Turbocharger Axial Turbine Nozzle Ring Flow Guidance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing turbochargers with axial turbine stages suffer from non-uniform and poorly guided axial flow, leading to high energy losses, reduced aerodynamic efficiencies, and increased mechanical and vibrational stresses due to flow misalignment, as well as higher aerodynamic losses from supersonic flows.
Innovation Solution
A turbocharger design featuring a housing with a compressor shroud and a turbine shroud, including a turbine wheel and compressor wheel connected by a shaft, with a nozzle ring in the axial channel to direct exhaust flow tangentially, radially, and axially, optimizing flow uniformity and reducing energy losses through a volute with specific geometries and vanes/blade configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a high reaction axial turbine stage is used to accelerate exhaust gas flow, then the turbine can handle wide operating conditions, but it creates supersonic flows with higher aerodynamic losses in blade passages
Solution Approach 1:
The patent changes the reaction parameter from high to low by redesigning the turbine stage configuration. The axial turbine stage is configured with specific blade geometries and spacing that maintain subsonic flow velocities across a wide operating range, fundamentally altering the flow regime parameter to eliminate supersonic losses while preserving adaptability to various operating conditions
2Quantity of substance
If exhaust flow is directed through a conventional axial turbine stage, then the turbine can process high volume flow, but the non-uniform and poorly guided flow creates high energy losses and reduced aerodynamic efficiencies
Solution Approach 1:
The patent introduces guide vanes as an intermediary element between the exhaust inlet and the turbine blades. These vanes condition the flow by straightening and uniformizing the velocity profile before the exhaust reaches the turbine wheel, acting as a flow conditioning mediator that transforms non-uniform poorly guided flow into uniform well-directed flow, thereby reducing energy losses while maintaining high flow volume processing capability
Solution Approach 2:
The guide vanes perform preliminary flow conditioning action before the exhaust enters the turbine stage. By pre-straightening and uniformizing the flow in advance, the system eliminates the need for the turbine blades to handle non-uniform flow conditions, thereby preventing energy losses rather than correcting them downstream
3Device complexity
If non-uniform axial flow is directed through the turbine wheel, then the turbine can operate with simple inlet geometry, but flow misalignment with blades creates increased mechanical and vibrational stresses
Solution Approach 1:
The guide vanes serve as a mechanical intermediary that corrects flow direction and uniformity before exhaust reaches the turbine blades. This intermediary structure, while adding some geometric complexity to the inlet, prevents severe blade loading and vibrational stresses by ensuring proper flow alignment, thereby protecting the structural integrity of the turbine assembly
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 achieves lower aerodynamic losses, improved efficiency, and reduced mechanical and vibrational stresses by ensuring uniform flow alignment, extending turbine wheel life and reducing material costs through optimized flow guidance and reduced vane/blades.
Implementation Method 1
The volute may have a generally spiral shape and an interior surface... The axial channel may be disposed between an annular tongue and a coaxial inner annular surface
Implementation Method 2
receiving exhaust from an exhaust manifold of the engine in a tangential direction
Implementation Method 3
a nozzle ring disposed within the axial channel at a location upstream of the turbine wheel
Implementation Method 4
a turbine wheel disposed within the turbine shroud that may be configured to receive exhaust from the axial channel... a shaft connecting the turbine wheel to the compressor wheel
Data Source
AI summary
A turbocharger is disclosed for use with an engine. The turbocharger may include a housing at least partially defining a compressor shroud and a turbine shroud. The turbine shroud may form a volute having an inlet configured to receive exhaust from an exhaust manifold of the engine in a tangential direction. The volute may also include an axial channel disposed downstream of the inlet. The turbocharger may also include a turbine wheel disposed within the turbine shroud that may be configured to receive exhaust from the axial channel. The turbocharger may also include a compressor wheel disposed within the compressor shroud, and a shaft connecting the turbine wheel to the compressor wheel. The turbocharger may also include a nozzle ring disposed within the axial channel at a location upstream of the turbine wheel.