Radial Compressor Baffle Reduces Interstage Leakage
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Solution Overview
Problem
In two-stage radial compressor assemblies, interstage leakage occurs due to gas flowing from a high pressure stage to a low pressure stage, reducing overall compressor efficiency and increasing the temperature of gas flowing to the second stage, thereby diminishing its effectiveness.
Innovation Solution
The use of a baffle with labyrinthine features and specific hub shapes on the compressor wheels to redirect gas flow, forming eddies that slow down the gas and reduce leakage between the stages, thereby isolating the work of each compressor wheel and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a two-stage radial compressor assembly is used to increase compression output, then the compression capability is improved, but interstage leakage occurs reducing overall efficiency
Solution Approach 1:
A baffle component is introduced as an intermediary element between the first and second compressor stages. This baffle includes a labyrinthine passage that acts as a mediator to control and redirect gas flow, preventing direct leakage from the high-pressure second stage to the low-pressure first stage, thereby reducing energy loss while maintaining compression capability
Solution Approach 2:
The compressor assembly is segmented into distinct stages with a physical baffle structure separating them. The baffle divides the compression space and creates separate flow paths for each stage, allowing independent control of gas flow between stages and preventing mixing of high and low pressure zones
2Device complexity
If interstage leakage is allowed to occur, then the structure remains simple, but gas temperature increases reducing second stage effectiveness
Solution Approach 1:
The baffle serves as a thermal intermediary by physically separating the hot high-pressure gas from the cooler low-pressure gas. The labyrinthine passage design allows thermal management by controlling contact between gas streams, preventing excessive temperature rise that would reduce second stage compression effectiveness
Solution Approach 2:
The baffle introduces a spatial dimension to flow control by creating a three-dimensional labyrinthine passage structure. This multi-dimensional flow path redirects gas through a complex route that increases path length and allows thermal management, controlling temperature rise without requiring additional active cooling systems
3Productivity
If a baffle with labyrinthine features is added to reduce interstage leakage, then compression efficiency is improved, but device complexity increases
Solution Approach 1:
The baffle structure is merged with the existing compressor housing and stage assembly. The labyrinthine passage is integrated into the baffle component itself rather than being a separate add-on, combining flow control, separation, and structural support functions into a single integrated element that reduces overall system complexity despite the intricate passage design
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 design effectively decreases interstage leakage, improving the overall efficiency of the compressor stages by hindering undesirable flow from the high pressure stage to the low pressure stage, thus maintaining the effectiveness of the second stage compression.
Implementation Method 1
redirect gas flow, forming eddies that slow down the gas and reduce leakage between the stages
Data Source
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AI summary
An assembly can include a first radial compressor wheel that has a rotational axis and that includes a hub surface that includes an annular ridge disposed at a radius measured from the rotational axis; a second radial compressor wheel that includes a hub surface; and an annular baffle disposed at least in part between the hub surfaces where the annular baffle includes an outer surface and an inner edge that defines an opening having a central axis where the outer surface includes a surface portion to one side of the inner edge that faces the hub surface of the first radial compressor wheel, where the surface portion includes an annular channel over a radial width measured from the central axis and where the radial width spans the radius of the annular ridge.