Compressor Rotor Magnet Segmentation for Turbocharger Air Gap Flow
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Solution Overview
Problem
Turbochargers face delays in providing the correct air quantity during startup and acceleration from low rotation speeds due to the inertia of turbine and compressor wheels, leading to inefficiencies in internal combustion engines.
Innovation Solution
A turbocharger design with a large rotor gap between the rotor and stator, allowing at least 50% of the air mass flow to be compressed through the rotor gap, featuring an electric motor with a rotor magnet and stator, where the rotor magnet is integrated into the compressor wheel or attached as a separate component, and the stator has a larger inner diameter relative to the rotor, facilitating efficient air compression and reduced leakage flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the rotor gap is increased to allow air mass flow through the rotor gap, then the delay in air supply is reduced, but the risk of mechanical and thermal stress on components increases
Solution Approach 1:
The rotor magnet is designed as a separate component that can be assembled onto the compressor wheel, allowing the rotor gap to be optimized for air flow while the magnet itself remains protected. This segmentation enables the rotor gap to be larger without compromising the structural integrity of the magnet assembly.
Solution Approach 2:
A rotor magnet is introduced as an intermediary element between the stator and the compressor wheel, creating a functional rotor gap that directs air flow while the magnet itself acts as a protective element that manages the stress distribution in the system.
2Device complexity
If the rotor magnet is integrated into the compressor wheel, then the device complexity is reduced, but the ease of repair deteriorates
Solution Approach 1:
The rotor magnet is designed as a separate component that can be assembled onto the compressor wheel, allowing for easy removal and replacement during maintenance while maintaining a relatively simple overall construction. The magnet can be detached without disassembling the entire compressor wheel.
Solution Approach 2:
The rotor magnet assembly is designed to be dynamically attachable and detachable from the compressor wheel, enabling flexible maintenance operations. The magnet can be removed and reattached as needed, providing adaptability between operational simplicity and maintenance ease.
3Quantity of substance
If the stator inner diameter is increased relative to the rotor outer diameter, then the air mass flow through the rotor gap is improved, but the volume of the electric motor increases
Solution Approach 1:
The stator inner diameter is selectively increased only in the region where the rotor gap is located, rather than uniformly increasing the entire stator diameter. This localized dimensional optimization allows improved air mass flow through the rotor gap while minimizing the overall volume increase of the electric motor.
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 minimizes delays in air supply, enhances manufacturing efficiency, and simplifies maintenance by ensuring a significant portion of the air mass flow is directed through the rotor gap, improving the turbocharger's performance and reducing the risk of mechanical and thermal stress on components.
Implementation Method 1
an electric motor with a rotor and stator, wherein a rotor magnet of the rotor is designed such that it is partially or also completely integrated into the compressor wheel
Data Source
AI summary
A compressor arrangement for compressing fresh air for internal combustion engines includes a compressor wheel and an electric motor having at least one stator and at least one rotor having a rotor magnet and a rotor gap between the rotor and stator. The rotor gap is designed such that when the compressor wheel rotates, at least 50%, of the air mass flow to be compressed is fed through the rotor gap. The compressor wheel is mounted on a shaft or contains the shaft and at least one rotor magnet or a carrier for holding the rotor magnet and is mountable as a separate part on said shaft and may be bolted, splinted, glued, shrunk, or secured by form-fit to said shaft to prevent rotation.