Turbocharger Vane Sealing Ring for Leakage Reduction
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Solution Overview
Problem
Existing variable-nozzle turbochargers face challenges in reducing gaps between vanes and nozzle walls, leading to exhaust gas leakage, which impairs turbine performance, particularly at low engine speeds.
Innovation Solution
A floating vane sealing ring is introduced, positioned within the nozzle ring recess, which utilizes pressure differentials to urge the vanes against the nozzle walls, reducing or closing gaps at both the proximal and distal ends, thereby minimizing exhaust gas leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If gaps between vanes and nozzle walls are reduced to minimize exhaust gas leakage, then turbine efficiency is improved, but vane pivotability is impaired
Solution Approach 1:
A floating seal ring is introduced as an intermediary element between the vanes and the nozzle ring. The seal ring has a first surface that contacts the proximal ends of the vanes and a second surface that contacts the first face of the nozzle ring, thereby mediating the interaction between these components and enabling gap reduction while preserving pivotability
Solution Approach 2:
The seal ring is designed to float dynamically between the vanes and the nozzle ring, allowing it to adapt its position based on operating conditions. This dynamic characteristic enables the system to maintain both tight sealing and free vane movement across different operational states
2Loss of energy
If a fixed sealing structure is used to eliminate gaps, then exhaust gas leakage is reduced, but manufacturing complexity and precision requirements increase
Solution Approach 1:
The floating seal ring is self-adjusting and self-aligning, automatically positioning itself to maintain optimal sealing contact with the vanes and nozzle ring. This self-service capability eliminates the need for complex fixed sealing structures and reduces manufacturing precision requirements
Solution Approach 2:
The seal ring's floating capability allows it to adapt its position and contact pressure based on operating parameters such as exhaust gas pressure and temperature, maintaining effective sealing across varying conditions without requiring high manufacturing precision
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 solution significantly improves turbine efficiency, especially at low engine speeds, by effectively reducing gas leakage and maintaining vane pivotability, enhancing overall engine performance.
Implementation Method 1
the exhaust gas adjacent the first face of the nozzle ring is substantially stagnated and therefore at a higher pressure than exhaust gas flowing through the nozzle adjacent the second face thereof, the exhaust gas adjacent the first face being communicated through the communication orifices so as to urge the vane sealing ring against the proximal ends of the vanes
Data Source
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AI summary
A variable-nozzle turbocharger includes a turbine housing and a center housing, and a generally annular nozzle ring and an array of vanes rotatably mounted to the nozzle ring such that the vanes can be pivoted about their axes for regulating exhaust gas flow to the turbine wheel. The vanes extend between the nozzle ring and an opposite wall of the nozzle. An axially floating vane sealing ring is disposed in an annular recess formed in the face of the nozzle ring adjacent proximal ends of the vanes. The vane sealing ring is urged by exhaust gas pressure differential toward the proximal ends of the vanes, and the vanes are thus urged toward the opposite nozzle wall so that distal ends of the vanes are close to or abutting the wall, resulting in a reduction or closing of the gaps at the proximal and distal ends of the vanes.