Compressor Housing with Sacrificial Impeller Cover
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Turbochargers face challenges in containing debris and energy during compressor impeller failures, leading to increased weight, volume, and cost due to massive housings required for containment.
Innovation Solution
A compressor housing design with a sacrificial impeller cover, resilient inner and outer volutes, and a compressor diffuser that fragments upon impact, along with alignment pins and fins, to absorb and dissipate energy during failure, while containing fragments and oil within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If massive housings are used to contain debris and energy during compressor impeller failure, then containment reliability is improved, but weight, volume, and cost increase
Solution Approach 1:
The housing is segmented into multiple functional zones: a containment chamber with frangible wall for initial impact absorption, a deformation chamber for energy dissipation through controlled deformation, and a second containment chamber for final debris containment. This segmentation allows each zone to perform its specific function with optimized mass, reducing the total housing mass while maintaining containment reliability.
Solution Approach 2:
The housing structure utilizes parameter changes through controlled deformation. The deformation chamber is designed to undergo controlled plastic deformation during failure events, absorbing energy through the deformation process rather than requiring the entire housing to be massively reinforced. This allows the housing to be lighter while still providing adequate containment.
2Reliability
If massive housings are used to contain debris and energy during compressor impeller failure, then containment reliability is improved, but volume increases
Solution Approach 1:
The housing is segmented into multiple functional zones: a containment chamber with frangible wall for initial impact absorption, a deformation chamber for energy dissipation through controlled deformation, and a second containment chamber for final debris containment. This segmentation allows each zone to perform its specific function with optimized volume, reducing the total housing volume while maintaining containment reliability.
Solution Approach 2:
The housing structure utilizes parameter changes through controlled deformation. The deformation chamber is designed to undergo controlled plastic deformation during failure events, absorbing energy through the deformation process rather than requiring the entire housing to be massively reinforced. This allows the housing to be more compact while still providing adequate containment.
3Reliability
If massive housings are used to contain debris and energy during compressor impeller failure, then containment reliability is improved, but cost increases
Solution Approach 1:
The housing is segmented into multiple functional zones: a containment chamber with frangible wall for initial impact absorption, a deformation chamber for energy dissipation through controlled deformation, and a second containment chamber for final debris containment. This segmentation allows each zone to be optimized for its specific function, reducing material costs while maintaining containment reliability.
Solution Approach 2:
The housing structure utilizes parameter changes through controlled deformation. The deformation chamber is designed to undergo controlled plastic deformation during failure events, absorbing energy through the deformation process rather than requiring the entire housing to be massively reinforced. This reduces material requirements and manufacturing cost while maintaining containment capability.
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 manages energy dissipation and containment during compressor impeller failures, reducing the risk of external damage and maintaining structural integrity without the need for massive housings, thus optimizing weight, volume, and cost.
Implementation Method 1
The impeller cover is configured to fragment during impact with the compressor impeller during a failure condition of the compressor impeller
Implementation Method 2
The compressor diffuser includes an annular body, a fin and the alignment pin. The fin extending from the annular body to the impeller cover
Data Source
AI summary
Disclosed is a compressor housing and method of assembling. The compressor housing may comprise an outer volute, a cavity, an impeller cover, a compressor diffuser and an inner volute. The outer volute includes a back wall and a curved casing. The back wall may include a receptacle and a first plurality of annular steps. The receptacle configured to receive an alignment pin. The cavity is configured to receive the compressor impeller and is at least partially defined by the back wall of the outer volute and the impeller cover. The impeller cover is configured to fragment during impact with the compressor impeller during a failure condition of the compressor impeller. The impeller cover is disposed between the inner volute and the cavity. The compressor diffuser is disposed between the back wall and the impeller cover.