Two-Stage Turbocharger Module with Perpendicular Axes
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Solution Overview
Problem
Existing exhaust gas turbocharger modules for internal combustion engines lack the ability to finely grade turbocharging according to engine parameters, such as cylinder number and power, leading to suboptimal performance and increased production costs due to the need for diverse turbocharger variants.
Innovation Solution
A two-stage turbocharging assembly with a low-pressure and high-pressure turbocharger system, where the low-pressure turbine is connected downstream of the high-pressure turbine via an exhaust gas connection line, and the high-pressure compressor is connected downstream of the low-pressure compressor via a charge air connection line, allowing for compact and modular design with integrated wastegate and cooling features, enabling precise power gradation and reduced component costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single large turbocharger module is used, then the device complexity is reduced, but the adaptability to different engine parameters (cylinder number, power) deteriorates
Solution Approach 1:
The turbocharging system is segmented into two independent stages: a low-pressure turbocharger and a high-pressure turbocharger. Each stage can operate independently or in combination, allowing the system to adapt to different engine requirements. The low-pressure turbocharger handles base load conditions while the high-pressure turbocharger provides boost for higher power demands, enabling fine-grained adaptation across various engine configurations without requiring multiple complete turbocharger variants.
Solution Approach 2:
The dual-stage turbocharger system serves multiple functions within a single integrated module. The low-pressure turbocharger optimizes for efficiency at lower loads, while the high-pressure turbocharger delivers performance at higher loads. This multi-functionality allows a single module design to serve diverse engine applications (different cylinder counts, power ratings) that would traditionally require different specialized turbocharger variants.
2Adaptability or versatility
If multiple diverse turbocharger variants are used to adapt to different engine parameters, then the adaptability improves, but the manufacturing cost increases
Solution Approach 1:
By segmenting the turbocharging function into two standardized stages (low-pressure and high-pressure), the system achieves adaptability through configuration rather than through diverse component variants. Each stage uses standardized components that can be mass-produced, and the same basic module design can be applied across different engine types by adjusting operational parameters rather than redesigning the entire turbocharger for each application.
Solution Approach 2:
The system achieves adaptation to different engine parameters by changing operational parameters (which stage is active, flow distribution between stages) rather than changing physical components. This allows a single module design to be used across multiple engine variants, reducing manufacturing complexity and cost while maintaining adaptability.
3Volume of moving object
If a compact modular design is used, then the space efficiency improves, but the device complexity increases
Solution Approach 1:
The low-pressure turbocharger and high-pressure turbocharger are merged into a single integrated housing, sharing common components such as the exhaust gas inlet, mounting flanges, and control systems. This merging achieves compact installation space while the internal modular architecture (distinct turbine/compressor assemblies for each stage) manages the complexity through standardized sub-components rather than a completely custom integrated design.
Solution Approach 2:
The turbocharger components are arranged in a nested configuration where the low-pressure and high-pressure stages are positioned concentrically or in close proximity, with exhaust gas flow from one stage feeding into the other. This nesting achieves compact volume while the systematic arrangement of nested components provides a logical structure that manages design complexity.
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 allows for optimized turbocharging of diverse engine variants with fewer but more versatile turbocharger modules, reducing production costs and improving engine performance by enabling close power gradations and efficient use of space, while also enhancing reliability through compact and preassembled designs.
Implementation Method 1
a low-pressure turbine (61) and a low-pressure compressor (62) which have a common first turbocharger axis (A1), and a high-pressure turbine (71) and a high-pressure compressor (72) which have a common second turbocharger axis (A2)
Implementation Method 2
a low-pressure compressor (62) and a high-pressure compressor (72) which have a common second turbocharger axis (A2)
Implementation Method 3
the turbocharging assembly further has a charge air intercooler which is arranged outside of the housing and connected into the charge air connection line
Data Source
AI summary
An exhaust gas turbocharger module and internal combustion engine outfitted therewith are disclosed. The exhaust gas turbocharger modules have an individual turbocharging assembly with a low-pressure exhaust gas turbocharger with a low-pressure turbine and a low-pressure compressor which have a common first turbocharger axis. A high-pressure exhaust gas turbocharger is provided with a high-pressure turbine and a high-pressure compressor which have a common second turbocharger axis extending perpendicular to the first turbocharger axis. The low-pressure turbine is connected downstream of the high-pressure turbine via an exhaust gas connection line, and the high-pressure compressor is connected downstream of the low-pressure compressor via a charge air connection line. A housing receives the low-pressure turbine, the high-pressure turbine and the exhaust gas connection line. The low-pressure compressor, the high-pressure compressor, and the charge air connection line are arranged outside of the housing.