Compressor system with remotely installed recirculation valve

Abstract

A compressor system includes a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet to a mounting surface of the compressor housing. The compressor housing defines a cavity that receives a compressor wheel. The inlet adapter is mounted to the mounting surface of the compressor housing, and the inlet adapter includes a second recirculation passage in communication with the first recirculation passage in the compressor housing and with the compressor air inlet passage of the inlet adapter. A recirculation valve is mounted to the inlet adapter and disposed in communication with the second recirculation passage to provide a selective connection of the first recirculation passage to the compressor air inlet passage.

Description

Technical Field

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. The work of the presently named inventors, to the extent it is described in this section and in all aspects of the description that may not otherwise be considered prior art at the time of filing, is neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0003] The present disclosure relates to a compressor system having a remotely mounted recirculation valve. Background Art

[0004] Compressor Recirculation Valves (CRVs) are used on turbocharged applications to mitigate surge, anti-ice and drive exhaust gas recirculation flow. Available valves are limited in the range of application temperatures due to sealing and electronic component limitations. High boost engine applications exceed the limits of currently available valve designs. Summary of the invention

[0005] The compressor recirculation valve is displaced from the typical mounting position on the compressor outlet to the compressor inlet. This improves the thermal capability of the valve by moving the valve to a cooler position on the compressor housing or inlet duct. Additionally, NVH noise is mitigated by shortening the length of the low-pressure section of the recirculation passage. When a blow-down event occurs, the pressure pulse generated by the CRV immediately reaches the compressor inlet duct and dissipates. In contrast, the current industry standard approach causes the pressure pulse to travel through the exhaust passage at high speed, thereby generating audible noise when the valve opens under pressure.

[0006] The designated CRV mounting location on the compressor inlet duct reduces heat transfer by conduction by positioning the CRV in components adjacent to the compressor housing and providing thermal isolation between adjacent components. Additionally, the remote location of the valve reduces convective heating of the valve by the high temperature and high pressure air flow path present at the compressor outlet.

[0007] According to aspects of the present disclosure, a compressor system includes a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet to a mounting face of the compressor housing. The compressor housing defines a cavity for receiving a compressor impeller. An inlet adapter is mounted to the mounting face of the compressor housing, and the inlet adapter includes a second recirculation passage that communicates with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter. A recirculation valve is mounted to the inlet adapter and is arranged to communicate with the second recirculation passage so as to provide selective connection of the first recirculation passage to the compressor air inlet passage.

[0008] According to a further aspect, the compressor housing includes a coolant passage disposed between the diffuser and the recirculation valve.

[0009] According to a further aspect, the compressor housing includes a coolant passage disposed between the diffuser and the inlet adapter.

[0010] According to a further aspect, the inlet adapter is made of a material with low thermal conductivity, such as plastic.

[0011] According to a further aspect, the plastic material is nylon.

[0012] According to a further aspect, the first recirculation passage is defined by a hole in the compressor housing, the hole extending directly from the diffuser to an exterior face of the compressor housing.

[0013] According to a further aspect, the second recirculation passage extends from a mounting face of the inlet adapter to a surface of the compressor air inlet passage.

[0014] According to a further aspect, a gas recirculation valve is mounted to the exterior of the inlet adapter and communicates with a middle portion of the second recirculation passage.

[0015] According to yet another aspect of the present disclosure, a compressor system includes a compressor housing including an inlet opening communicating with a cavity and a diffuser outlet. The compressor housing includes a first recirculation passage extending from the diffuser outlet. The compressor impeller is disposed in the cavity. An inlet adapter is made of a plastic material and mounted to the inlet of the compressor housing. The inlet adapter includes a second recirculation passage communicating with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter. A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

[0016] According to a further aspect of the present disclosure, a compressor system includes a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet. The compressor housing defines a cavity in which a compressor impeller is disposed. An inlet adapter is mounted to the inlet of the compressor housing. The inlet adapter includes a second recirculation passage that communicates with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter. The compressor housing includes a coolant passage disposed between the diffuser outlet and the inlet adapter. A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

[0017] The present invention at least includes the following technical solutions:

[0018] Solution 1. A compressor system, comprising:

[0019] a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet, the compressor housing defining a cavity in communication with the inlet opening and the diffuser outlet;

[0020] a compressor impeller disposed in the cavity;

[0021] an inlet adapter mounted to the inlet opening of the compressor housing, the inlet adapter including a second recirculation passage communicating with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter; and

[0022] A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

[0023] Option 2. The compressor system according to Option 1, wherein the compressor housing includes a coolant passage disposed between the diffuser outlet and the recirculation valve.

