side journal bearing <NUM>.

Next, the bearing structure around the compressor-side journal bearing <NUM> will be described.

The rotary shaft <NUM> has a large diameter portion 4a on the turbine <NUM> side and a small diameter portion 4b on the compressor <NUM> side. The large diameter portion 4a and the small diameter portion 4b are connected to each other via a step part 4c. The step part 4c has a surface orthogonal to the center axis line CL.

A cylindrical sleeve (sleeve) <NUM> is provided on the inner circumference side of the compressor-side journal bearing <NUM>. The cylindrical sleeve <NUM> has a cylindrical shape and is inserted so as to surround the small diameter portion 4b of the rotary shaft <NUM>. A radial gap is formed between the outer circumference of the cylindrical sleeve <NUM> and the inner circumference of the compressor-side journal bearing <NUM>, and a lubricant is guided into this radial gap so that the rotary shaft <NUM> is radially supported.

Thrust collars (collars) 34a and 34b are provided on both sides of the compressor-side journal bearing <NUM>, respectively. Each of the thrust collars 34a and 34b has a disc shape, and the small diameter portion 4b of the rotary shaft <NUM> is inserted so as to penetrate the center of each of the thrust collars 34a and 34b. The outer diameter of each of the thrust collars 34a and 34b is larger than the outer diameter of the cylindrical sleeve <NUM>. That is, respective thrust collars 34a and 34b radially protrude at both ends of the cylindrical sleeve <NUM>. The end faces of respective thrust collars 34a and 34b are in contact with both the ends of the cylindrical sleeve <NUM>, respectively.

The dimension in the center axis line CL direction of the cylindrical sleeve <NUM> is larger than the dimension in the center axis line CL direction of the compressor-side journal bearing <NUM>. Thus, a predetermined thrust gap is formed between the compressor-side journal bearing <NUM>, which has a shorter dimension in the center axis line CL direction than the cylindrical sleeve <NUM>, and each of the thrust collars 34a and 34b. A lubricant is guided into the thrust gaps, and the rotary shaft <NUM> is supported in the thrust direction.

The compressor-side journal bearing <NUM> is arranged so as to be located in a region surrounded by the cylindrical sleeve <NUM> and the thrust collars 34a and 34b on both sides. The compressor-side journal bearing <NUM> is held so as to restrict circumferential pivot movement to the bearing housing 5c side.

At both ends of the compressor-side journal bearing <NUM>, oil grooves (not illustrated) are formed in respective surfaces facing the thrust collars 34a and 34b. A plurality of oil grooves are provided circumferentially at predetermined intervals. A lubricant is retained in these oil grooves to form a liquid film, and thereby, thrust force applied to the compressor-side journal bearing <NUM> from the thrust collars 34a and 34b is supported. In such a way, with the oil grooves being provided at both the ends, the compressor-side journal bearing <NUM> also functions as thrust pads.

The thrust collar 34a on the turbine <NUM> side has a side end face on the turbine <NUM> side, and the side end face is in contact with the step part 4c of the rotary shaft <NUM>. That is, the thrust collar 34a on the turbine <NUM> side abuts against the step part 4c and is unable to further move to the turbine <NUM> side in the center axis line CL direction.

The thrust collar 34b on the compressor <NUM> side has a side face on the compressor <NUM> side, and the side face is in contact with the end of an intermediate sleeve <NUM>. The intermediate sleeve <NUM> has a cylindrical shape and is arranged to as to surround the rotary shaft <NUM>. The end of the intermediate sleeve <NUM> on the compressor <NUM> side is in contact with the end of the compressor impeller <NUM>.

A fixing nut (fastener) <NUM> is provided to the compressor impeller <NUM> on the tip side (intake side). The fixing nut <NUM> is screwed onto external threads formed in the tip (the left end in <FIG>) of the small diameter portion 4b of the rotary shaft <NUM>. When the fixing nut <NUM> is tightened, the compressor impeller <NUM>, the intermediate sleeve <NUM>, the thrust collar 34b, the cylindrical sleeve <NUM>, and the thrust collar 34a in this order are pushed against the step part 4c of the rotary shaft <NUM>. The compressor impeller <NUM>, the intermediate sleeve <NUM>, the thrust collar 34b, the cylindrical sleeve <NUM>, and the thrust collar 34a are integrated with the rotary shaft <NUM> by such tightening of the fixing nut <NUM>. Accordingly, the compressor impeller <NUM>, the intermediate sleeve <NUM>, the cylindrical sleeve <NUM>, and the thrust collars 34a and 34b are rotated together with the rotary shaft <NUM>.

<FIG> illustrates the positional relationship of the compressor impeller <NUM>, the intermediate sleeve <NUM>, the thrust collar 34b, the cylindrical sleeve <NUM>, and the thrust collar 34a as described above in a simplified manner.

