Compressor Casing Flexible Element Bursting Protection
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Solution Overview
Problem
Existing exhaust gas turbochargers face challenges in effectively managing bursting forces on compressor impellers, leading to material defects and potential damage to adjacent casings, with existing solutions often requiring large construction volumes and high precision manufacturing, increasing costs and complexity.
Innovation Solution
A compressor design featuring a flexible element with offset ribs and a support element oriented at an angle, which deflects axial forces and absorbs bursting energy through plastic deformation, reducing the load on outer casing connections and preventing fragment penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing bursting protection measures (design break points, support flanges, necked-down bolts) are implemented, then the axial load on casing connections is reduced, but the construction volume increases and manufacturing precision requirements increase
Solution Approach 1:
The flexible element is segmented into multiple ribs (at least two ribs) that are axially oriented and arranged in an offset manner. This segmentation allows the element to absorb bursting energy through progressive deformation of individual ribs while maintaining overall structural integrity, providing effective bursting protection without requiring excessive construction volume.
Solution Approach 2:
The flexible element incorporates dynamic characteristics through its ability to deform plastically under bursting loads. The offset arrangement of ribs allows sequential engagement and deformation, creating a dynamic response to axial forces that dissipates energy progressively rather than transmitting it rigidly to the casing connections.
2Strength
If existing bursting protection measures (support flanges with large distances, long necked-down bolts) are used, then the load on outer casing connections is reduced, but manufacturing precision and production costs increase
Solution Approach 1:
The flexible element functions as a deformable structural component that absorbs axial bursting forces through plastic deformation of its rib structure. This flexible approach replaces rigid precision-fit solutions with a compliant element that accommodates manufacturing tolerances while effectively reducing loads on outer casing connections through energy absorption.
Solution Approach 2:
The flexible element changes its structural parameters (shape, density, deformation characteristics) in response to applied axial loads. During normal operation, it maintains a configuration that provides structural support, but under bursting conditions, it undergoes controlled plastic deformation to absorb energy, effectively adapting its properties to the loading regime without requiring high precision manufacturing.
3Device complexity
If a compact design is pursued without additional bursting protection elements, then construction volume is reduced, but the axial load on outer casing connections increases leading to potential failure
Solution Approach 1:
The flexible element is integrated directly into the compressor casing structure, merging the bursting protection function with the existing casing components. This integration provides effective axial load reduction while minimizing additional construction volume, as the flexible element becomes part of the overall casing assembly rather than a separate add-on component.
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 achieves a compact, burst-proof configuration with reduced axial load on outer casing connections, effectively dissipating kinetic energy and preventing casing failure, while maintaining structural integrity and operational efficiency.
Implementation Method 1
the kinetic energy of the compressor is already dissipated in the inner casing sections which are close to the rotor as a result of plastic deformation
Data Source
AI summary
A compressor casing includes a casing insert with a flexible element in the force flux between the insert wall contour and the outer compressor casing. The flexible element is assembled from a support ring and ribs, wherein the ribs axially in front of the support ring and the ribs axially behind the support ring are arranged in an offset manner in relation to each other. Due to the arrangement of the ribs in an offset manner, the axial force flux between the insert wall contour and the outer compressor casing is deflected twice, and an axially compliant flexible construction is achieved.