Electrically assisted supercharging device and method with adjustable intake gap

Abstract

The application provides an electric auxiliary supercharging device and method with adjustable air inlet gap, comprising: a compressor casing, a compressor impeller is arranged in the compressor casing, the compressor impeller is rotationally connected with the compressor casing, an air inlet pipe is connected with an air inlet of the compressor casing; a motor rotor, the motor rotor is a conical structure; a motor stator, the motor stator is located at the inner side of the air inlet pipe, the motor rotor is located at the inner side of the motor stator, the motor stator is movably connected with the air inlet pipe along the length direction of the air inlet pipe, and the inner side of the motor stator is a conical hole. The application has the beneficial effects that: through the axial relative movement of the motor rotor and the motor stator, the stepless continuous adjustment of the air inlet gap is realized, the gap is reduced at low speed and large load, the motor electromagnetic force is stronger, the compressor impeller can be quickly dragged, the turbine hysteresis is significantly eliminated, the transient response is improved; the gap is appropriately increased at high speed and cruise, the throttling loss of the air inlet pipe is reduced, the compressor efficiency is improved, the engine pumping loss and the motor power consumption are reduced.

Description

Technical Field

[0001] This invention belongs to the field of engine turbocharger technology, and in particular relates to an electrically assisted turbocharger device and method with adjustable intake clearance. Background Technology

[0002] Traditional externally mounted electric-assisted turbochargers integrate a high-speed motor directly into the compressor inlet section. The motor supplements the turbine shaft power in real time to improve low-speed response and eliminate "turbo lag." However, this design has the following problems: First, to ensure motor efficiency, the compressor intake must bypass the motor stator and enter through a bypass, which takes up a lot of space and has a complex structure. Second, the intake clearance is not adjustable and cannot be adjusted according to the engine's operating conditions. Summary of the Invention

[0003] In view of this, the present invention aims to provide an electrically assisted supercharging device and method with adjustable intake clearance, in order to solve at least one of the above-mentioned technical problems.

[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows: The first aspect of the present invention provides an electrically assisted booster device with adjustable intake clearance, comprising: A compressor housing, wherein a compressor impeller is provided inside the compressor housing, and the compressor impeller is rotatably connected to the compressor housing; An air intake pipe is connected to the air inlet of the compressor housing; The motor rotor is connected to one end of the compressor impeller near the air inlet of the compressor housing. The motor rotor has a conical structure, and the diameter of the end of the motor rotor near the compressor impeller is larger than the diameter of the other end. The motor stator is located inside the intake pipe, and the motor rotor is located inside the motor stator. The motor stator is movably connected to the intake pipe along the length of the intake pipe. The inner side of the motor stator is a tapered hole, and the inner diameter of the tapered hole at one end near the compressor impeller is larger than the inner diameter at the other end.

[0005] Furthermore, the taper of the motor rotor matches the taper of the tapered bore; The motor rotor is sleeved on the outside of the rotating shaft of the air compressor impeller, and the locking nut is threadedly connected to the rotating shaft to tighten the end face of the motor rotor away from the air compressor impeller.

[0006] Furthermore, a connecting ring 1 is provided on the outer side of the intake pipe near the compressor housing, and a connecting hole 1 is opened on the connecting ring 1. A connecting ring 2 corresponding to the connecting ring 1 is fixedly provided at the inlet of the compressor housing, and a connecting hole 2 is opened on the connecting ring 2. The connecting bolts pass through connecting hole one and connecting hole two in sequence and are threaded into the nuts. A sealing ring is provided between the first connecting ring and the second connecting ring.

[0007] Furthermore, the motor rotor has multiple guide grooves on its conical surface, which are arranged along the length of the motor rotor and are evenly arranged circumferentially along the motor rotor.

[0008] Furthermore, a distance sensor is provided at one end of the motor stator near the compressor housing, and the distance sensor is used to detect the distance between the motor stator and the compressor housing.