[0024] Option 3. The compressor system according to Option 1, wherein the compressor housing includes a coolant passage disposed between the diffuser outlet and the inlet adapter.

[0025] Option 4. The compressor system according to Option 1, wherein the inlet adapter is made of a plastic material.

[0026] Option 5. A compressor system according to Option 4, wherein the plastic material is nylon.

[0027] Embodiment 6. The compressor system of embodiment 1, wherein the first recirculation passage is defined by a hole in the compressor housing, the hole extending directly from the diffuser outlet to the exterior face of the compressor housing.

[0028] Embodiment 7. The compressor system of embodiment 1, wherein the second recirculation passage extends from a mounting surface of the inlet adapter to a surface of the compressor air inlet passage.

[0029] Option 8. The compressor system according to Option 7, wherein the gas recirculation valve is mounted to the outside of the inlet adapter and communicates with a middle portion of the second recirculation passage.

[0030] Solution 9. A compressor system, comprising:

[0031] a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet, the compressor housing defining a cavity in communication with the inlet opening and the diffuser outlet;

[0032] a compressor impeller disposed in the cavity;

[0033] an inlet adapter made of a plastic material and mounted to the inlet of the compressor housing, the inlet adapter comprising a second recirculation passage communicating with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter; and

[0034] A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

[0035] Embodiment 10. The compressor system of embodiment 9, wherein the compressor housing includes a coolant passage disposed between the diffuser outlet and the recirculation valve.

[0036] Embodiment 11. The compressor system of embodiment 9, wherein the compressor housing includes a coolant passage disposed between the diffuser outlet and the inlet adapter.

[0037] Option 12. The compressor system of Option 9, wherein the plastic material is nylon.

[0038] Embodiment 13. The compressor system of embodiment 9, wherein the first recirculation passage is defined by a hole in the compressor housing, the hole extending directly from the diffuser outlet to the exterior face of the compressor housing.

[0039] Embodiment 14. The compressor system of embodiment 9, wherein the second recirculation passage extends from a mounting surface of the inlet adapter to a surface of the compressor air inlet passage.

[0040] Embodiment 15. The compressor system according to embodiment 14, wherein the gas recirculation valve is mounted to the outside of the inlet adapter and communicates with a middle portion of the second recirculation passage.

[0041] Solution 16. A compressor system, the compressor system comprising:

[0042] a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet, the compressor housing defining a cavity;

[0043] a compressor impeller disposed in the cavity;

[0044] an inlet adapter mounted to the inlet of the compressor housing, the inlet adapter including a second recirculation passage communicating with the first recirculation passage in the compressor housing and with the compressor air inlet passage of the inlet adapter, wherein the compressor housing includes a coolant passage disposed between the diffuser and the inlet adapter; and

[0045] A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

[0046] Embodiment 17. The compressor system according to Embodiment 16, wherein the inlet adapter is made of a plastic material.

[0047] Embodiment 18. The compressor system of embodiment 16, wherein the first recirculation passage is defined by a hole in the compressor housing, the hole extending directly from the diffuser outlet to the exterior face of the compressor housing.

[0048] Embodiment 19. The compressor system of embodiment 16, wherein the second recirculation passage extends from a mounting surface of the inlet adapter to a surface of the compressor air inlet passage.

[0049] Embodiment 20. The compressor system according to embodiment 19, wherein the gas recirculation valve is mounted to the outside of the inlet adapter and communicates with a middle portion of the second recirculation passage.

[0050] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The present disclosure will become more fully understood from the detailed description and accompanying drawings, in which:

[0052] Figure 1 is a cross-sectional view of a compressor section of a turbocharger according to the principles of the present disclosure; and

[0053] Figure 2is a cross-sectional view of a compressor section of a turbocharger according to a second embodiment of the present disclosure.

[0054] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0055] refer to Figure 1 , the compressor section 10 of the turbocharger 12 will be described. The compressor section 10 includes a compressor housing 14 that defines a cavity 16 that receives a compressor impeller 18. The compressor housing 14 further includes a diffuser outlet passage 20 that communicates with the cavity 16. The diffuser outlet passage 20 can surround the cavity 16 and include an outlet opening that can be connected to an engine air inlet so that the compressor section 10 can provide compressed air to the engine. The compressor housing 14 includes an inlet opening 22 that leads to the cavity 16. The inlet opening 22 is surrounded by a mounting surface 24 of the compressor housing 14.

[0056] The inlet adapter 26 is mounted to the mounting face 24 of the compressor housing 14. The inlet adapter 26 includes a tubular passage 28 for directing air to the inlet opening 22 to the compressor housing 14. A mounting flange portion 30 surrounds the tubular passage 28 for mounting to the mounting face 24 of the compressor housing 14.

