A method and apparatus with air pressurization and flow stabilization functions

Abstract

This invention relates to the field of diesel engine technology and discloses a method and apparatus with air boosting and flow stabilization functions. The first flange and the second flange are of the same size and are connected by a bellows. The air guide sleeve extends sequentially through the second flange and the bellows to the flange opening of the first flange, and is fixedly connected to the first flange by welding. This invention uses two sets of flanges as connectors between the turbocharger and the intercooler front pipe. Under the guidance of the bellows' expansion and contraction, the air guide sleeve, which extends into the intercooler front pipe, maintains a certain amount of deformation displacement. Then, under the pressure boosting and flow stabilization of high-pressure gas by the flared air guide sleeve, it not only compensates for the connection between components but also boosts the air, increasing the intake pressure into the diesel engine, reducing energy loss caused by airflow turbulence, and improving turbocharger efficiency.

Description

Technical Field

[0001] This invention relates to the field of diesel engine technology, specifically to a method and apparatus with air boosting and flow stabilization functions. Background Technology

[0002] Current diesel engines use an expansion joint design to compensate for gaps that occur during the assembly of various components. The structure of the existing expansion joint is shown in the attached instruction manual. Figure 1 As shown, the connection point between the expansion joint and the air cooler pipe is a large cavity. (See the attached instruction manual.) Figure 2 As shown, using existing expansion joints for connection, the expansion joints can serve to connect and compensate for gaps.

[0003] However, existing technologies using expansion joints for connection only serve a connecting function for diesel engine components. Furthermore, in the location where this invention is used, if it only serves a connecting function, the sudden entry of pressurized air into a large cavity would cause airflow turbulence, resulting in energy loss and reduced turbocharger efficiency. Therefore, those skilled in the art have provided a method and apparatus with air pressurization and flow stabilization functions to solve the problems mentioned in the background art. Summary of the Invention

[0004] The purpose of this invention is to provide a method and apparatus with air pressurization and flow stabilization functions to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method with air pressurization and flow stabilization functions.

[0006] On one hand, the present invention provides a method with air pressurization and flow stabilization functions, including the following steps: S1, production and processing: the production and processing of the first flange and the second flange adopts the flange rolling process to roll and form the first flange and the second flange, and the size of the ring and the number of bolt holes of the first flange and the second flange are respectively matched with the high pressure pipe port of the pressurizer and the intercooler front pipe; the production and processing of the corrugated pipe adopts the form of an extruder to form the extruded hose through the extruder and water cooling to form the corrugated pipe, and the pipe diameter of the corrugated pipe is matched with the ring diameter of the first flange and the second flange; the production and processing of the air guide sleeve adopts the roller rolling method to roll and process the flared shape of the air guide sleeve, and then selects a suitable pipe according to the size of the flared mouth and cuts it to a specified length. Using the flared internal support method, one end of the pipe is expanded into a wide flared mouth that matches the first flange. Then, the flared mouth and the pipe mouth are welded and fixed together to form the air guide sleeve.

[0007] S2. Assembly and processing: First, the bellows is screwed and fixed between the first flange and the second flange using bolts, and the bellows is then fitted onto the air guide sleeve. Second, the flared end of the air guide sleeve is welded to the first flange using welding, while the other end of the air guide sleeve can move freely, allowing the overall structure of the device to extend and retract by 3mm in the length direction and move by about 2mm in the circumferential direction, which compensates for the positional deviation of the two connecting parts caused by installation or parts processing.

[0008] S3. Installation and Use: Using bolts, connect the first flange and the second flange to the turbocharger and the intercooler front pipe respectively. During installation, extend the flared end of the air guide sleeve into the cavity of the intercooler front pipe. When air passes through, the "Bernoulli effect" will occur, the airflow velocity will decrease and the pressure will increase, which will play the role of air pressurization and flow stabilization buffer.

[0009] As a further aspect of the present invention: the "Bernoulli effect" is based on Bernoulli's equation:

[0010] p+1 / 2ρv 2 +ρgh= C

[0011] In the formula, p is the pressure at a certain point inside the air guide sleeve duct, v is the flow velocity inside the air guide sleeve duct, ρ is the fluid density, g is the acceleration due to gravity, h is the height of that point, and C is a constant.

