Electric Compressor for Turbocharger Surge Suppression

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Solution Overview

Problem

Turbocharger compressors experience oscillations and 'turbocharger lag' due to sudden changes in air flow, leading to inefficiencies and delayed engine torque production, as existing solutions like compressor bypass valves result in energy loss and inadequate boost pressure.

Innovation Solution

Implementing an electrically driven compressor that can be activated by a controller in response to surge conditions, adjusting its speed to maintain optimal air pressure and reduce oscillations, thereby conserving boost pressure and minimizing lag.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a compressor bypass valve is opened to reduce compressor oscillation, then compressor stability is improved, but energy is lost and boost pressure is reduced

Engineering Contradiction:

Improvecompressor stabilityVSAvoidenergy loss

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The patent replaces the purely mechanical compressor bypass valve system with an electronically controlled system. The controller receives sensor data about compressor operating conditions and activates the second compressor (or opens the bypass valve) based on analyzed surge conditions, enabling precise control that reduces energy loss while maintaining stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the operational parameters of the compressor by activating a second compressor or opening a bypass valve only when specific surge conditions are detected through sensor data analysis. This conditional parameter change allows the system to maintain compressor stability only when needed, rather than continuously, thereby reducing energy loss.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If a compressor bypass valve is opened to reduce compressor oscillation, then compressor stability is improved, but turbocharger lag increases

Engineering Contradiction:

Improvecompressor stabilityVSAvoidturbocharger lag

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The system uses sensor data to continuously monitor compressor operating conditions and provides feedback to the controller. The controller analyzes this data to detect surge conditions and responds by activating the second compressor or opening the bypass valve only when necessary, minimizing the time the system operates in a suboptimal state and reducing turbocharger lag.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The controller analyzes sensor data to detect surge conditions before they fully develop, allowing the system to take preliminary action by activating the second compressor or opening the bypass valve in advance. This prevents full surge oscillation from occurring, maintaining compressor stability while minimizing the duration of any intervention.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If the throttle is quickly closed to reduce air flow through the compressor, then compressor oscillation is reduced, but engine air flow demand is not met

Engineering Contradiction:

Improvecompressor stabilityVSAvoidengine air flow

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent segments the compressor system into a first compressor (turbocharger) and a second compressor (electrically driven). When surge conditions are detected, the controller activates the second compressor to provide additional air flow, allowing the system to maintain engine air flow demand while managing compressor stability through the combined operation of both compressors.

Inventive Principle:

Principle #1Segmentation

4Stability of the object's composition

If a second compressor is activated to reduce compressor oscillation, then compressor stability is improved, but device complexity increases

Engineering Contradiction:

Improvecompressor stabilityVSAvoidcompressor system complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The second compressor is designed with multi-functionality: it can operate independently to provide air flow when the first compressor is in surge conditions, and it can also operate in conjunction with the first compressor under normal conditions. The controller analyzes sensor data to determine the appropriate operating mode, allowing a single component to serve multiple functions and reducing the need for additional dedicated surge protection components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach reduces compressor oscillations, conserves turbocharger boost, and provides quick access to boost pressure, improving engine performance and reducing turbocharger lag by actively managing air flow and pressure through the electrically driven compressor.

Implementation Method 1

activating a second compressor in an engine intake via the controller

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS9790849B2Method and system to operate a compressor for an engine

Publication Date: 2017.10.17 FORD GLOBAL TECH LLC

AI summary

Methods and systems for operating an engine that includes two compressors is disclosed. In one example, an electrically driven compressor is activated in response to conditions where a turbocharger compressor speed oscillates. The electrically driven compressor is activated to cancel engine air intake flow oscillations that may be caused by the turbocharger compressor.