Hydraulic system with modular inserts

Abstract

A hydraulic turbocharger having replaceable, insertable components, including volute inserts, vaned diffuser inserts, nozzle inserts, diffuser inserts, nozzle liners and diffuser liners, that define the internal passageways of a hydraulic turbocharger. By making various components of the turbocharger removably insertable and replaceable, turbochargers can be manufactured in a cost-effective way to maximize efficiency, obtain improved performance and make it easier to operate these types of devices over a wide range of operating conditions. Moreover, the devices can be readily modified while in the field when operating conditions change.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims priority to and benefit of U.S. Provisional Patent Application No. 61 / 703,963 entitled “REPLACEABLE HYDRAULIC PATHWAYS”, filed Sep. 21, 2012, which is herein incorporated by reference in its entirety.BACKGROUND[0002]The present invention relates generally to a hydraulic system.[0003]The pump industry now has available computational fluid dynamic based machine design software that allows pumps to be designed to achieve various performance parameters. The resultant designs require a high degree of dimensional precision to obtain the desired performance characteristics. The challenge is to convert the complex computer design into actual components.[0004]To produce the desired geometry for internal casing components, investment castings are often used. Investment castings use metal molds that produce a wax pattern that in turn is used to make a ceramic mold. The wax pattern is then heated so that the wax melts and is re...

AI Technical Summary

Benefits of technology

The present invention introduces enhancements to the use of removable components in the construction of hydraulic pumps, turbines, and turbochargers. These improvements are focused on the design of removably insertable components that outline the internal hydraulic passageways of a turbocharger. The invention provides more versatility and adaptability in the operation of these devices, allowing them to function effectively across various operating conditions and facilitate modifications in the field when conditions change. The technical effects include improved performance and reliability of hydraulic pumps, turbines, and turbochargers.

Problems solved by technology

The challenge is to convert the complex computer design into actual components.

However, investment casting tooling is expensive and is best suited to small size, mass produced parts.

Flexibility in the design is important to achieving the performance objectives and this does not fit well with the use of mass produced parts.

Accordingly, custom designed pumps are not a good fit with investment casting technology.

However, the cross section of the volute is limited to parallel wall design configurations as the machining tools must be inserted and removed from the interior of the casing.

There is little flexibility in the shape that can be machined under such restrictions.

These restrictions on the shape of the internal chamber of the volute significantly limit the performance and efficiency characteristics of a pump produced with this technology.

However, sand casting does not work well for the internal casings of small pumps or turbines, as the surface finish produced is not smooth enough for good efficiency.

Without the necessary level of efficiency such small pumps and turbines have a difficult time being a competitive product.

In addition, the cores that are used to create the internal voids such as the volute can shift during the molding or pouring process.

Such shifting results in uneven flow entrances and a loss of efficiency for the pump.

In addition, the surface finish of such a cast pump casing is not as smooth as desired to obtain the best flow characteristics and efficiency.

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