It is preferable that the outer diameter of the cylindrical sleeve <NUM> be substantially the same as the outer diameter of the large diameter portion 4a of the rotary shaft <NUM>. Accordingly, the inner diameter of the turbine-side journal bearing <NUM> that pivotably supports the large diameter portion 4a and the inner diameter of the compressor-side journal bearing <NUM> can be substantially the same.

<FIG> illustrates a path of a lubricant guided by the compressor-side lubricant supply path 30b (see <FIG>). As indicated by the arrow A1, the lubricant passes through a lubricant supply hole formed radially in the compressor-side journal bearing <NUM> and opened to the inner circumference side of the compressor-side journal bearing <NUM>. As indicated by the arrow A2, the lubricant is divided into both sides to flow through a radial gap between the inner circumference of the compressor-side journal bearing <NUM> and the outer circumference of the cylindrical sleeve <NUM> in the center axis line CL direction. Then, as indicated by the arrow A3, the lubricant flows in each thrust gap between the compressor-side journal bearing <NUM> and the thrust collars 34a and 34b. In such a way, the lubricant flows into the thrust gap after flowing through the radial gap.

The bearing structure around the compressor-side journal bearing <NUM> described above is assembled as follows.

The thrust collar 34a on the turbine <NUM> side is inserted to the small diameter portion 4b of the rotary shaft <NUM> and abutted against the step part 4c (abutting step).

The cylindrical sleeve <NUM> to which the compressor-side journal bearing <NUM> is fitted, the thrust collar 34b on the compressor <NUM> side, the intermediate sleeve <NUM>, and the compressor impeller <NUM> are then inserted in this order. In such a way, arrangement is made such that the compressor-side journal bearing <NUM> is located between the thrust collars 34a and 34b (arrangement step).

Then, the fixing nut <NUM> is screwed onto the small diameter portion 4b of the rotary shaft <NUM>, and thereby, the compressor impeller <NUM>, the intermediate sleeve <NUM>, the thrust collar 34b on the compressor <NUM> side, the cylindrical sleeve <NUM>, and the thrust collar 34a on the turbine <NUM> side are abutted and pushed against and fixed to the step part 4c (fixing step). Accordingly, the compressor impeller <NUM>, the intermediate sleeve <NUM>, the thrust collar 34b on the compressor <NUM> side, the cylindrical sleeve <NUM>, and the thrust collar 34a on the turbine <NUM> side are integrated with the rotary shaft <NUM> and rotated together with the rotary shaft <NUM>.

As described above, according to the present embodiment, the following effects and advantages are achieved.

The cylindrical sleeve <NUM> rotated together with the rotary shaft <NUM> is provided, and the thrust collars 34a and 34b rotated together with the rotary shaft <NUM> so as to abut against both ends of the cylindrical sleeve <NUM> are provided. Further, the compressor-side journal bearing <NUM> is provided on the outer circumference side of the cylindrical sleeve <NUM> and in a manner interposed between both the thrust collars 34a and 34b. This enables the compressor-side journal bearing <NUM> to support the rotary shaft <NUM> in the radial direction via the cylindrical sleeve <NUM> and support the rotary shaft <NUM> in the thrust direction via the thrust collars 34a and 34b. Accordingly, since the single compressor-side journal bearing <NUM> can function as both a journal bearing and a thrust bearing, the number of components can be reduced, and a reduction in size can be realized.

Further, since the distance between the thrust collars 34a and 34b is defined by the cylindrical sleeve <NUM>, it is possible to suitably manage the thrust gap between the compressor-side journal bearing <NUM> and each of the thrust collars 34a and 34b in the center axis line CL direction.

Oil grooves are formed at both the ends of the compressor-side journal bearing <NUM>. Accordingly, a lubricant is guided to both the ends of the compressor-side journal bearing <NUM>, and thereby, both the ends of the compressor-side journal bearing <NUM> can be used as thrust pads. Therefore, since it is not required to provide thrust pads as separate components from the compressor-side journal bearing <NUM>, the number of components can be reduced.

The lubricant supply hole with the downstream side opened to the inner circumference side of the compressor-side journal bearing <NUM> is formed. Thus, after flowing out to the inner circumference side of the compressor-side journal bearing <NUM> (see the arrow A1 of <FIG>), the lubricant passes through the radial gap between the inner circumference of the compressor-side journal bearing <NUM> and the outer circumference of the cylindrical sleeve <NUM> (see the arrow A2 of <FIG>) and then flows in the thrust gap between the end of the compressor-side journal bearing <NUM> and each of the thrust collars 34a and 34b (see the arrow A3 of <FIG>). In such a way, after heated by friction heat and reduced in viscosity while passing through the radial gap, the lubricant flows in the thrust gap. By reducing the viscosity of the lubricant with a rise in temperature in such a way, it is possible to reduce a mechanical loss occurring in the thrust gap.

