Turbocharger Vaned Diffuser Ring Assembly
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Solution Overview
Problem
Conventional turbochargers with vaned diffusers are costly due to the additional expense of vane inclusion, which affects compressor stability and surge margin.
Innovation Solution
A vaned diffuser configuration where a diffuser ring with integrally formed vanes is mounted between the compressor and center housings, using a seal ring for axial compression and a locating pin for precise positioning, reducing the need for fasteners and minimizing vane height to one-third to one-half of the diffuser passage width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vanes are included in the diffuser to improve compressor stability and surge margin, then compressor performance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The diffuser is segmented into a diffuser ring that can be manufactured separately and then assembled to the compressor housing. This allows the vanes to be integrated into the diffuser ring using cost-effective casting or additive manufacturing processes, rather than requiring expensive precision machining of the entire diffuser assembly. The segmentation enables specialized, economical production methods for the vane-containing component.
Solution Approach 2:
The vanes are merged integrally with the diffuser ring structure, forming a single monolithic component. This integration eliminates the need for separate vane assemblies, fasteners, and alignment procedures, significantly reducing manufacturing complexity and cost while maintaining the aerodynamic benefits of the vaned diffuser configuration.
2Reliability
If a complete diffuser assembly with fasteners is used to ensure proper positioning, then assembly reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The diffuser ring is nested within the compressor housing with an interference fit arrangement. The diffuser ring's outer circumference is designed to fit tightly within the compressor housing's inner circumference, providing self-location and self-retention. This nesting eliminates the need for separate fasteners, keys, or locating features, simplifying the overall assembly while ensuring reliable positioning.
Solution Approach 2:
The diffuser ring incorporates self-locating and self-retaining features through its geometric design. The interference fit between the diffuser ring outer surface and compressor housing inner surface automatically positions and secures the diffuser ring during assembly, without requiring external fastening elements. The assembly process becomes self-service, where the components themselves provide the necessary alignment and retention.
Data Source
AI summary
A turbocharger having a centrifugal compressor includes a vaned diffuser. The vaned diffuser is formed by a diffuser ring formed separately from the compressor housing and center housing. The diffuser ring is installed between the compressor and center housings such that a diffuser passage is defined between a surface of the compressor housing and a surface of the diffuser ring. Integral vanes on the diffuser ring extend only partially across the axial width of the diffuser passage. A rectangular-section seal ring is axially compressed between the compressor housing and the diffuser ring for sealing and axial locating of the diffuser ring. Radial locating of the diffuser ring is accomplished by an integral locating pin on the ring, which fits into a receptacle in the center housing.