Two-Stage Turbo System with Series and Parallel Modes
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Solution Overview
Problem
Conventional turbocharging systems face challenges in achieving stable flow control and high engine performance at high speeds, particularly with temperature rise issues and the need for complex structures and large turbochargers.
Innovation Solution
A turbocharging system with two small size turbochargers connected in series for improved responsiveness and acceleration, and in parallel for high flow needs, using control valves to switch between modes and maintain pressure balance, with optional variable flow and twin scroll turbochargers for enhanced control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large size turbocharger is used on the low-pressure stage, then the flow capacity is improved, but the system complexity and temperature rise issues worsen
Solution Approach 1:
The patent divides the turbocharging system into two separate turbochargers (first turbocharger and second turbocharger) operating in series, where each turbocharger handles a portion of the compression task. This segmentation allows the system to achieve high flow capacity without requiring a single large turbocharger, thereby reducing system complexity and temperature rise issues associated with oversized components.
Solution Approach 2:
The first turbocharger and second turbocharger are arranged in series configuration, where the output of the first turbocharger feeds into the input of the second turbocharger. This nested arrangement allows both turbochargers to work together to achieve the desired pressure and flow capacity while maintaining compact system architecture and avoiding the complexity of parallel configurations.
2Productivity
If two-stage turbocharging is used, then the engine performance is improved, but the temperature rise and cooling requirements worsen
Solution Approach 1:
By segmenting the compression process across two turbochargers operating in series, each turbocharger performs a smaller pressure ratio increment, which reduces the temperature rise at each stage compared to a single large turbocharger performing the entire compression in one step.
3Ease of operation
If conventional two-stage turbocharging with large and small turbochargers is used, then the flow control is improved, but the structure complexity and inertia worsen
Solution Approach 1:
The patent employs variable flow control mechanisms (such as variable nozzle geometry or flow control valves) localized at each turbocharger stage, allowing independent optimization of flow control at each stage. This localized control approach achieves effective flow management while using smaller, lower-inertia turbochargers compared to a conventional single large turbocharger system.
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
This configuration enhances turbocharger responsiveness, reduces pressure loss, and simplifies the structure, allowing for precise engine performance control without the imbalance and complexity issues of conventional systems.
Implementation Method 1
a first turbocharger 2A and a second turbocharger 2B which have the same turbine capacity, when a series turbocharging mode is selected, the supercharging pressure is increased
Implementation Method 2
an intercooler 5 which is arranged on an upstream side of the internal combustion engine 1 (in an intake path) and cools the air having been heated by compression by the turbochargers while maintaining the pressure of the air
Data Source
AI summary
A two-stage turbo system using small-sized turbo-superchargers and simply configured. A two-stage turbo system provided with an internal combustion engine (1), two turbo-superchargers (2A, 2B) driven by exhaust gas from the internal combustion engine (1), control valves (V1-V5) for switching between the flow path of intake gas sucked into the internal combustion engine (1) and the flow path of exhaust gas from the internal combustion engine (1), and a control device for controlling the control valves (V1-V5) and the turbo-superchargers (2A, 2B). The two turbo-superchargers (2A, 2B) have the same turbine capacity, function respectively as the high-pressure side turbo-supercharger (2A) on the exhaust path upstream side and the low-pressure side turbo-supercharger (2B) on the exhaust path downstream side, and have, by switching between the flow paths by using the control valves (V1-V5), a series mode in which the two turbo-superchargers (2A, 2B) are serially connected to each other, a one-stage supercharging mode in which gas flows only to the high-pressure-side turbo-supercharger (2A) or only to the low-pressure-side turbo-supercharger (2B), and a parallel mode in which the two turbo-superchargers (2A, 2B) are connected in parallel to each other.