Cover Cap Flow Guide for Turbocharger Media Gap Machine
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Solution Overview
Problem
Media gap machines in turbochargers face issues with particle deposition on the rotor, leading to potential imbalances and reduced efficiency, while existing solutions often increase installation space and fail to effectively prevent turbulence and soiling.
Innovation Solution
A device with a cover cap and inner sleeve is integrated into the stator, directing the flow past the rotor and preventing direct contact, combined with a flow-optimized design that includes securing struts and an outer sleeve to create a defined media gap, minimizing particle deposition and enhancing cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the rotor is directly exposed to the flow medium, then the media gap machine can be compact, but particle deposition on the rotor occurs leading to imbalance and reduced efficiency
Solution Approach 1:
A cover cap is introduced as an intermediary component between the flow medium and the rotor. The cover cap is arranged upstream of the rotor in the flow direction and directs the flow past the rotor, preventing direct contact between particles and the rotor surface. This mediator component solves the particle deposition problem without requiring a complete enclosure that would increase installation space.
Solution Approach 2:
The cover cap is designed with a specific three-dimensional geometry that extends in the axial direction to cover the rotor at its end face. By utilizing the axial dimension and positioning the cover cap upstream, the solution creates a protective configuration that guides flow along the rotor surface rather than allowing direct impingement, maintaining compact dimensions while preventing deposition.
2Object-affected harmful factors
If flow-optimized measures are implemented to prevent particle deposition, then rotor cleanliness is improved, but installation space requirements increase
Solution Approach 1:
The cover cap serves multiple functions simultaneously: it directs the flow past the rotor to prevent particle deposition, covers the rotor at its end face, and maintains a compact overall configuration. This multi-functional design achieves particle deposition prevention without requiring additional separate components that would increase installation space.
Solution Approach 2:
The cover cap is integrated with the stator structure, merging the protective function with the existing stator components. The cover cap is secured to the stator teeth, combining multiple functions into a unified structure that prevents particle deposition while maintaining compact dimensions and avoiding increased installation space requirements.
3Temperature
If the rotor is exposed to direct flow, then cooling is effective, but turbulence and soiling occur
Solution Approach 1:
The cover cap acts as a flow guide that mediates between the cooling requirement and the prevention of turbulence. It directs the flow in a controlled manner past the rotor, maintaining sufficient flow velocity for cooling while preventing chaotic turbulence that would cause soiling. The cover cap shapes the flow path to achieve both cooling effectiveness and flow stability.
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 improves flow behavior, prevents particle deposition, reduces turbulence, and enhances stator cooling, maintaining efficiency and balance without increasing installation space.
Implementation Method 1
the stator has a multi-phase drive winding for generating a drive magnetic field
Implementation Method 2
a rotating drive magnetic field, which drives the rotor, rotatably mounted by means of the shaft
Implementation Method 3
the rotor and stator of the media gap machine are cooled by the air flow
Data Source
AI summary
The invention relates to an electric media gap machine (10) for a compressor and/or a turbine, in particular for a turbocharger of an internal combustion engine, including a shaft (5) which is rotatably mounted in a housing (6) and on which a rotor (11) is arranged in a rotationally fixed manner, a stator (12) which is fixed to the housing and which has at least one multi-phase drive coil (16) for generating a drive magnetic field and multiple stator teeth (15) that protrude radially inward, and a device (17) which is fixed to the stator for optimizing the flow of a medium flowing through the media gap machine. The device (17) has a cover cap (18) which covers at least the rotor (11) upstream thereof, wherein the cover cap (18) is adjoined by an inner sleeve (19) which surrounds the rotor (11) completely in the circumferential direction and at least partly in the axial direction. The device (17) has an outer sleeve (23) which is arranged coaxially to the inner sleeve (19) such that the only flow path for the medium between the inner sleeve (19) and the outer sleeve (23) is formed solely through the stator (12) of the media gap machine.