[0012] As a further aspect of the present invention: after the first flange and the second flange are rolled and formed, they need to be shot peened. The shot peening equipment uses a high-pressure blower or compressed air as power, and the shot peening uses cast steel shot of 40~50HRC, and the particle size of the shot is 0.8~1.2mm.

[0013] As a further aspect of the present invention: the crests and troughs of the corrugated pipe correspond to the stress concentration points of the pipe. The location of the maximum equivalent stress of the corrugated pipe diameter is closely related to the load. The maximum equivalent stress increases with the increase of the corrugated pipe diameter, and the maximum equivalent stress decreases logarithmically with the increase of the corrugated pipe wall thickness.

[0014] As a further aspect of the present invention: the flared opening of the air guide sleeve is formed by rolling with a three-roll hydraulic conical plate rolling machine.

[0015] On the other hand, the present invention provides a device with air boosting and flow stabilization functions, which is used to improve the air boosting and flow stabilization functions of a diesel engine. The device includes a first flange, a bellows, a second flange, and an air guide sleeve, wherein the first flange and the second flange are the same size; the air guide sleeve extends through the second flange and the bellows to the flange opening of the first flange.

[0016] As a further embodiment of the present invention: the first flange, the second flange, and the air guide sleeve are all made of stainless steel, and the surfaces of the first flange, the second flange, and the air guide sleeve are all coated with anti-corrosion paint, and the corrugated pipe is made of PA or PP material.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] This invention uses two sets of flanges as connectors between the turbocharger and the intercooler front pipe. Under the guidance of the bellows' expansion and contraction, the air guide sleeve inserted into the intercooler front pipe can maintain a certain amount of deformation displacement. Then, under the pressure and stabilization of high-pressure gas by the flared air guide sleeve, it can not only compensate for the connection of components, but also boost the air pressure, increase the intake pressure entering the diesel engine, reduce energy loss caused by airflow turbulence, and improve turbocharger efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of an existing structure of a device with air pressurization and flow stabilization functions;

[0020] Figure 2 This is a schematic diagram of an existing installation of a device with air boosting and flow stabilization functions.

[0021] Figure 3 This is a schematic diagram of a device with air pressurization and flow stabilization functions.

[0022] Figure 4 This is a schematic diagram of the installation of a device with air pressurization and flow stabilization functions.

[0023] In the diagram: 1. First flange; 2. Bellows; 3. Second flange; 4. Air guide sleeve. Detailed Implementation

[0024] Please see Figures 3-4 In this embodiment of the invention, a method with air pressurization and flow stabilization functions includes the following steps:

[0025] S1. Production and Processing: The production and processing of the first flange 1 and the second flange 3 adopts the flange rolling process. The first flange 1 and the second flange 3 are rolled and formed, and the size of the ring and the number of bolt holes of the first flange 1 and the second flange 3 are matched with the high pressure pipe port of the booster and the intercooler front pipe respectively. The production and processing of the bellows 2 adopts the form of an extruder. The extruded hose is formed by an extruder and water-cooled to form the bellows 2. The pipe diameter of the bellows 2 is matched with the ring diameter of the first flange 1 and the second flange 3. The production and processing of the air guide sleeve 4 adopts the roller rolling method. The bell shape of the air guide sleeve 4 is rolled and processed. Then, according to the size of the bell, a suitable pipe is selected and cut to a specified length. Using the flaring and internal support method, one end of the pipe is expanded into a wide flared opening that matches the first flange 1. Then, the bell opening is welded and fixed to the pipe opening to form the air guide sleeve 4.

[0026] S2. Assembly and processing: First, using bolts, the bellows 2 is screwed and fixed between the first flange 1 and the second flange 3, and the bellows 2 is fitted onto the air guide sleeve 4; Second, using welding, the flared end of the air guide sleeve 4 is welded to the first flange 1, while the other end of the air guide sleeve 4 can move freely, so that the overall structure of the device can freely extend and retract by 3mm in the length direction and move about 2mm in the circumferential direction, which can compensate for the positional deviation of the two connecting parts caused by installation or parts processing.

[0027] S3. Installation and Use: Using bolts, connect the first flange 1 and the second flange 3 to the turbocharger and the intercooler front pipe respectively. During installation, extend the flared end of the air guide sleeve 4 into the cavity of the intercooler front pipe. When air passes through, the "Bernoulli effect" will occur, the airflow velocity will decrease and the pressure will increase, which will play the role of air pressurization and flow stabilization buffer.

