Compressor Inlet Orifice Mechanism for Surge Range and Low Wear
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional compressor inlet adjustment mechanisms increase weight, require more maintenance due to wear, and are inefficient in enhancing the compressor map, especially in preventing surging and improving the operating range.
Innovation Solution
A mechanism with rotatable orifice elements and an actuation ring, supported by axial members and optionally preloaded with springs, allows for adjustable cross-sections of the compressor inlet, reducing unwanted movement and contact surfaces, thereby minimizing vibration, noise, and wear, while enabling a more efficient compressor map by moving the surge line to smaller flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional compressor inlet adjustment mechanisms are used to enhance the compressor map and prevent surging, then the compressor operating range is improved, but the weight increases and maintenance requirements increase due to wear
Solution Approach 1:
The adjustment mechanism is segmented into multiple discrete orifice elements (at least three) that can be independently rotated to adjust the inlet cross-section. Each orifice element functions as an independent segment, allowing precise control of the inlet area without requiring a large, heavy monolithic structure. This segmentation enables effective compressor map enhancement with reduced overall mechanism weight.
Solution Approach 2:
The orifice elements are designed to be rotatable about their longitudinal axes, transforming the static inlet adjustment into a dynamic system. The actuation ring mechanically couples to multiple orifice elements, enabling coordinated rotation that dynamically adjusts the inlet cross-section area. This dynamic capability achieves enhanced adaptability without increasing weight, as the same components serve multiple functions across different operating positions.
2Adaptability or versatility
If traditional adjustment mechanisms are used to move the surge line to the left, then the compressor map is enhanced, but wear increases leading to higher maintenance needs
Solution Approach 1:
The actuation ring serves as an intermediary component that mechanically couples to multiple orifice elements. Instead of each orifice element directly contacting and wearing against the compressor housing or other fixed structures, the actuation ring mediates the adjustment motion. This intermediary role distributes wear across the actuation ring's bearing surfaces rather than concentrating it on the orifice elements, significantly reducing maintenance requirements while enabling effective surge line adjustment.
Solution Approach 2:
The support members are designed to be axially preloaded by spring forces, creating a self-service mechanism where the springs continuously apply force to maintain proper contact and alignment between the orifice elements and actuation ring. This self-adjusting preload compensates for wear and dimensional variations over time, maintaining reliable operation without requiring external intervention or frequent maintenance, while still enabling the surge line to be positioned effectively.
3Stability of the object's composition
If the actuation ring is mounted in the radial outer region of the compressor housing, then the adjustment mechanism is stable, but the compressor housing dimensions increase
Solution Approach 1:
The mounting approach transitions from radial mounting (in the radial dimension) to axial mounting (in the axial dimension). The actuation ring is mounted axially against the orifice elements rather than radially in the compressor housing, effectively moving the mounting interface to a different dimension. This dimensional change allows the actuation ring to be supported within the existing radial envelope of the compressor, avoiding increases in housing outer dimensions while maintaining stability through axial preload from springs.
4Strength
If full surface contact is used between orifice elements and actuation ring, then the connection is strong, but vibration and noise increase due to unwanted movement
Solution Approach 1:
Instead of uniform full-surface contact between the orifice elements and actuation ring, the design employs localized point contact through support members. Each support member creates a discrete contact point with a small contact area, concentrating the connection strength at specific locations rather than distributing it uniformly. This local quality approach reduces the surface area where unwanted relative movement and vibration can occur, thereby reducing noise and vibration while maintaining sufficient connection strength through the preloaded support members.
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 solution results in a lighter, more efficient compressor design with reduced wear and noise, improved sealing, and enhanced operational efficiency by allowing the compressor to operate within a broader range without increased maintenance needs.
Implementation Method 1
The adjustment mechanism further comprises one or more springs, preferably a ring-shaped wave spring, adapted to axially preload the plurality of orifice elements and/or the actuation ring
Implementation Method 2
The arrangement of support members axially between the plurality of orifice elements and the actuation ring establishes the option of mounting the plurality of orifice elements and the actuation ring axially against each other via contacts through said support members
Data Source
AI summary
The present invention relates to an adjustment mechanism (100) for variably adjusting the cross-section of a compressor inlet (22) and further relates to a corresponding compressor (20) including such an adjustment mechanism (100). The adjustment mechanism (100) comprises a plurality of rotatable orifice elements (110) and an actuation ring (120). The actuation ring (120) is mechanically coupled to the plurality of orifice elements 110 such that rotation of the actuation ring 120 causes movement of the orifice elements 110. The movement of the orifice elements (110) thereby adjusts the cross-section of a compressor inlet (22). The adjustment mechanism (100) further comprises a plurality of support members (140) which are arranged axially between the plurality of orifice elements (110) and the actuation ring (120). Additionally, the adjustment mechanism (100) comprises a spring (130), more specific a ring-shaped wave spring. The spring (130) is adapted to axially preload the plurality of orifice elements (110) and the actuation ring (120) when being in a mounted state.