Turbocharger Compressor Wheel Thermal Protection Control

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Solution Overview

Problem

Turbocharger compressor wheels experience reduced hardness due to thermal stress during rapid engine stops, leading to increased bore size and contact with the casing, exacerbated by multiple turbochargers in sequential series configurations, causing thermal rebound and lubrication system interruptions.

Innovation Solution

A method involving continuous temperature evaluation of the compressor wheel, inhibiting engine stoppages when the temperature exceeds a setpoint, and configuring the engine into a non-damaging operating mode based on stoppage frequency, using a processing unit connected to temperature sensors and an engine control device to manage harmful operating modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the engine is stopped rapidly during high thermal stress operation, then the stoppage response time is reduced, but the compressor wheel temperature increases beyond thermal limits causing hardness reduction

Engineering Contradiction:

Improvestoppage response speedVSAvoidcompressor wheel temperature

Core Design Contradiction:

SpeedVSTemperature

Solution Approach 1:

The control system performs preliminary evaluation of the compressor wheel temperature before allowing engine stoppage. When the temperature exceeds the thermal limit, the system preemptively prevents the stoppage action from occurring, thereby avoiding the thermal rebound that would otherwise cause hardness reduction in the compressor wheel

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors compressor wheel temperature and uses this feedback to dynamically control engine stoppage permissions. The feedback loop compares real-time temperature data against thermal limits and adjusts stoppage authorization accordingly, preventing temperature excursions that lead to material degradation

Inventive Principle:

Principle #23Feedback

2Strength

If complex machining processes are applied to improve compressor wheel hardness resistance, then the thermal resistance is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvecompressor wheel hardness resistanceVSAvoidmachining process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Instead of modifying the physical structure or material properties through complex machining, the system changes the operational parameters by controlling engine stoppage timing based on temperature conditions. This parameter-based approach achieves the same protective effect without the manufacturing complexity of specialized machining processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical/manufacturing solutions (complex machining processes) with a control system approach. The electronic control system monitors temperature and manages stoppage events, substituting the need for complex mechanical hardening processes with a software-based protective mechanism

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If multiple turbochargers are arranged in sequential series configuration, then the powertrain performance is improved, but the compressor wheel temperature increases by 75% causing accelerated thermal damage

Engineering Contradiction:

Improvepowertrain performanceVSAvoidcompressor wheel temperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The control system dynamically adapts stoppage restrictions based on the operational context of multi-turbocharger configurations. By continuously evaluating temperature conditions and adjusting stoppage permissions in real-time, the system accounts for the amplified thermal effects of sequential series arrangements while maintaining powertrain performance

Inventive Principle:

Principle #15Dynamics

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

Prevents structural modifications and thermal limit overruns in the compressor wheel, maintaining its hardness and reducing the risk of contact with the casing, thereby extending the turbocharger's lifespan and efficiency.

Implementation Method 1

a processing unit and temperature sensors as well as a link network connecting this processing unit to the temperature sensors

Methodology Applied

Scientific EffectTemperature sensing: Thermocouple

Implementation Method 2

the heat accumulated at the level of the turbine partly passes through the turbo axis, thus increasing the temperature in the compressor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

This lubrication system participates in maintaining the temperature in the compressor and in particular the temperature of the compressor wheel at a stabilized temperature

Methodology Applied

Scientific EffectThermal convection: Convection

Data Source

PatentEP3330520B1Method and system for protecting a turbocharger compressor wheel

Publication Date: 2019.08.28 RENAULT SA

Figure 1~3
Figure 4~5

AI summary

The invention relates to a method of protecting a wheel (12a, 12b) of a compressor (10a, 10b) of a turbocharger (7a, 7b), in particular a high-pressure turbocharger (7a) of a powertrain (24) of a vehicle, the method comprising a step of continuously evaluating (17) a temperature (Tr) of the wheel (12a, 12b) and if a motor (6) of the powertrain (24) is in an operating mode damaging to said wheel (12a, 12b) the method comprises a step of inhibiting a shutdown of the motor (6) when the temperature (Tr) of the wheel (12a, 12b) is greater than a setpoint temperature (Tc).