[0009] Furthermore, the intake pipe is equipped with a drive assembly for moving the stator of the drive motor; The drive assembly includes a sliding sleeve and a servo motor. The sliding sleeve is installed inside the intake pipe. The motor stator is movably connected to the inside of the sliding sleeve along the axis of the intake pipe. A worm gear is fixedly mounted on the outside of the motor stator. The housing of the servo motor is fixedly connected to the intake pipe. A worm wheel is fixedly mounted on the output shaft of the servo motor, and the worm wheel meshes with the worm gear.

[0010] Furthermore, the intake pipe is equipped with a drive assembly for moving the stator of the drive motor; The drive assembly includes an electric cylinder and a sliding tube. The housing of the electric cylinder is fixedly connected to the compressor housing. The sliding tube is fixedly installed on the outside of the motor stator. The sliding tube is movably connected to the inside of the intake pipe along the axis of the intake pipe. A drive rod is fixedly provided on the outer wall of the sliding tube. The drive rod passes through the intake pipe and is fixedly connected to the output shaft of the electric cylinder.

[0011] A second aspect of the present invention provides an electrically assisted booster method with adjustable intake clearance, using the electrically assisted booster device with adjustable intake clearance described in the first aspect, comprising the following steps: S1. Obtain engine operating parameters, including engine speed and target boost pressure; S2. Find the optimal intake clearance value corresponding to the operating parameters according to the preset MAP diagram; S3. Collect the actual distance between the motor stator and the compressor housing using a distance sensor, and calculate the actual intake clearance value based on the actual distance. S4. Move the motor stator until the absolute value of the deviation between the actual intake gap value and the optimal intake gap value is no greater than the error threshold, then stop moving the motor stator.

[0012] Furthermore, the error threshold in S4 is in the range of 0.1mm-0.5mm.

[0013] Furthermore, in S4, if the absolute value of the deviation between the actual intake clearance value and the optimal intake clearance value is greater than the error threshold and exceeds the time threshold, a fault mode is triggered, limiting the engine torque output. The time threshold value ranges from 0.5s to 2s.

[0014] Compared with the prior art, the electrically assisted booster device and method with adjustable intake clearance described in this invention have the following advantages: The present invention discloses an electrically assisted supercharger with adjustable intake clearance. By moving the motor rotor and the motor stator axially relative to each other, the intake clearance can be continuously adjusted steplessly. When the speed is low and the load is high, the clearance is reduced, the electromagnetic force of the motor is stronger, and the compressor impeller can be driven quickly, which significantly eliminates turbine hysteresis and improves transient response. When cruising at high speed, the clearance is appropriately increased to reduce the throttling loss of the intake pipeline, improve the compressor efficiency, and reduce the engine pumping loss and motor power consumption. Attached Figure Description

[0015] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic cross-sectional view of the device described in an embodiment of the present invention; Figure 2 This is a side view of the motor stator structure according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the pressurization method described in an embodiment of the present invention.

[0016] Explanation of reference numerals in the attached figures: 1. Motor stator; 2. Worm gear; 3. Worm wheel; 4. Servo motor; 5. Inlet pipe; 6. Locking nut; 7. Tapered hole; 8. Motor rotor; 9. Tapered surface; 10. Impeller hub; 11. Compressor blade; 12. Compressor housing; 13. Sliding sleeve; 14. Sealing ring; 15. Distance sensor; 16. Guide groove. Detailed Implementation

[0017] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0018] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0019] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0020] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0021] like Figure 1-2 As shown, an electrically assisted supercharging device with adjustable intake clearance includes: Compressor housing 12, and a compressor impeller is provided inside the compressor housing 12. The compressor impeller is rotatably connected to the compressor housing 12. Inlet pipe 5, the inlet pipe 5 is connected to the air inlet of compressor housing 12; The motor rotor 8 is connected to one end of the compressor impeller near the air inlet of the compressor housing 12. The motor rotor 8 has a conical structure, and the diameter of the end of the motor rotor 8 near the compressor impeller is larger than the diameter of the other end. The motor stator 1 is located inside the air intake pipe 5, and the motor rotor 8 is located inside the motor stator 1. The motor stator 1 is movably connected to the air intake pipe 5 along the length of the air intake pipe 5. The inner side of the motor stator 1 is a tapered hole 7, and the inner diameter of the tapered hole 7 near the end of the compressor impeller is larger than the inner diameter of the other end.

