Compressor Housing Add-on for Turbocharger Flow Mixing
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Solution Overview
Problem
Existing exhaust gas turbochargers face challenges in maintaining flow properties and vibration behavior when a gaseous medium is introduced upstream of the compressor, particularly when a muffler is directly attached, leading to unwanted excitations and thermal stratification of the rotor blades.
Innovation Solution
A compressor housing attachment is designed between the silencer and compressor housing, featuring an annular cavity with injection openings in the end face of the muffler, allowing gaseous medium to be injected before the flow deflects from radial to axial direction, ensuring uniform distribution and mixing with the air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silencer is directly attached to the compressor housing, then the vibration behavior of the exhaust gas turbocharger and silencer unit is improved, but the flow characteristics of the compressor are deteriorated due to unwanted excitations and thermal stratification when a gaseous medium is injected
Solution Approach 1:
A housing insert is introduced as an intermediary component between the silencer and compressor housing. This insert provides a dedicated injection chamber with injection openings that allow gaseous medium to be injected into the axial flow before it reaches the compressor impeller, preventing direct injection into the radial flow and eliminating turbulence and thermal stratification while maintaining compact integration
2Object-affected harmful factors
If a gaseous medium is injected at a considerable distance from the compressor wheel inlet, then the flow characteristics are improved, but the device complexity increases due to compensator elements and spacers
Solution Approach 1:
The housing insert merges multiple functions into a single compact component: it serves as both the injection chamber and the structural element providing the required distance from the compressor inlet. The injection openings are directly formed in the end face of the silencer housing, eliminating the need for separate compensator elements or spacers while maintaining proper flow conditions
3Object-affected harmful factors
If injection openings are provided in the end face of the silencer housing, then the gaseous medium is uniformly distributed around the circumference, but the manufacturing precision requirements increase
Solution Approach 1:
The injection openings are strategically positioned in the end face of the silencer housing where the flow conditions are most favorable for uniform distribution. The local geometry of the injection chamber and the specific location of openings in the end face create optimal flow patterns that ensure even circumferential distribution of the gaseous medium, reducing the impact of manufacturing tolerances
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 ensures uniform flow dynamics and thermal homogeneity, reducing turbulence and unwanted excitations of the compressor wheel, thus maintaining optimal compressor operation while compactly integrating with the muffler and compressor housing.
Implementation Method 1
injection openings are provided in the end face of the silencer housing, which connect an annular cavity inside the housing insert with the flow channel inside the silencer
Implementation Method 2
an annular chamber with an annular cavity for collecting and distributing the air or gas is advantageously arranged downstream of the annular injection opening
Implementation Method 3
Damping elements are arranged at intervals within the silencer, allowing the air to be compressed to be drawn in between them
Data Source
Figure 1
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Figure 3
AI summary
The cylindrical silencer (50) comprises an air outlet opening (54) for connection to the inlet channel of the compressor of an exhaust gas turbocharger, as well as a flow channel leading to the air outlet opening and making at least one deflection from the radial direction to the axial direction. The compressor housing extension (40) has an annular cavity (43) and a supply line (44) for a gaseous medium opening into the cavity. In the region of an end wall (51) of the silencer, inlet openings (55) are provided, which are axially oriented and connect the annular cavity (43) to the flow channel of the silencer.By injecting the gaseous medium into the air to be compressed before the flow is deflected as it exits the central opening of the silencer, the gaseous medium is mixed with the air during this deflection, and the turbulence in the intake flow caused by the injection is eliminated.