Diffuser Divider for Turbocharger Compressor Surge Control
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Solution Overview
Problem
Compressor surge occurs in turbocharged engines due to flow instabilities, particularly at high load or low engine speed, leading to unstable operation and rapid pressure and flow reversals, which existing technologies struggle to prevent effectively.
Innovation Solution
Incorporating a diffuser divider in the compressor assembly that creates two throats for the air streams from dual-faced compressor wheels, allowing mixing at a lower radial velocity and improving stability by relocating the interaction point downstream, thus delaying surge and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single diffuser section is used in the compressor assembly, then the structure is simple, but compressor surge occurs at lower flow rates limiting the operating envelope
Solution Approach 1:
The diffuser section is divided into a first diffuser passage and a second diffuser passage using a diffuser divider, allowing separate flow paths for air streams from different compressor wheel faces. This segmentation delays surge by enabling independent flow development in each passage while maintaining overall structural integrity.
Solution Approach 2:
The diffuser divider extends axially through the diffuser section, creating a three-dimensional flow separation that organizes air streams from dual-faced compressor wheels into distinct radial and axial flow zones. This dimensional organization prevents flow interference and stabilizes operation at lower flow rates.
2Productivity
If dual-faced compressor wheels are used to increase flow capacity, then productivity increases, but flow instability and surge occur more readily
Solution Approach 1:
The diffuser divider separates air streams from the first and second faces of the dual-faced compressor wheel into distinct first and second diffuser passages. This segmentation prevents flow interference between the two faces while maintaining the high flow capacity benefits of dual-faced design.
Solution Approach 2:
The diffuser divider acts as an intermediary structure between the two compressor wheel faces, mediating the interaction of air streams by providing separate flow paths that converge downstream. This intermediary structure eliminates direct flow interference that would otherwise cause instability.
3Power
If the compressor operates at high load and low engine speed, then power output is maintained, but surge conditions are more likely to occur
Solution Approach 1:
The diffuser divider creates dynamic flow separation that adapts to varying operating conditions. At high load and low speed conditions, the separated passages maintain stable flow patterns that prevent surge, while allowing the compressor to operate at high power output requirements.
Solution Approach 2:
The diffuser divider modifies flow parameters (velocity distribution, pressure gradient) in each diffuser passage independently, allowing the compressor to maintain stable operation across a wider range of operating conditions including high load, low speed scenarios where surge would normally occur.
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 diffuser divider stabilizes compressor operation at lower flow rates, delays surge, and widens the compressor map, reducing the risk of instability and improving transient response and turbine efficiency, especially in high exhaust gas recirculation scenarios.
Implementation Method 1
a first throat of the two throats configured to receive an air stream via an exducer of the first face, and a second throat of the two throats configured to receive an air stream via an exducer of the second face
Implementation Method 2
mixing of two air streams occurs... where a leading edge of a divider is positioned proximate to an outer circumference of a dual-faced compressor wheel, each exducer air stream travels radially outward in a respective throat until the throats join
Implementation Method 3
via a diffuser section... As cross-sectional flow area of a diffuser section typically increases with increasing radial position
Data Source
AI summary
A diffuser divider shaped as disc with a central axis, a leading edge disposed at an inner radius about the central axis, a trailing edge disposed at an outer radius about the central axis, an upper surface disposed between the leading edge and the trailing edge, a lower surface disposed between the leading edge and the trailing edge and one or more mounting features configured to mount the disc in a diffuser section configured to receive air compressed by two compressor wheel faces and to direct the compressed air to a volute. Such a divider can define throats in a diffuser section of a compressor assembly. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.