[0022] The compressor impeller includes an impeller hub and compressor blades 11 mounted on the impeller hub 10.

[0023] The taper of the motor rotor 8 matches the taper of the tapered bore 7; The motor rotor 8 is sleeved on the outside of the rotating shaft of the air impeller, and the locking nut 6 is threadedly connected to the rotating shaft to tighten the end face of the motor rotor 8 away from the air impeller.

[0024] A connecting ring 1 is provided on the outer side of one end of the air intake pipe 5 near the compressor housing 12. A connecting hole 1 is opened on the connecting ring 1. A connecting ring 2 corresponding to the connecting ring 1 is fixedly provided at the inlet of the compressor housing 12. A connecting hole 2 is opened on the connecting ring 2. The connecting bolts pass through connecting hole one and connecting hole two in sequence and are threaded into the nuts. A sealing ring 14 is provided between connecting ring one and connecting ring two.

[0025] Multiple guide grooves 16 are formed on the conical surface 9 of the motor rotor 8. The guide grooves 16 are arranged along the length of the motor rotor 8 and are evenly distributed circumferentially along the motor rotor. The circumferentially evenly distributed axial guide grooves 16 on the conical surface of the motor rotor 8 can rectify the turbulent airflow at the inlet into an orderly flow along the rotor surface, reduce flow resistance, reduce intake noise, and at the same time help the motor to dissipate heat and improve the reliability of continuous operation.

[0026] A distance sensor 15 is provided at one end of the motor stator 1 near the compressor housing 12. The distance sensor 15 is used to detect the distance between the motor stator 1 and the compressor housing 12.

[0027] In some embodiments, the intake pipe 5 is provided with a drive assembly for moving the stator 1 of the motor; the drive assembly includes a sliding sleeve 13 and a servo motor 4. The sliding sleeve 13 is installed on the inner side of the intake pipe 5, the motor stator 1 is movably connected to the inner side of the sliding sleeve 13 along the axial direction of the intake pipe 5, a worm gear 2 is fixedly provided on the outer side of the motor stator 1, the housing of the servo motor 4 is fixedly connected to the intake pipe 5, and a worm wheel 3 is fixedly provided on the output shaft of the servo motor 4, the worm wheel 3 meshing with the worm gear 2.

[0028] In other embodiments, the intake pipe 5 is provided with a drive assembly for moving the stator 1 of the motor; the drive assembly includes an electric cylinder and a sliding tube. The housing of the electric cylinder is fixedly connected to the compressor housing 12. The sliding tube is fixedly installed on the outside of the motor stator 1. The sliding tube is movably connected to the inside of the intake pipe 5 along the axial direction of the intake pipe 5. A drive rod is fixedly provided on the outer wall of the sliding tube. The drive rod passes through the intake pipe 5 and is fixedly connected to the output shaft of the electric cylinder.

[0029] like Figure 3 As shown, an electric-assisted supercharging method with adjustable intake clearance, using the aforementioned electric-assisted supercharging device with adjustable intake clearance, includes the following steps: S1. Obtain engine operating parameters, including engine speed and target boost pressure; S2. Find the optimal intake clearance value corresponding to the operating parameters based on the preset MAP diagram; The preset MAP map is obtained through the following steps: This electric booster is installed on an engine bench, and external sensors are connected to measure boost pressure, intake air flow, turbine speed, fuel consumption, emissions, etc.

[0030] Select several speed-load (target boost pressure) nodes across the entire operating range, taking one point every 500 rpm and every 10 kPa.

