E-Assist Turbocharger Bleed Passage for Thrust Load Suppression
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Solution Overview
Problem
Conventional compressor devices are inefficient, bulky, complex, and have limitations in load bearing capacity and reliability, with bearings being a source of contamination and inefficiency.
Innovation Solution
An electric-motor-assisted turbocharger with a bleed fluid system connecting the compressor section to the turbine section, utilizing a bleed pressure member and air bearings for thrust load suppression and rotodynamic stability, which includes a radially extending body to counterbalance thrust loads and provide radial mass to the rotating group.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bearings are used in compressor devices, then the device can support load, but the bearing becomes a source of contamination and reduces operating efficiency
Solution Approach 1:
The patent removes the bearing component entirely from the compressor device, replacing it with a bearingless design where the compressor wheel rotates directly on the drive shaft. This extraction of the bearing eliminates the source of contamination while maintaining load support capability through direct contact between the compressor wheel and shaft.
Solution Approach 2:
The patent replaces the mechanical bearing system with a direct mechanical connection between the compressor wheel and drive shaft. This substitution eliminates the intermediate bearing component that generates contamination, using a simpler direct-contact mechanical interface to achieve both rotation and load support.
2Strength
If conventional compressor devices are designed to handle thrust loads, then load bearing capacity is maintained, but the device becomes bulky and complex
Solution Approach 1:
The patent merges the thrust load support function directly into the compressor wheel structure by adding a thrust face that contacts the drive shaft. This integration combines rotation support and thrust load handling into a single unified interface, eliminating the need for separate thrust bearings and reducing overall device complexity.
Solution Approach 2:
The drive shaft is designed to perform multiple functions simultaneously: it provides rotational drive to the compressor wheel, supports axial thrust loads through direct contact with the thrust face, and maintains centered alignment. This multi-functionality eliminates the need for separate dedicated components for each function, reducing complexity.
3Strength
If bearing capacity is increased to handle higher thrust loads, then load bearing capacity improves, but the device becomes heavier and more complex
Solution Approach 1:
The patent extracts and eliminates the heavy bearing components traditionally used to support thrust loads, replacing them with a lightweight direct-contact interface between the compressor wheel thrust face and the drive shaft. This removal of unnecessary mass significantly reduces device weight while maintaining adequate thrust load capacity.
4Productivity
If conventional compressor devices are designed for high efficiency, then operating efficiency improves, but the device becomes more complex and bulky
Solution Approach 1:
The patent removes complex bearing assemblies and associated sealing systems from the compressor device, simplifying the overall structure. This extraction of unnecessary components reduces device complexity while actually improving operating efficiency by eliminating sources of friction, contamination, and mechanical loss.
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 enhances operating efficiency, reduces complexity and cost, and improves load bearing capacity while maintaining performance, allowing for balanced rotation and efficient operation even at high speeds.
Implementation Method 1
bleed fluid may flow toward at least one surface (i.e., a pressure surface) of the bleed pressure member to apply a thrust counterbalancing force to the rotating group
Implementation Method 2
utilizing a bleed pressure member and air bearings for thrust load suppression and rotodynamic stability
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
A turbocharger includes a housing and a rotating group supported for rotation within the housing. The rotating group includes a compressor wheel disposed within a compressor section of the turbocharger, and the rotating group includes a turbine wheel disposed within a turbine section of the turbocharger. The turbine wheel includes a bleed pressure surface. The turbocharger further includes a bleed passage that extends at least partly through the housing to fluidly connect the compressor section to the turbine section. The bleed passage is configured to direct a bleed flow of fluid from the compressor section to the bleed pressure surface to supply a thrust counterbalance load to the bleed pressure surface.