Compressor Baffle Eddy-Reducing Features

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Solution Overview

Problem

Compressor systems experience inefficiencies and structural issues due to recirculation flows and vortex formation at the compressor inlet, leading to noise and vibration, which can cause premature fatigue and reduce the service life of components.

Innovation Solution

An adjustment mechanism with rotatably mounted baffle elements featuring eddy-reducing designs, such as recesses or chamfers, is implemented to reduce or eliminate recirculation flows and vortex formation, thereby minimizing noise and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the adjustment mechanism constricts the compressor inlet cross-section to stabilize operation and prevent surging, then compressor map stability is improved, but recirculation flows and vortex formation increase causing noise and vibration

Engineering Contradiction:

Improvecompressor map stabilityVSAvoidnoise and vibration

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by providing eddy-reducing features (recesses or chamfers) at specific locations on the baffle elements where recirculation flows are most likely to occur. This localized modification targets the harmful eddy formation without changing the overall adjustment mechanism structure, allowing the baffle elements to maintain their flow constriction function while reducing localized turbulence and noise.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent converts the harmful recirculation flows into beneficial effects by using the recesses or chamfers to guide and control the flow paths. The eddy-reducing features transform the harmful vortex filaments into more controlled flow patterns, reducing noise and vibration while maintaining the necessary flow constriction for compressor stability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Loss of energy

If smooth inner face components are used to reduce flow resistance, then pressure loss is reduced, but recirculation flows and vortex filaments form more easily causing noise

Engineering Contradiction:

Improvepressure lossVSAvoidnoise

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The patent maintains smooth surfaces throughout the compressor inlet to minimize pressure loss, but introduces localized eddy-reducing features (recesses or chamfers) at specific positions on the baffle elements. This local modification prevents vortex filament formation without compromising the overall smooth flow path, thus reducing noise while maintaining low pressure loss.

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If baffle elements are added to adjust inlet cross-section, then compressor operation stability is improved, but structural fatigue risk increases due to vortex filaments hitting the impeller

Engineering Contradiction:

Improvecompressor operation stabilityVSAvoidstructural fatigue resistance

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent converts the harmful effect of vortex filaments into a beneficial outcome by using the eddy-reducing features to eliminate the vortices before they can reach the impeller. The recesses or chamfers on the baffle elements create flow control zones that prevent vortex formation, thereby reducing structural fatigue risk while maintaining the stability benefits of the baffle elements.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies preliminary anti-action by preventing vortex filament formation at its source through the eddy-reducing features on the baffle elements. By addressing the root cause of the harmful vortices rather than treating the effects after they reach the impeller, the design proactively prevents structural fatigue while maintaining operational stability.

Inventive Principle:

Principle #9Preliminary anti-action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively reduces noise and vibration, extending the service life of compressor components by minimizing eddy formation and improving operational efficiency.

Implementation Method 1

Because of the smooth inner face of the compressor inlet and the components of the adjustment mechanism which are in contact with the flow, a recirculation flow (and/or eddy) can form between the compressor impeller at the components of the adjustment mechanism

Methodology Applied

Scientific EffectFlow separation: Flow Separation

Implementation Method 2

Because of the main flow and/or recirculation flow, vortex filaments can form on components of the adjustment mechanism and hit the compressor impeller

Methodology Applied

Scientific EffectVortex formation: Vortex Ring

Data Source

PatentUS11959385B2Adjustment mechanism with noise reducing features

Publication Date: 2024.04.16 BORGWARNER INC

AI summary

The present invention concerns an adjustment mechanism (200) for variable adjustment of an inlet cross-section (321) of a compressor inlet (322). The adjustment mechanism comprises a plurality of rotatably mounted baffle elements (210) which are arranged in a circumferential direction (26) and are adjustable between a first position and a second position. At least one baffle element (210) of the plurality of baffle elements (210) comprises an eddy-reducing feature (220).