Convolute-Swirl Integrated Duct for Compressor Stability
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Solution Overview
Problem
Gas turbocharger direct injection engines face instability, aerodynamic losses, and noise, vibration, and harshness (NVH) issues due to misaligned air intake rotation with the compressor impeller, and existing swirl vane devices add complexity and weight while restricting flow.
Innovation Solution
A convolute-swirl integrated duct (CSID) with inwardly protruding spiral threads is used to generate pre-swirl and absorb engine roll, aligning air intake with the compressor impeller without additional components or flow restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a swirl vane device is inserted into the intake passage to generate pre-swirl, then compressor stability is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the convolute housing (which absorbs engine roll) with swirl-generating elements (spiral threads or vanes) into a single integrated device. This merging eliminates the need for separate swirl vanes, reducing component count and system complexity while maintaining both vibration absorption and pre-swirl generation functions
Solution Approach 2:
The convolute housing is designed to perform multiple functions simultaneously: it absorbs engine roll vibrations through its flexible bellows structure and generates pre-swirl in the intake air through integrated spiral threads or vanes. This multi-functionality reduces the overall number of components needed in the air induction system
2Reliability
If swirl vanes are added to the intake passage, then air flow alignment with compressor impeller is improved, but weight increases
Solution Approach 1:
The swirl-generating elements are integrated directly into the convolute housing structure, eliminating the need for separate swirl vane assemblies. This integration reduces the total weight of the air induction system while maintaining effective pre-swirl generation capability
Solution Approach 2:
The swirl-generating features (spiral threads or vanes) are placed only in the specific region where air flow redirection is needed, rather than using a complete swirl vane assembly throughout the intake passage. This localized approach reduces material usage and weight
3Reliability
If traditional swirl vane devices are installed, then pre-swirl is generated, but flow restriction occurs
Solution Approach 1:
The convolute housing with its flexible bellows structure allows for dynamic adjustment of the intake passage geometry in response to engine vibrations, maintaining optimal flow characteristics. The spiral threads or vanes are integrated in a way that guides air flow smoothly without creating sharp restrictions
Solution Approach 2:
The spiral threads or curved vanes are designed with smooth, gradual curvature rather than sharp edges, creating a streamlined flow path that generates pre-swirl while minimizing flow separation and pressure losses. The curved geometry of the convolute housing itself also contributes to smooth air flow transition
4Ease of manufacture
If additional assembly components are used to couple the swirl device, then device installation is enabled, but manufacturing complexity increases
Solution Approach 1:
The swirl-generating elements are integrated directly into the convolute housing during manufacturing, eliminating the need for separate assembly steps and additional coupling components. This integration simplifies both manufacturing and installation processes while maintaining the functional benefits of pre-swirl generation
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 CSID improves compressor stability and efficiency by aligning air intake with the compressor impeller, reducing NVH issues and maintaining flow rates while absorbing engine vibrations in a single, accessible device.
Implementation Method 1
absorbing vibrational motion transmitted to the intake passage from the moving engine
Implementation Method 2
The flexible conduit may be a convolute-swirl integrated duct (CSID) formed from flexible materials
Implementation Method 3
The threads guide air flow, similar to the guide vanes of the swirl vane device, to swirl in a direction according to a direction that the threads wind around the CSID
Data Source
AI summary
Methods and systems are provided for a convolute-swirl integrated duct (CSID). In one example the CSID may be configured to comply with engine roll and induce swirl in an intake air flow. Engine roll is absorbed as a result of a positioning of the CSID along an intake passage upstream of a compressor inlet and pre-whirl is introduced to intake air prior to delivery of the intake air to a compressor.