Split Tube Cooling for Turbocharger Stator Housing
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Solution Overview
Problem
Exhaust gas turbochargers and electric turbochargers face inefficiencies due to large stator housing designs and inadequate cooling, which affect performance and reliability, especially at low engine speeds and during high-load conditions.
Innovation Solution
A compact stator housing design with an axially extending cooling channel and a split or separation tube between the rotor and stator, allowing direct coolant flow for efficient cooling, and potentially using die casting for production to reduce material costs and simplify manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are provided in the stator housing, then cooling of the stator is achieved, but the stator housing design becomes large and complex
Solution Approach 1:
The cooling function is extracted from the stator housing by introducing a separate split tube between the rotor and stator. The split tube contains cooling channels that are independent of the stator housing structure, allowing efficient cooling without complicating the housing design.
Solution Approach 2:
The split tube acts as an intermediary component that mediates between the rotor and stator. It provides a dedicated cooling pathway through the split tube walls, enabling heat transfer from the stator without requiring integrated cooling channels in the stator housing.
2Temperature
If the stator housing is designed with integrated cooling channels, then cooling is provided, but material costs and manufacturing complexity increase
Solution Approach 1:
The charging device is segmented into distinct functional components: the stator housing for structural support, the split tube for cooling, and the rotor-stator assembly. This segmentation allows each component to be manufactured independently using optimal processes, such as die casting for the housing and simpler fabrication for the split tube.
Solution Approach 2:
The cooling function is extracted from the stator housing structure and implemented through a separate split tube component. This extraction simplifies the stator housing design, enabling easier and more cost-effective manufacturing without integrated cooling channels.
3Ease of manufacture
If a compact stator housing design is used, then material costs are reduced, but cooling efficiency of the stator may be insufficient
Solution Approach 1:
The split tube serves as an intermediary cooling structure that provides efficient thermal management without requiring a large stator housing. The cooling channels in the split tube walls offer direct thermal contact with the stator, achieving high cooling efficiency in a compact configuration.
Solution Approach 2:
A coolant fluid is circulated through the cooling channels in the split tube, utilizing fluid-based heat transfer to efficiently cool the stator. This hydraulic cooling system achieves high thermal management effectiveness in a compact design.
4Volume of moving object
If the rotor and stator are directly adjacent without separation, then device compactness is improved, but cooling of the rotor is insufficient
Solution Approach 1:
The split tube serves multiple functions simultaneously: it acts as a structural separator between the rotor and stator, provides cooling channels for the stator, and facilitates rotor cooling through its wall structure. This multi-functionality achieves both compactness and effective cooling.
Solution Approach 2:
The split tube acts as an intermediary structure between the rotor and stator, enabling both components to be cooled effectively while maintaining compact spacing. The tube walls provide thermal pathways for cooling both the rotor (from the inside) and stator (from the outside).
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 design achieves efficient cooling of both the stator and rotor, enabling improved performance and reliability by reducing material costs and simplifying production, while maintaining a compact form factor.
Implementation Method 1
a cooling channel for accommodating a coolant extending axially between the stator housing and the stator
Implementation Method 2
the stator is directly flushed by cooling fluid and thus an efficient cooling of the stator is facilitated
Implementation Method 3
a first seal is provided in the axial direction between the stator housing and a first end of the stator and a second seal is provided in the axial direction between the stator housing and a first end of the split tube
Data Source
AI summary
A charging device for an internal combustion engine with a shaft, a compressor wheel arranged on the shaft, a stator housing and a stator. The stator is arranged within the stator housing. A rotor is arranged on the shaft and a cooling channel for accommodating a coolant extends axially between the stator housing and the stator. A split tube is provided between the rotor and stator. A first seal is provided in the axial direction between the stator housing and a first end of the stator and a second seal is provided in the axial direction between the stator housing and a first end of the split tube. Alternatively to the split tube, a separation tube is arranged between the stator and the stator housing so that the cooling channel is formed in the radial direction between the separation tube and the stator housing.