Segmented Nozzle Ring Flow Contour for Compact Radial Turbines
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Solution Overview
Problem
Existing manufacturing processes for exhaust gas turbochargers with radial turbines face challenges in producing a flow contour between the nozzle ring and turbine wheel due to insufficient material, as modifying the blank would compromise the core gap's stability and manufacturability.
Innovation Solution
A nozzle ring design comprising a first and second ring element with a convex curvature and radial inward extension, along with guide vanes, to overcome material limitations and improve flow guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the blank is modified to provide sufficient material for the flow contour, then the flow contour between nozzle ring and turbine wheel can be produced, but the core gap stability and manufacturability are compromised
Solution Approach 1:
The nozzle ring is divided into two separate ring elements (first ring element and second ring element) that can be manufactured independently and then assembled together. This segmentation allows each element to be produced within feasible manufacturing limits while collectively forming the complete flow contour that would otherwise require modifying the blank
Solution Approach 2:
The two ring elements are nested together to form the complete nozzle ring structure. The first ring element and second ring element fit together to create the full flow contour, enabling the formation of complex geometries that cannot be achieved from a single blank without compromising core gap stability
2Length of moving object
If small turbine blade heights are used, then the turbocharger size is reduced, but the flow contour cannot be produced from existing blank due to insufficient material
Solution Approach 1:
By segmenting the nozzle ring into two elements, the design enables small turbine blade heights to be achieved while still providing sufficient material for the flow contour. Each ring element can be optimized for compact dimensions while collectively maintaining the required flow geometry
Solution Approach 2:
The flow contour is formed by combining two ring elements in the radial direction, effectively using an additional dimensional approach to provide sufficient material volume for the flow contour while maintaining compact turbine blade heights in the axial direction
3Shape
If the core gap is reduced to provide more material, then the flow contour can be formed, but the connection stability to the outer mold becomes insufficient
Solution Approach 1:
Segmenting the nozzle ring into two elements eliminates the need to reduce the core gap for material purposes. Each element can be manufactured with adequate core gap dimensions for stable connection, while the assembled pair provides the complete flow contour geometry
Data Source
Figure 1~2
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AI summary
The invention relates to a nozzle ring (10) for a radial turbine. The nozzle ring (10) comprises a first ring element (11), a second ring element (12), and a plurality of guide vanes (13) arranged between the first ring element (11) and the second ring element (12). The second ring element (12) comprises an end region (12E), which extends inwards exclusively in the radial direction and has a convex curvature (141) on a side (121) facing the first ring element (11). The invention also relates to an exhaust turbine and to a turbocharger.