[0028] The "Bernoulli effect" is based on Bernoulli's equation:

[0029] p+1 / 2ρv 2 +ρgh= C

[0030] In the formula, p is the pressure at a certain point inside the air guide sleeve 4 pipe, v is the flow velocity inside the air guide sleeve 4 pipe, ρ is the fluid density, g is the gravitational acceleration, h is the height of that point, and C is a constant.

[0031] After the first flange 1 and the second flange 3 are rolled and formed, they need to be shot peened. The shot peening equipment uses a high-pressure blower or compressed air as power. The shot peening uses 40~50HRC cast steel shot, and the shot particle size is 0.8~1.2mm. After shot peening, the first flange 1 and the second flange 3 still need to be cleaned. The cleaning level is Sa2.5. The treatment technical standard is: the surface of the workpiece should be free of grease, dirt, oxide scale, rust, paint, oxides, corrosion and other foreign substances (except for defects). The defects are limited to no more than 5% of the surface area per square meter, which may include: slight shadows, a small amount of slight discoloration caused by defects and rust, oxide scale and paint defects.

[0032] The crests and troughs of the corrugated pipe 2 correspond to the stress concentration points of the pipe. The location of the maximum equivalent stress in the diameter of the corrugated pipe 2 is closely related to the load. The maximum equivalent stress increases with the increase of the diameter of the corrugated pipe 2, and decreases logarithmically with the increase of the wall thickness of the corrugated pipe 2. After the corrugated pipe 2 is processed and formed, it still needs to undergo a vulcanization process. The vulcanization method adopts the continuous vulcanization method of liquid medium. The vulcanization medium is a molten alloy (40~45% tin, 55~60% bismuth) with a melting point of 150℃, or a molten salt (50~53% potassium nitrate, 40~43% sodium nitrite, 7~10% ammonium nitrate) with a melting point of 142℃ and a boiling point of 500℃. During the vulcanization process, the vulcanization medium is first heated to 180-250℃, and then the semi-finished product (the time depends on the vulcanization conditions of the rubber compound) is continuously vulcanized.

[0033] The flared opening of the air guide sleeve 4 is formed by rolling with a three-roll hydraulic conical plate rolling machine. The structure of the three-roll hydraulic conical plate rolling machine is a three-roll symmetrical type. The upper roller of the plate rolling machine is symmetrically positioned in the center of the two lower rollers. The hydraulic oil in the hydraulic cylinder acts on the piston to make vertical lifting and lowering movements. Then, the drive mechanism drives the two lower roller gears to mesh and rotate, providing torque for rolling the plate. Then, the flat plastic metal plate passes between the three working rollers (two lower rollers and one upper roller) of the plate rolling machine. With the help of the downward pressure of the upper roller and the rotation of the lower roller, the metal plate undergoes multiple continuous bending, producing permanent plastic deformation and being rolled into the flared opening shape required by the air guide sleeve 4.

[0034] Please see Figures 3-4In this embodiment of the invention, a device with air boosting and flow stabilization functions is provided to improve the air boosting and flow stabilization functions of a diesel engine. The device includes a first flange 1, a bellows 2, a second flange 3, and an air guide sleeve 4. The first flange 1 and the second flange 3 are of the same size. The air guide sleeve 4 extends sequentially through the second flange 3 and the bellows 2 to the flange opening of the first flange 1. When using this device to install diesel engine components, the first flange 1 and the second flange 3 are respectively connected to the turbocharger and the intercooler front pipe. The bellows 2's extension and retraction allow the overall structure of the device to freely extend and retract by 3mm in length and move approximately 2mm in circumferential direction, compensating for positional deviations caused by installation or component processing when connecting the turbocharger and the intercooler front pipe. Furthermore, by designing the air guide sleeve 4 in a trumpet shape, the Bernoulli effect occurs when air passes through it, reducing the airflow velocity and increasing the pressure, thus boosting the airflow. This also makes the boosted airflow more stable, reducing work loss and improving the turbocharger's efficiency.

[0035] The first flange 1, the second flange 3, and the air guide sleeve 4 are all made of stainless steel, and the surfaces of the first flange 1, the second flange 3, and the air guide sleeve 4 are all coated with anti-corrosion paint. The bellows 2 is made of PA or PP material. During the installation and use of this device, the stainless steel flanges and air guide sleeves have good corrosion resistance, high strength, low cost performance, long service life and better applicability. The bellows 2 made of PA or PP rubber has good expansion and deflection performance as well as anti-aging, high temperature resistance and corrosion resistance, and can adapt to workplaces in different environments.