[0031] Under each fixed pair of speeds and target boost pressures, the intake clearance value is gradually changed by moving the stator 1 of the drive motor back and forth, and the values ​​corresponding to different clearances are recorded: The optimal value for this node is determined by factors such as the turbocharger response time (transient), the steady-state deviation between the actual boost pressure and the target value, compressor efficiency, motor power consumption, noise, surge margin, etc. Based on the following objectives, select the "optimal gap": Fastest transient response (the motor rotor-stator gap is reduced, making it easier for the motor to drive the compressor impeller to quickly increase its speed); High steady-state efficiency (the gap should not be too small to avoid air intake blockage and excessive aerodynamic losses); Avoid surge and control the motor load within a reasonable range; The optimal gap is usually filled into the table by compromising various performance indicators through weighted optimization.

[0032] Connect the optimal clearance values ​​of each node to form a surface, check the smoothness of the surface, and adjust it under transition conditions to finally generate calibration data that can be written to the ECU.

[0033] The current operating speed is obtained from the crankshaft position sensor.

[0034] The target boost pressure is derived from the engine's required torque and the combustion requirements under operating conditions. The range is found on the speed axis (e.g., 1800 rpm is between 1500 and 2000 rpm), and the range is found on the pressure axis. The corresponding optimal gap value is calculated using bilinear interpolation.

[0035] S3. Collect the actual distance between the motor stator 1 and the compressor housing 12 using the distance sensor 15, and calculate the actual air intake clearance value based on the actual distance. Distance sensor 15 employs, but is not limited to, existing eddy current, Hall effect, ultrasonic, or laser displacement sensors. The gap calculation formula is as follows: g = K × L + B; Where L is the distance currently collected by distance sensor 15, K is tanθ, and θ is the taper.

[0036] S4. Move the motor stator 1 until the absolute value of the deviation between the actual intake gap value and the optimal intake gap value is no greater than the error threshold, then stop moving the motor stator 1.

[0037] The error threshold value in S4 ranges from 0.1mm to 0.5mm.

[0038] In S4, if the absolute value of the deviation between the actual intake clearance value and the optimal intake clearance value is greater than the error threshold and exceeds the time threshold, a fault mode is triggered, limiting the engine torque output. The time threshold ranges from 0.5s to 2s.

[0039] The intake clearance can be continuously adjusted steplessly by the axial relative movement of the motor rotor 8 and the motor stator 1. When the speed is low and the load is high, the clearance is reduced, the electromagnetic force of the motor is stronger, and the compressor impeller can be driven quickly, which significantly eliminates turbine lag and improves transient response. When cruising at high speed, the clearance is appropriately increased to reduce the throttling loss of the intake pipe 5, improve the compressor efficiency, and reduce the pumping loss of the engine and the power consumption of the motor.

[0040] It achieves full-condition matching boost characteristics, and a single hardware component can cover a wide range of operating conditions without the need for a complex staged boost system.

[0041] The motor rotor 8 is directly mounted on the rotating shaft of the compressor impeller and rotates coaxially, eliminating the need for an intermediate transmission mechanism. This results in fewer parts, a compact axial dimension, and easy retrofitting of existing turbochargers.

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An electrically assisted booster device with adjustable intake clearance, characterized in that, include: Compressor housing (12), wherein a compressor impeller is provided inside the compressor housing (12), and the compressor impeller is rotatably connected to the compressor housing (12); Air inlet pipe (5), which is connected to the air inlet of compressor housing (12); The motor rotor (8) is connected to one end of the compressor impeller near the air inlet of the compressor housing (12). The motor rotor (8) has a conical structure, and the diameter of the end of the motor rotor (8) near the compressor impeller is larger than the diameter of the other end. The motor stator (1) is located inside the air intake pipe (5), and the motor rotor (8) is located inside the motor stator (1). The motor stator (1) is movably connected to the air intake pipe (5) along the length direction of the air intake pipe (5). The inner side of the motor stator (1) is a tapered hole (7). The inner diameter of the tapered hole (7) near the end of the compressor impeller is larger than the inner diameter of the other end.

