Turbo Compressor Insert Unit for Surge Prevention
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Solution Overview
Problem
Conventional turbochargers experience compressor surge, leading to efficiency decreases, wear on bearing components, and noise vibration harshness issues due to violent airflow oscillations.
Innovation Solution
A turbo compressor assembly with an insert unit and actuator unit that controls airflow by variably positioning the insert unit along the air intake channel, adjusting air speed to prevent compressor surge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional turbo charger with a solid shaft coupling the compressor wheel and exhaust gas turbine wheel is used, then the structure is simple and manufacturing cost is low, but compressor surge occurs leading to efficiency decrease and bearing wear
Solution Approach 1:
The air intake channel is segmented into multiple sections with adjustable flow control devices positioned at different locations. Each segment can independently control airflow characteristics, allowing precise management of air velocity and flow distribution to the compressor wheel, thereby preventing surge while maintaining structural organization
Solution Approach 2:
The flow control devices are designed to be dynamically adjustable based on operating conditions. By varying the opening positions of the flow control devices, the airflow characteristics can be optimized for different mass flow rates, preventing compressor surge at both high and low operating points without requiring a completely different structure
2Productivity
If the air intake channel is designed to provide high mass flow rate, then the compressor efficiency is improved, but violent airflow oscillations and compressor surge occur
Solution Approach 1:
Different sections of the air intake channel have different flow control characteristics. The flow control devices are positioned to create localized flow management zones, ensuring that each region of the channel contributes optimally to overall airflow stability while maintaining high mass flow rate to the compressor wheel
Solution Approach 2:
The system incorporates flow control devices that can be adjusted based on feedback from compressor operating conditions. By monitoring mass flow rate and adjusting the flow control device positions accordingly, the system maintains stable airflow and prevents surge while maximizing productivity
3Stability of the object's composition
If the air intake channel is designed to provide low mass flow rate, then airflow stability is improved, but compressor efficiency decreases
Solution Approach 1:
The flow control devices enable dynamic adjustment of airflow characteristics to match compressor demands. At low mass flow rates, the devices are positioned to optimize stability and prevent surge, while at higher rates they are adjusted to maximize efficiency, allowing the system to maintain good performance across the entire operating range
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 solution effectively reduces or eliminates compressor surge, ensuring a stable air supply to the compressor wheel, thereby improving turbocharger efficiency and reducing mechanical stress and noise.
Implementation Method 1
the compressor wheel is configured to rotate for compressing the drawn air from the air intake channel
Implementation Method 2
The insert unit is arranged between the air intake channel and the compressor wheel and configured to control an airflow to the compressor wheel
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The present disclosure relates to a turbo compressor assembly, a vehicle comprising such a turbo compressor assembly, a method for manufacturing such a turbo compressor assembly. The turbo compressor assembly comprises an air intake channel, a compressor wheel, an insert unit and an actuator unit. The air intake channel is configured to draw air to the compressor wheel and the compressor wheel is configured to rotate for compressing the drawn air from the intake channel. The insert unit is arranged between the air intake channel and the compressor wheel and configured to control an airflow to the compressor wheel. The actuator unit is connected to the insert unit and configured to move the insert unit at least partially along the air intake channel.