Inclined Vaneless Space for Turbocharger Compressor
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Solution Overview
Problem
Existing compressor assemblies in turbochargers face issues with high frequency vibrations and fatigue failure of compressor impeller blades due to pressure wakes generated by diffuser vanes, and are not optimized for mixed flow compressors with angular and axial velocity components.
Innovation Solution
A compressor assembly with a diffuser ring having at least one vane and a vaneless space inclined at an angle relative to the rotational axis, which reduces the impact of pressure wakes and improves airflow efficiency by minimizing gaps between vane tips and the inner wall, thereby reducing vibrations and fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If diffuser vanes are used to direct air flow, then air pressure is increased, but high frequency vibrations and fatigue failure of compressor blades occur
Solution Approach 1:
The diffuser is segmented into two functional zones: a vaneless diffuser space that extends from the impeller outlet to capture and smooth wake effects, and a vane-equipped diffuser section that begins where the vaneless space ends. This segmentation allows each zone to perform its specific function optimally without the harmful effects of the other.
Solution Approach 2:
The vaneless diffuser space acts as an intermediary element between the impeller and the vane diffuser section. It serves as a transition zone that smooths out turbulent wake effects and pressure fluctuations before the air enters the vane diffuser section, thereby protecting the compressor blades from vibration-induced fatigue.
2Object-affected harmful factors
If vaneless diffuser space is used to smooth wake effects, then vibration is reduced, but the space may not be large enough to prevent high frequency excitation
Solution Approach 1:
The vaneless diffuser space is designed with an inclined configuration rather than a simple radial extension. By tilting the diffuser space at an angle relative to the impeller rotation plane, the design creates additional spatial volume in the axial direction while maintaining effective radial coverage, thereby increasing the space available to capture wake effects without increasing overall radial dimensions.
3Productivity
If traditional diffuser design is used, then air flow is directed efficiently, but gaps between vane tips and inner wall create leakage and reduce efficiency
Solution Approach 1:
The diffuser ring is designed with flexibility to allow dynamic adjustment of vane positions. The vanes can move independently to respond to varying flow conditions, enabling them to maintain optimal contact with the inner wall across different operating points and preventing gaps that would cause leakage and energy loss.
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 solution effectively reduces high frequency vibrations and fatigue failures of compressor blades, enhances airflow pressure, and improves the overall efficiency of the compressor stage by ensuring vane tips remain in contact with the inner wall, thus improving engine performance.
Implementation Method 1
the vaneless diffuser space, by virtue of its lack of vanes or other structural barriers, serves to smooth out wake and sonic shock effects inherent in the compressed fluid discharged radially outwardly from the impeller blades
Implementation Method 2
smooth out wake and sonic shock effects inherent in the compressed fluid discharged radially outwardly from the impeller blades
Implementation Method 3
The compressor stage of a turbocharger often includes a diffuser configured to reduce the speed of the air leaving the compressor wheel. Reducing the air speed causes the air pressure within the compressor stage to increase
Implementation Method 4
The compressor wheel receives cool air from the ambient and forces compressed air into combustion chambers of the engine
Data Source
AI summary
A compressor assembly is disclosed. The compressor assembly may have a compressor housing. The compressor housing may have an inner wall. The compressor assembly may also have a compressor impeller disposed within the compressor housing. Further, the compressor assembly may have a bearing housing attached to the compressor housing. The bearing housing may have a body portion and a web extending outward from the body portion to a web end. The compressor assembly may also have a diffuser ring disposed between the inner wall and the web. The diffuser ring may have at least one vane. In addition, the compressor assembly may have a vaneless space extending between the compressor impeller and the vane. The vaneless space may be inclined at an angle relative to a plane disposed orthogonal to a rotational axis of the compressor assembly.