Compressor Inlet Segmentation for Surge Management
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Solution Overview
Problem
Existing intake air compressors for internal combustion engines are limited by surge and choke conditions, restricting their operational range and efficiency, necessitating the use of multiple turbochargers or auxiliary compressors to achieve acceptable performance.
Innovation Solution
The design includes a compressor housing with a secondary inlet passage and a compressor wheel with stepped vanes, creating an enlarged inducer bore diameter and enhanced flow area, allowing for improved airflow and extended operational range by managing airflow near surge and choke conditions through aerodynamic profiles and recirculation passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single compressor is used, then device complexity is reduced, but the operational range and efficiency are limited due to surge and choke conditions
Solution Approach 1:
The compressor inlet is segmented into multiple independent inlet passages (first inlet passage and second inlet passage) that can operate semi-independently. This segmentation allows different portions of the inlet flow to be optimized for different operating conditions, extending the overall operational range while maintaining a single compressor unit.
Solution Approach 2:
The invention introduces a secondary inlet passage that accesses the inducer bore from a different spatial dimension (through the side wall) rather than only from the front. This dimensional approach creates additional flow paths and allows the compressor to handle a broader range of airflow conditions without increasing mechanical complexity.
2Reliability
If recirculation chamber is added, then surge condition is delayed, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The inducer bore serves multiple functions: it is the primary inlet passage for the compressor and simultaneously acts as a recirculation chamber. The side wall of the inducer bore functions both as a structural boundary and as a pathway for the secondary inlet passage. This multi-functionality provides surge resistance without adding separate recirculation components.
Solution Approach 2:
The invention merges the recirculation chamber function with the inducer bore structure. Instead of adding a separate recirculation chamber as in prior art, the inducer bore itself is configured to provide recirculation capabilities through its side wall, combining multiple functions into a single structural element that is easier to manufacture.
3Productivity
If multiple inlet passages are created, then airflow capacity and operational range are extended, but device complexity increases
Solution Approach 1:
The inducer bore's side wall serves dual purposes: it provides structural support for the compressor and simultaneously forms the pathway for the secondary inlet passage. The existing structural geometry is utilized to create additional flow paths without requiring separate supporting structures, allowing the system to serve itself rather than requiring additional components.
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 configuration enhances the compressor's operational range and efficiency by increasing airflow capacity and reducing pressure losses, enabling the compressor to handle a wider range of airflows and speeds without surging or choking.
Implementation Method 1
the secondary inlet passage may have an aerodynamic profile and be positioned in the compressor housing around the main inlet bore
Implementation Method 2
a recirculation passage from the outlet of the compressor to the inlet of the compressor
Data Source
AI summary
A compressor assembly (404) includes a compressor housing (412) having a main inlet bore (424) and a secondary inlet passage (422) that has an increasing flow cross-sectional area. The secondary inlet passage (422) is positioned in the compressor housing (412) and around the main inlet bore (424). A secondary inlet slot (426) and an outlet slot (420) fluidly connect the secondary inlet passage (422) with the main inlet bore (424). A compressor wheel (418) is in the compressor housing (412) and has a stepped portion (518) formed by at least one plurality of vanes (506). The stepped portion (518) is located adjacent to the outlet slot (420) of the housing (412).