[0057] According to the principles of the present disclosure, the compressor housing 14 can include a first recirculation gas passage 32 that can extend from the diffuser outlet passage 20 to the mounting face 24 of the compressor housing 14. The inlet adapter 26 further includes a second recirculation gas passage 34 in the mounting flange portion 30 that communicates with the first recirculation passage 32 and with an outlet opening 36 to the interior of the tubular passage 28 of the inlet adapter 26. A recirculation valve 38 is mounted to the mounting flange portion 30 of the inlet adapter 26 through an opening 40 that communicates with the second recirculation passage 34. The recirculation valve 38 can open and close a passage through the second recirculation passage 34 and provide a selective connection of the first recirculation passage 32 to the tubular passage 28 of the inlet adapter 26.

[0058] The present disclosure uses a compressor recirculation valve (CRV) 38 mounted to the compressor inlet duct 26 to extend the range of CRV operation. The compressor inlet adapter 26 features a mounting flange portion 30 located near the compressor flow path inlet of the recirculation valve 38 and a passage from the high pressure outlet of the compressor diffuser passage 20 back to the inlet of the recirculation valve 38. The compressor recirculation valve 38 is located at a sufficient distance from the compressor housing 14 to ensure that the material temperature experienced by the compressor recirculation valve 38 is low and within the operable range of the compressor recirculation valve 38. The inlet adapter 26 in which the compressor recirculation valve 38 is mounted can be made of a plastic material with low thermal conductivity, such as nylon PA66-GF35.

[0059] refer to Figure 2 The compressor housing 14 may include a water cooling passage 42 to further reduce heat transfer to the valve 38 .

[0060] The disclosed system provides a greater range of CRV operability, reduces noise due to CRV operation, and improves sealing at the CRV to compressor interface. The system also allows the use of existing commercially available CRV designs, as opposed to requiring the use of custom high temperature valves.

[0061] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because other modifications will become apparent when studying the drawings, the specification and the following claims. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in any of the other embodiments and / or combined with the features of any of the other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the arrangement of one or more embodiments to each other is still within the scope of the present disclosure.

[0062] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "immediately adjacent," "on top of," "above," "below," and "disposed." Unless explicitly described as "directly," when describing a relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship in which no other intervening elements exist between the first element and the second element, but can also be an indirect relationship in which one or more intervening elements exist (either spatially or functionally) between the first element and the second element. As used herein, the phrase at least one of A, B, and C should be interpreted to mean a logical (A or B or C) using a non-exclusive logical or, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

Claims

1. A compressor system, comprising: a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet, the compressor housing defining a cavity in communication with the inlet opening and the diffuser outlet; a compressor impeller disposed in the cavity; an inlet adapter mounted to the inlet opening of the compressor housing, the inlet adapter including a second recirculation passage in communication with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter; as well as A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

2. The compressor system according to claim 1, wherein: The compressor housing includes a coolant passage disposed between the diffuser outlet and the recirculation valve.

3. The compressor system according to claim 1, wherein: The compressor housing includes a coolant passage disposed between the diffuser outlet and the inlet adapter.

4. The compressor system according to claim 1, wherein: The inlet adapter is made of plastic material.

5. The compressor system according to claim 4, wherein: The plastic material is nylon.

6. The compressor system according to claim 1, wherein: The first recirculation passage is defined by a bore in the compressor housing that extends directly from the diffuser outlet to an exterior face of the compressor housing.

7. The compressor system according to claim 1, wherein: The second recirculation passage extends from a mounting face of the inlet adapter to a surface of the compressor air inlet passage.

8. The compressor system according to claim 7, wherein: The gas recirculation valve is mounted to the outside of the inlet adapter and communicates with a middle portion of the second recirculation passage.

9. A compressor system, comprising: a compressor housing including an inlet opening and a diffuser outlet, the compressor housing including a first recirculation passage extending from the diffuser outlet, the compressor housing defining a cavity in communication with the inlet opening and the diffuser outlet; a compressor impeller disposed in the cavity; an inlet adapter made of a plastic material and mounted to the inlet of the compressor housing, the inlet adapter including a second recirculation passage communicating with the first recirculation passage in the compressor housing and with a compressor air inlet passage of the inlet adapter; as well as A recirculation valve is mounted to the inlet adapter and disposed in the second recirculation passage to provide selective connection of the first recirculation passage to the compressor air inlet passage.

10. The compressor system according to claim 9, wherein: The compressor housing includes a coolant passage disposed between the diffuser outlet and the recirculation valve.

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