Split Electric Turbocharger Without Wastegate for Altitude Control
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Solution Overview
Problem
Aircraft turbochargers face challenges in delivering optimal manifold air pressure at varying altitudes, with traditional turbochargers performing poorly at sea level when designed for high altitudes and vice versa, and wastegates wasting valuable exhaust heat and pressure to regulate performance.
Innovation Solution
A split turbocharger design with independent electric turbine and compressor components connected to a high-voltage electric bus, allowing the turbine to extract maximum torque and power from the exhaust stream and the compressor to optimize performance at different altitudes without a wastegate, using inlet guide vanes and valves for control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional turbocharger is designed for high altitude performance, then it delivers optimal manifold air pressure at high altitudes, but it performs poorly at sea level
Solution Approach 1:
The turbocharger is divided into independent electric turbine and electric compressor components connected to a high-voltage electric bus, allowing each component to be independently controlled and optimized for different operating conditions including various altitudes
Solution Approach 2:
The electric turbine and compressor enable dynamic adjustment of turbocharger performance characteristics, allowing the system to adapt in real-time to changing altitude conditions and maintain optimal engine power output across the full altitude range
2Ease of operation
If a wastegate is used to regulate turbocharger performance, then the turbocharger can control manifold air pressure, but valuable exhaust heat and pressure are wasted
Solution Approach 1:
The mechanical wastegate system is replaced with an electric turbine and electric compressor controlled by inlet guide vanes and valves, eliminating the need to dump exhaust gases and allowing full utilization of exhaust energy for driving the electric turbine
Solution Approach 2:
The control mechanism changes from mechanical pressure-based wastegate operation to electrically controlled inlet guide vanes and valves, enabling precise regulation of manifold air pressure without energy loss through exhaust gas dumping
3Device complexity
If a traditional turbocharger design is used, then the structure is simple, but the power-to-weight ratio is inferior
Solution Approach 1:
The turbocharger is segmented into independent electric turbine and electric compressor modules connected to a shared high-voltage electric bus, allowing for optimized component sizing and reduced overall weight while maintaining functional performance
Solution Approach 2:
The high-voltage electric bus serves multiple functions by powering both the electric turbine and electric compressor, reducing the need for separate mechanical drive systems and thereby reducing overall turbocharger weight
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 split turbocharger design enhances engine power output, reduces weight, and provides a better power-to-weight ratio by optimizing compressor performance across altitude ranges and eliminating the need for wastegates, resulting in a net increase in available power.
Implementation Method 1
a turbine configured to receive exhaust air from the engine
Implementation Method 2
an electric generator configured to be driven by the turbine to generate electric power
Implementation Method 3
an electric motor configured to power the compressor
Implementation Method 4
a compressor configured to compress intake air for an engine
Data Source
AI summary
A turbocharger includes a compressor configured to compress intake air for an engine. The turbocharger further includes an electric motor configured to power the compressor. The turbocharger further includes a turbine configured to receive exhaust air from the engine. The turbocharger further includes an electric generator configured to be driven by the turbine to generate electric power.