Modular Multi-Stage Supercharger Architecture for Reduced Development Complexity
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Solution Overview
Problem
Existing supercharging devices for internal combustion engines are typically designed individually for specific applications, making it difficult to reuse or adapt existing components, leading to increased development costs and complexity.
Innovation Solution
A modular multi-stage supercharging device design that allows for the reuse of core components across different configurations, with independent modules on the charge air side and exhaust gas side, enabling flexible assembly and reduced spare parts inventory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If supercharging devices are designed individually for specific applications, then the device can be optimized for defined requirements, but the development cost and complexity increase significantly
Solution Approach 1:
The supercharging device is divided into independent modular components: compressors (low-pressure and high-pressure), turbines (low-pressure and high-pressure), intercooler, muffler, and housing. Each module can be independently designed, tested, and optimized for specific requirements while maintaining standardized interfaces for assembly.
Solution Approach 2:
Standardized modular components are designed to be reusable across different supercharging device configurations. The same compressor, turbine, or intercooler modules can be adapted for various applications by combining them in different arrangements, reducing development complexity while maintaining optimization capabilities.
2Reliability
If all subassemblies are subjected to new development for a newly designed supercharging device, then the device can be optimized for specific requirements, but the development time and resources increase
Solution Approach 1:
Modular components are pre-designed, tested, and validated independently before being integrated into the complete supercharging device. Calculation and test results from individual module development can be transferred and reused across different device configurations, significantly reducing overall development time.
Solution Approach 2:
Previously developed and tested modular components are recovered and reused in new supercharging device designs. Instead of discarding existing validated modules, they are adapted and integrated into new configurations, reducing redundant development work.
3Reliability
If existing components cannot be accessed or reused when developing a new charging device, then each device can be optimized independently, but the manufacturing cost and complexity increase
Solution Approach 1:
The modular architecture enables existing components to be accessed and reused across different supercharging device models. Standardized modules such as compressors, turbines, and intercoolers can be manufactured once and used in multiple configurations, reducing manufacturing costs while maintaining independent optimization capabilities through module selection and arrangement.
4Adaptability or versatility
If multiple assembly variants are provided for different charging devices, then specific requirements can be met, but the spare parts inventory and training expenses increase
Solution Approach 1:
By segmenting the supercharging device into standardized modular components with uniform interfaces, the number of unique assembly variants is reduced. Different configurations are achieved by assembling the same set of standardized modules in different arrangements, rather than creating entirely different device designs, thereby simplifying spare parts inventory and training requirements.
Data Source
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AI summary
Modular system for multiple-stage supercharging devices which have, as exhaust gas-side assemblies, at least one high pressure turbine (11), a low pressure turbine (12) and an exhaust-gas outflow housing (13), and which have, as charge air-side assemblies, at least one high pressure compressor (20), a low pressure compressor (19) and a charge air cooler (27) which is connected between the low pressure compressor and the high pressure compressor, wherein a supercharging device can be assembled from a plurality of modules of the modular system, namely in such a way that: the charge air-side modules, namely at least the high pressure compressor (20) with the high pressure compressor rotor (24) and the high pressure compressor housing (26), the low pressure compressor (19) with the low pressure compressor rotor (21) and the low pressure compressor housing (23), and the charge air cooler (27) which is connected between the low pressure compressor and the high pressure compressor, are independent of the design of the exhaust gas-side modules; as exhaust gas-side modules, the high pressure turbine (11) with the high pressure turbine rotor (14) and the high pressure turbine housing (15) and the low pressure turbine (12) with the low pressure turbine rotor (16) and the low pressure turbine housing (17) are dependent on whether the high pressure turbine is configured as a radial turbine or as an axial turbine and the low pressure turbine is configured as a radial turbine or as an axial turbine; as exhaust gas-side modules, the high pressure turbine housing (15) and the low pressure turbine housing (17) are dependent on whether the supercharging device is configured without exhaust gas aftertreatment or with exhaust gas aftertreatment between the high pressure turbine and the low pressure turbine. An associated supercharging device is likewise presented.