Turbocharger Compressor EGR Gas Condensation Control
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Solution Overview
Problem
In exhaust turbocharger compressors used in EGR systems, condensed water generated by cooling EGR gas can damage the impeller, especially when outdoor temperatures are low, as it mixes with intake air and increases in size within the compressor's circular passage.
Innovation Solution
The compressor design includes a circular space surrounding the inlet that communicates with both the intake and EGR passages, with specific blocking configurations to prevent intake air from cooling the EGR gas excessively, allowing high-temperature EGR gas to flow along the outer peripheral wall and reduce condensed water formation by directing EGR gas to overflow from the inlet, thereby minimizing its size and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If intake air is flown into the circular passage from the first recirculation port when the amount of intake air is large, then EGR gas can be introduced into the compressor, but condensed water is generated due to cooling of EGR gas by intake air and the inner wall of the circular passage
Solution Approach 1:
The circular passage is divided into two separate passages: a first circular passage that receives EGR gas from the EGR passage and a second circular passage that receives intake air from the intake passage. This segmentation prevents mixing of EGR gas and intake air, eliminating the cooling effect that causes condensed water generation while still allowing both gases to be introduced into the compressor through their respective recirculation ports.
Solution Approach 2:
The housing structure acts as an intermediary by providing separate pathways (first and second circular passages) for EGR gas and intake air to travel through. This intermediary structure prevents direct contact between the two gas streams, thereby preventing heat transfer from intake air to EGR gas that would cause condensed water formation.
2Ease of operation
If EGR gas is cooled by components and intake air in the circular passage, then EGR gas can be introduced into the compressor, but condensed water combines together and increases in size, potentially damaging the impeller
Solution Approach 1:
By segmenting the circular passage into separate first and second circular passages for EGR gas and intake air respectively, the invention prevents the cooling interaction that leads to condensed water formation. This maintains EGR gas introduction functionality while protecting the impeller from condensed water damage.
Solution Approach 2:
The invention extracts the harmful cooling interaction between intake air and EGR gas by providing separate pathways. Intake air is taken out from the EGR gas flow path and directed through a separate second circular passage, thereby eliminating the source of condensed water generation while preserving the EGR gas introduction function.
3Speed
If the inner diameter of the inlet is larger than the inner diameter of the intake passage end, then EGR gas flow is improved, but intake air may cool the EGR gas excessively
Solution Approach 1:
The invention segments the flow paths so that the larger inner diameter of the inlet benefits EGR gas flow velocity without allowing intake air to cool the EGR gas. The separate first and second circular passages ensure that the improved flow dynamics do not lead to excessive cooling and condensed water formation.
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
This design effectively reduces the generation and size of condensed water within the compressor, enhancing heat retention and preventing impeller damage by controlling the flow of EGR gas and intake air, ensuring efficient operation even at low outdoor temperatures.
Implementation Method 1
the inner wall of the circular passage is cooled by intake air flown into the circular passage from the first recirculation port. Then, because EGR gas is cooled by the inner wall of the circular passage or intake air flown into the circular passage, condensed water can be generated inside the circular passage
Implementation Method 2
EGR gas contains vapor. Therefore, when EGR gas is cooled, there are instances where condensed water is generated
Data Source
AI summary
A compressor includes an impeller, a housing, and a connecting shaft. An inlet for introducing gas into a suction side of the impeller, and an annular groove formed in an outer periphery of the inlet are formed in the housing. The groove communicates with the inlet on the intake passage side. The groove is blocked on the impeller side. A gas outlet of an EGR passage is connected with a middle of the groove. An inner diameter of the groove is machined to be larger than an inner diameter of an end part of the gas outlet of the intake passage (an end part on the inlet side).