Turbo Compressor Flow Diversion Channel Stabilization
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Solution Overview
Problem
Turbo compressors are not optimized for efficient operation at volume flows significantly below the design point, leading to flow instabilities and 'pumping' due to vortices and backflow, which affects performance and stability.
Innovation Solution
A flow diversion channel with an increasing cross-sectional area from the impeller-side to the inlet-side opening, decelerating the bypass volume flow and stabilizing part-load operation, combined with a closure unit to control diversion volume flow, prevents unwanted bypasses and flow instabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional turbo compressor design is used, then it operates efficiently at the design point volume flow, but it experiences flow instabilities and pumping at volume flows significantly below the design point
Solution Approach 1:
The flow diversion channel is divided into multiple channel segments arranged in the direction of rotation, which helps to stabilize the bypass volume flow and prevent flow instabilities at reduced volume flows
Solution Approach 2:
The flow diversion channel cross-sectional area increases from impeller-side to inlet-side, creating a dynamic expansion that decelerates the bypass volume flow and stabilizes operation at reduced volume flows
2Reliability
If the flow diversion channel has a constant cross-sectional area, then the structure is simpler, but the bypass volume flow causes turbulence and instability at part-load operation
Solution Approach 1:
The flow diversion channel has different cross-sectional areas at different locations - smaller at the impeller-side opening and larger at the inlet-side opening - to optimize flow deceleration and stability at specific operating conditions
3Reliability
If the inlet-side opening has the same cross-sectional area as the impeller-side opening, then the channel design is simpler, but the bypass volume flow cannot be adequately decelerated for flow stabilization
Solution Approach 1:
The cross-sectional area parameter of the flow diversion channel is changed along its length, increasing from the impeller-side to the inlet-side, to optimize the deceleration of bypass volume flow and achieve flow stabilization at part-load operation
4Reliability
If the flow diversion channel extends continuously around the impeller channel, then more bypass flow can be stabilized, but swirl occurring in the impeller area is transmitted through the channel
Solution Approach 1:
The flow diversion channel is segmented into multiple channel sections arranged in the direction of rotation, which interrupts the continuous path and prevents swirl transmission while maintaining bypass flow stabilization capability
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
Enables stable operation at reduced gas volume flows, preventing 'pumping' and maintaining efficiency down to 40% of the design point gas volume flow, while preventing diversion volume flows that could occur in overload conditions.
Implementation Method 1
the flow cross-sectional area of the flow diversion channel increases from the impeller-side opening to the inlet-side opening... a bypass volume flow flowing in this direction is decelerated due to the possible expansion
Implementation Method 2
depending on a pressure difference between the openings, guides a diversion volume flow
Data Source
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AI summary
The invention relates to a turbo compressor which comprises a compressor housing in which an incoming gas volume flow is supplied to a bladed wheel channel through an inlet channel, is compressed in the bladed wheel channel by a bladed wheel and is carried away by the bladed wheel through an outlet channel. The turbo compressor further comprises a flow deviation channel provided in the compressor housing which flow deviation channel extends outside the bladed wheel channel and the inlet channel and an inlet-side opening of which runs into the inlet channel and a bladed wheel-side opening runs into the bladed wheel channel, said flow deviation channel carrying a deviation volume flow depending on a pressure difference between the openings. In order to improve said turbo compressor such that it can be optimally operated at volume flows that lie far below the values of volume flow for which the turbo compressor is designed, the flow deviation channel, starting from the bladed wheel-side opening, has a flow area that increases towards the inlet-side opening.