Turbocharger Inlet Connector EGR Diffuser Design
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Solution Overview
Problem
Existing turbocharger inlet connectors face challenges in efficiently mixing and directing recirculated burnt gases and fresh air due to geometric constraints, leading to pressure drops and potential fires from oil residues, and are complex and costly to produce.
Innovation Solution
A turbocharger inlet connector design featuring a cylindrical duct for recirculated gases with a diffusion wall flush with the main duct surface, including conical orifices and a grid to reduce pressure drops and enhance mixing, made in one piece for ease of assembly and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recirculated gases are introduced into a rigid manifold to avoid fire hazards, then safety is improved, but pressure drops increase and gas flow efficiency deteriorates
Solution Approach 1:
The recirculated gas flow is divided into multiple separate inlets distributed around the periphery of the manifold, rather than a single large inlet. This segmentation allows the hot gases to be introduced at multiple locations, reducing localized turbulence and pressure drops while maintaining safe mixing with fresh air throughout the manifold volume.
Solution Approach 2:
Different regions of the manifold are designed with specific functions: peripheral inlets for recirculated gases, a central outlet for mixed gases, and a conical mixing zone in between. The geometry varies locally to optimize flow patterns, with the conical section specifically designed to enhance mixing while minimizing pressure losses in critical areas.
2Speed
If a conical shape is used to improve gas inlet velocity, then flow efficiency is improved, but mixing of recirculated gases and fresh air deteriorates
Solution Approach 1:
The conical mixing zone extends in the axial dimension along the flow direction, providing a prolonged interaction region. Multiple recirculated gas inlets are distributed circumferentially around the cone, creating three-dimensional flow patterns that enhance mixing through radial and axial velocity components, transforming a potentially simple conical flow into a complex multi-dimensional mixing process.
3Adaptability or versatility
If multiple separate components are used for recirculated gas inlet, then adaptability is improved, but device complexity increases
Solution Approach 1:
Multiple recirculated gas inlets, the conical mixing zone, and the central outlet are integrated into a single monoblock manifold structure. This merging of functions into one component eliminates the need for separate assemblies, reducing overall system complexity while maintaining the adaptability to handle varying recirculated gas flow rates through the distributed inlet configuration.
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 optimizes gas flow and mixing at the turbocharger inlet, reducing pressure drops and facilitating the safe integration of recirculated gases with fresh air, while simplifying production and reducing costs.
Implementation Method 1
the outlet of the recirculation gas duct comprises a conical diffusion wall diffusing the recirculated burnt gases into the fresh air flow
Implementation Method 2
improve the mixing of the gases from the mixing point to the inlet of the turbocharger
Data Source
Figure 1~2
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Figure 5~6
AI summary
Inlet connector (10) of a thermal engine turbocharger comprising: - a main fresh air supply duct (20) of revolution about a primary axis, - a cylindrical recirculation gas duct (22) whose axis is orthogonal to the primary axis and opening into the main duct (20), characterized in that said connector comprises a diffusion wall (25) flush with the wall (24) of the main duct (20) to mask the opening of the recirculation gas duct (22).