[0036] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method with air pressurization and flow stabilization functions, characterized in that, Includes the following steps: S1. Production and Processing: The production and processing of the first flange (1) and the second flange (3) adopts the flange rolling process. The first flange (1) and the second flange (3) are rolled and formed. The size of the ring and the number of bolt holes of the first flange (1) and the second flange (3) are matched with the high pressure pipe ports of the turbocharger and the intercooler front pipe respectively. The production and processing of the corrugated pipe (2) is carried out by an extruder. The extruded hose is formed by an extruder and cooled by water to form the corrugated pipe (2). The pipe diameter of the corrugated pipe (2) matches the annular diameter of the first flange (1) and the second flange (3). The air guide sleeve (4) is manufactured by rolling and pressing with rollers to roll and press the flared shape of the air guide sleeve (4). Then, according to the size of the flared opening, a suitable pipe is selected and cut to a specified length. Using the method of flaring and internal support, one end of the pipe is expanded into a wide flared opening that matches the first flange (1). Then, the flared opening is welded and fixed to the pipe opening to form the air guide sleeve (4). S2. Assembly and processing: First, the bellows (2) is screwed and fixed between the first flange (1) and the second flange (3) using bolt connection, and the bellows (2) is put on the air guide sleeve (4); Secondly, by using welding, the flared end of the air guide sleeve (4) is welded to the first flange (1), while the other end of the air guide sleeve (4) can move freely, so that the overall structure of the device can freely extend and retract by 3mm in the length direction and move about 2mm in the circumferential direction, which can compensate for the positional deviation caused by the installation or processing of the two connecting parts. S3. Installation and Usage: Using bolts, the first flange (1) and the second flange (3) are connected to the turbocharger and the intercooler front pipe respectively. During the installation and connection, the flared end of the air guide sleeve (4) extends into the cavity of the intercooler front pipe. When the air passes through, the "Bernoulli effect" will occur, the airflow velocity will decrease, and the pressure will increase, which plays the role of air pressurization and flow stabilization buffer.

2. The method for air pressurization and flow stabilization according to claim 1, characterized in that, The "Bernoulli effect" is based on Bernoulli's equation: p+1 / 2ρv 2 +ρgh= C In the formula, p is the pressure at a certain point in the air guide sleeve (4) pipe, v is the flow velocity in the air guide sleeve (4) pipe, ρ is the fluid density, g is the gravitational acceleration, h is the height of the point, and C is a constant.

3. The method for air pressurization and flow stabilization according to claim 1, characterized in that, After the first flange (1) and the second flange (3) are rolled and formed, they need to be shot peened. The shot peening equipment uses a high-pressure blower or compressed air as power. The shot peening uses 40~50HRC cast steel shot, and the shot particle size is 0.8~1.2mm.

4. The method for air pressurization and flow stabilization according to claim 1, characterized in that, The crests and troughs of the corrugated pipe (2) correspond to the stress concentration points of the pipe. The location of the largest equivalent stress of the corrugated pipe (2) is closely related to the load. The largest equivalent stress increases with the increase of the corrugated pipe (2) diameter, and the largest equivalent stress decreases logarithmically with the increase of the corrugated pipe (2) wall thickness.

5. The method for air pressurization and flow stabilization according to claim 1, characterized in that, The flared opening of the air guide sleeve (4) is formed by rolling with a three-roll hydraulic conical plate rolling machine.

6. A device with air pressurization and flow stabilization functions, wherein the method for achieving air pressurization and flow stabilization functions according to any one of claims 1 to 5 is characterized in that, It is used to improve the air boosting and flow stabilization function of diesel engines, including a first flange (1), a bellows (2), a second flange (3), and an air guide sleeve (4), wherein, The first flange (1) and the second flange (3) are the same size; The air guide sleeve (4) extends through the second flange (3) and the bellows (2) to the flange opening of the first flange (1).

7. The device with air pressurization and flow stabilization functions according to claim 6, characterized in that, The first flange (1), the second flange (3), and the air guide sleeve (4) are all made of stainless steel, and the surfaces of the first flange (1), the second flange (3), and the air guide sleeve (4) are coated with anti-corrosion paint. The corrugated pipe (2) is made of PA or PP material.

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