Turbocharger Compressor Housing Cooling Passages
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Solution Overview
Problem
Turbocharger compressors face efficiency drops due to high temperatures leading to oil coking and surge conditions, which are not adequately addressed by existing cooling solutions, particularly on the compressor side.
Innovation Solution
Incorporating a system with multiple coolant passages in thermally conductive contact with key regions of the compressor, fluidically coupled with a heat exchanger, to effectively cool the charge gas and reduce oil coking risks, including configurations where coolant flows in upstream directions relative to the general gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high pressure ratios and high temperature are produced to increase turbocharged engine power density, then engine power output is improved, but oil coking inside the compressor diffuser occurs causing efficiency drop
Solution Approach 1:
The cooling system is segmented into multiple independent coolant passages, each targeting specific high-temperature zones (inlet passage, impeller passage, diffuser passage, volute passage). This segmentation allows focused cooling where oil coking is most likely to occur, rather than using a single general cooling approach.
Solution Approach 2:
Different regions of the compressor are provided with dedicated cooling passages based on their specific thermal conditions and oil coking risks. The inlet passage cools the charge air before it enters the impeller, the impeller passage cools the rotating component directly, the diffuser passage prevents oil coking in the diffusion zone, and the volute passage cools the outlet region. Each passage is strategically positioned to address local thermal problems.
2Productivity
If variable inlet compressor and variable vaned diffuser are used to achieve high efficiency and wide flow range, then compressor efficiency is improved, but actuation systems are required increasing costs and durability concerns
Solution Approach 1:
The cooling passages serve a dual function: they cool the compressor components to maintain efficiency, and they indirectly optimize airflow characteristics by controlling temperatures in the inlet, impeller, diffuser, and volute regions. This eliminates the need for separate variable geometry actuation systems while still achieving high efficiency across a wide operating range.
3Reliability
If turbine side is cooled to handle hot exhaust gasses, then turbine durability is improved, but compressor side temperature management is insufficient leading to oil coking
Solution Approach 1:
The cooling system is divided into separate turbine and compressor cooling circuits. The turbine cooling jacket handles exhaust gas temperatures, while four dedicated compressor cooling passages (inlet, impeller, diffuser, volute) independently manage compressor side temperatures to prevent oil coking. This segmentation ensures both turbine durability and compressor protection.
4Speed
If compressor operates in surge condition during low air mass flow, then engine deceleration response is achieved, but air flow reversal causes power loss
Solution Approach 1:
The inlet coolant passage pre-cools the charge air before it enters the impeller, reducing the temperature of the air mass throughout the compression process. This preliminary cooling helps maintain stable airflow characteristics during deceleration, reducing the likelihood of surge and preventing the harmful effects of flow reversal on engine power.
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 cooling system enhances heat removal and reduces the likelihood of oil coking, maintaining compressor efficiency and reducing the burden on charge air coolers by effectively managing temperature across the compressor's operational range.
Implementation Method 1
A first coolant passage may be in thermally conductive contact with the charge gas in the inlet and fluidically coupled with a heat exchanger. A second coolant passage may be in thermally conductive contact with the impeller region and fluidically coupled with the heat exchanger.
Implementation Method 2
A first coolant passage may be in thermally conductive contact with the charge gas in the inlet and fluidically coupled with a heat exchanger. Coolant flows in an upstream direction relative to a general flow direction of charge gas through the compressor.
Implementation Method 3
A first coolant passage may be in thermally conductive contact with the charge gas in the inlet and fluidically coupled with a heat exchanger.
Data Source
AI summary
A turbocharger compressor and method are provided including a first coolant passage in thermal contact with an inlet configured to direct the charge gas toward an impeller; and second, third, and fourth coolant passages respectively in thermal contact with impeller, volute, and diffuser regions. All of the coolant passages are fluidically coupled with a heat exchanger. One or more of the coolant passages are configured such that coolant flows in an upstream direction relative to a general flow direction of charge gas through the compressor.