Turbocharger Direct Turbine Interface for Flow Alignment
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Solution Overview
Problem
Two-stage turbocharger systems face challenges in achieving desired gas flow and reliability while minimizing size, packaging, assembly, and installation costs, due to competing concerns with mass flow through turbines and other factors.
Innovation Solution
A turbocharger system design featuring a direct turbine-to-turbine interface with concentric rotational axes, where the outlet portion of one turbine housing radially surrounds the inlet portion of another, and a sealing structure hermetically seals the interface to maintain axial mobility and restrict radial displacement, ensuring smooth gas flow alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-stage turbocharger system is used to improve engine efficiency and achieve fuel economy targets, then the engine efficiency and environmental performance are improved, but the financial cost, size, packaging complexity, assembly difficulty, and installation constraints increase
Solution Approach 1:
The patent merges the first and second turbine housings into a single integrated structure where the outlet portion of the first turbine housing directly interfaces with the inlet portion of the second turbine housing. This consolidation eliminates the need for separate housings and intermediate connections, thereby reducing packaging space and assembly complexity while maintaining the two-stage turbocharging function for improved engine efficiency
Solution Approach 2:
The patent implements a nested configuration where the second turbine inlet portion is inserted within the first turbine outlet portion, creating a concentric arrangement. This nesting approach allows the turbines to be compactly arranged along a common rotational axis, reducing the overall size and packaging requirements of the two-stage turbocharger system while preserving the sequential gas flow path
2Device complexity
If a direct turbine-to-turbine interface is implemented to reduce size and number of components, then the packaging size and component count are reduced, but the manufacturing precision and assembly tolerances become more critical
Solution Approach 1:
The patent employs asymmetric design features at the turbine interface, including a sealing structure with specific geometric profiles and asymmetric positioning of the second turbine inlet within the first turbine outlet. This asymmetric configuration provides built-in alignment guidance that compensates for manufacturing tolerances, ensuring proper gas flow alignment without requiring extremely tight manufacturing precision
Solution Approach 2:
The patent introduces a sealing structure as an intermediary element at the interface between the first and second turbine housings. This sealing structure serves multiple functions: it hermetically seals the direct interface to prevent gas leakage, provides a tolerance buffer that accommodates manufacturing variations, and maintains the axial mobility of the turbine assembly while restricting radial displacement, thereby facilitating easier assembly without compromising manufacturing precision
3Reliability
If intervening components are eliminated to reduce leakage and improve gas flow alignment, then the gas flow efficiency and reliability are improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the sealing function and the structural interface function into a single integrated sealing structure that is hermetically sealed to both the first and second turbine housings. This merger eliminates the need for separate sealing components and intermediate flanges, reducing the total number of parts and simplifying assembly while maintaining reliable gas flow alignment between the turbines
Solution Approach 2:
The sealing structure performs multiple functions simultaneously: it hermetically seals the turbine interface to prevent gas leakage, provides alignment guidance for the concentric turbine arrangement, accommodates assembly tolerances, and maintains axial mobility while restricting radial displacement. This multi-functionality reduces the need for additional specialized components, thereby easing manufacturing and assembly despite the direct interface requirement
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
This configuration enhances gas flow alignment and reliability by eliminating intervening components, reducing leakage, and accommodating assembly tolerances, thereby improving the efficiency and cost-effectiveness of two-stage turbocharger systems.
Implementation Method 1
a sealing structure hermetically sealing the portion of the axial outlet portion to the second turbine housing
Implementation Method 2
provide a direct interface from the fluid outlet of the first turbine to the fluid inlet of the second turbine in an axial direction
Data Source
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AI summary
Turbine assemblies and related turbocharger systems having direct turbine interfaces are provided. One exemplary turbine assembly includes a first turbine housing having an outlet portion defining a fluid outlet of a first turbine and a second turbine housing having an inlet portion defining a fluid inlet of a second turbine, wherein at least a portion of the outlet portion radially surrounds at least a portion of the inlet portion to provide a direct interface from the fluid outlet of the first turbine to the fluid inlet of the second turbine in an axial direction.