The thrust collars 34a and 34b and the cylindrical sleeve <NUM> are pressed toward the step part 4c side of the rotary shaft <NUM> by the fixing nut <NUM> attached to the small diameter portion 4b of the rotary shaft <NUM>. Accordingly, the thrust collars 34a and 34b and the cylindrical sleeve <NUM> are fixed so as to rotate with the rotary shaft <NUM> in an integrated manner.

Further, tension is applied to the small diameter portion 4b of the rotary shaft <NUM> between the fixing nut <NUM> and the step part 4c. Since the small diameter portion 4b has larger extension due to elastic deformation than the large diameter portion 4a, a tightening margin (extension margin) can be increased for the thrust collars 34a and 34b and the cylindrical sleeve <NUM>, and the tightening robustness can be improved.

When the cylindrical sleeve <NUM> and the large diameter portion 4a of the rotary shaft <NUM> have substantially the same outer diameters, the compressor-side journal bearing <NUM> and the turbine-side journal bearing <NUM> can have substantially the same inner diameter. It is thus possible to manage the inner diameters of the compressor-side journal bearing <NUM> and the turbine-side journal bearing <NUM> together.

Further, by suitably adjusting the radial thickness of the cylindrical sleeve <NUM>, it is possible to change the diameter of the small diameter portion 4b of the rotary shaft <NUM>. This enables adjustment of the extension amount of the small diameter portion 4b when tightened by the fixing nut <NUM>. Further, by adjusting the contact area between the thrust collar 34a on the turbine <NUM> side and the step part 4c of the rotary shaft <NUM>, it is possible to suitably set the friction force.

Note that the present embodiment can be modified as illustrated in <FIG>, as an alternative not covered by the claims.

As illustrated in <FIG>, a single journal bearing may be provided. Specifically, a compressor-side journal bearing <NUM>' is provided which is formed such that the compressor-side journal bearing <NUM> illustrated in <FIG> is extended in the center axis line CL direction, and a cylindrical sleeve <NUM>' is provided which is formed such that the cylindrical sleeve <NUM> illustrated in <FIG> is extended in the center axis line CL direction. This also involves extension of a small diameter portion 4b' in the center axis line CL direction. Accordingly, since whirling about the center axis line CL of the rotary shaft <NUM> can be supported by the single compressor-side journal bearing <NUM>', the turbine-side journal bearing <NUM> illustrated in <FIG> can be omitted.

Claim 1:
A turbocharger (<NUM>) comprising:
an impeller (<NUM>);
a rotary shaft (<NUM>) to which the impeller (<NUM>) is attached; and
a bearing structure that supports the rotary shaft (<NUM>),
wherein the rotary shaft (<NUM>) comprises a small diameter portion (4b, 4b'), a large diameter portion (4a), and a step part (4c) connecting the small diameter portion (4b, 4b') to the large diameter portion (4a),
wherein the bearing structure comprises:
a sleeve (<NUM>, <NUM>') provided so as to surround an outer circumference of the rotary shaft (<NUM>) that rotates about a center axis line (CL) and configured to rotate together with the rotary shaft (<NUM>);
collars (34a, 34b) provided so as to abut against both ends in the center axis line (CL) direction of the sleeve (<NUM>, <NUM>'), respectively, having a larger diameter than the sleeve (<NUM>, <NUM>'), and configured to rotate together with the rotary shaft (<NUM>); and
a bearing (<NUM>, <NUM>') arranged on an outer circumference side of the sleeve (<NUM>, <NUM>') and between the collars (34a, 34b),
wherein the bearing (<NUM>, <NUM>') is suitable for functioning as a journal bearing that supports the rotary shaft (<NUM>) in a radial direction via the sleeve (<NUM>, <NUM>') and is suitable for functioning as a thrust bearing that supports the rotary shaft (<NUM>) in a thrust direction via the collars (34a, 34b),
wherein the sleeve (<NUM>) and the collars (34a, 34b) are provided on the small diameter portion (4b, 4b'), and
wherein one of the collars (34a) on the large diameter portion (4a) side is provided so as to abut against the step part (4c),
wherein the turbocharger (<NUM>) further comprises:
a fastener (<NUM>) that is attached to an end of the rotary shaft (<NUM>) on the small diameter portion (4b, 4b') side and presses the collars (34a, 34b) and the sleeve (<NUM>, <NUM>') toward the step part (4c) side; and
a journal bearing (<NUM>) provided on the large diameter portion (4a),
wherein the sleeve (<NUM>) has substantially the same outer diameter as the large diameter portion (4a).