2. The electrically assisted booster device with adjustable intake clearance according to claim 1, characterized in that: The taper of the motor rotor (8) matches the taper of the tapered hole (7); The motor rotor (8) is sleeved on the outside of the rotating shaft of the air impeller, and the locking nut (6) is threadedly connected to the rotating shaft to tighten the end face of the motor rotor (8) away from the air impeller.

3. The electrically assisted booster device with adjustable intake clearance according to claim 1, characterized in that, The air intake pipe (5) is provided with a connecting ring one on the outer side of one end near the compressor housing (12), and a connecting hole one is opened on the connecting ring one. The compressor housing (12) inlet is fixedly provided with a connecting ring two corresponding to the connecting ring one, and a connecting hole two is opened on the connecting ring two. The connecting bolts pass through connecting hole one and connecting hole two in sequence and are threaded into the nuts. A sealing ring (14) is provided between the first connecting ring and the second connecting ring.

4. The electrically assisted booster device with adjustable intake clearance according to claim 1, characterized in that: The motor rotor (8) has multiple guide grooves (16) on its conical surface (9). The guide grooves (16) are arranged along the length of the motor rotor (8), and the multiple guide grooves (16) are evenly arranged circumferentially along the motor rotor.

5. The electrically assisted booster device with adjustable intake clearance according to claim 1, characterized in that: A distance sensor (15) is provided at one end of the motor stator (1) near the compressor housing (12). The distance sensor (15) is used to detect the distance between the motor stator (1) and the compressor housing (12).

6. The electrically assisted booster device with adjustable intake clearance according to claim 1, characterized in that: The intake pipe (5) is provided with a drive assembly for moving the stator (1) of the drive motor; The drive assembly includes a sliding sleeve (13) and a servo motor (4). The sliding sleeve (13) is installed on the inner side of the air intake pipe (5). The motor stator (1) is movably connected to the inner side of the sliding sleeve (13) along the axial direction of the air intake pipe (5). A worm gear (2) is fixed on the outer side of the motor stator (1). The housing of the servo motor (4) is fixedly connected to the air intake pipe (5). A worm wheel (3) is fixed on the output shaft of the servo motor (4). The worm wheel (3) meshes with the worm gear (2).

7. The electrically assisted booster device with adjustable intake clearance according to claim 1, characterized in that: The intake pipe (5) is provided with a drive assembly for moving the stator (1) of the drive motor; The drive assembly includes an electric cylinder and a sliding tube. The housing of the electric cylinder is fixedly connected to the compressor housing (12). The sliding tube is fixedly installed on the outside of the motor stator (1). The sliding tube is movably connected to the inside of the intake pipe (5) along the axial direction of the intake pipe (5). A drive rod is fixedly provided on the outer wall of the sliding tube. The drive rod passes through the intake pipe (5) and is fixedly connected to the output shaft of the electric cylinder.

8. A method for electrically assisted supercharging with adjustable intake clearance, characterized in that, The electric-assisted supercharging device with adjustable intake clearance as described in any one of claims 1-7 includes the following steps: S1. Obtain engine operating parameters, including engine speed and target boost pressure; S2. Find the optimal intake clearance value corresponding to the operating parameters according to the preset MAP diagram; S3. The actual distance between the motor stator (1) and the compressor housing (12) is collected by the distance sensor (15), and the actual air intake gap value is calculated based on the actual distance. S4. Move the motor stator (1) until the absolute value of the deviation between the actual intake gap value and the optimal intake gap value is not greater than the error threshold, then stop moving the motor stator (1).

9. The electrically assisted booster method with adjustable intake clearance according to claim 8, characterized in that: The error threshold value in S4 is in the range of 0.1mm-0.5mm.

10. The electrically assisted booster method with adjustable intake clearance according to claim 8, characterized in that: In S4, if the absolute value of the deviation between the actual intake clearance value and the optimal intake clearance value is greater than the error threshold and exceeds the time threshold, a fault mode is triggered to limit the engine torque output. The time threshold value ranges from 0.5s to 2s.

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