Variable Geometry Nozzle Reducing Turbocharger Complexity
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Solution Overview
Problem
Conventional variable geometry turbochargers have a mechanically complex and costly design due to numerous moving components, which affects reliability and efficiency, particularly during part-load operations.
Innovation Solution
A variable geometry nozzle design where main blades are coupled to a first support and tandem blades to a second support, with only one support being movable to vary their positions relative to each other, reducing the number of moving parts and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional variable geometry turbochargers use rotatable/sliding nozzle guide vanes with each airfoil rotating about its own axis, then the turbine can adapt to different operating conditions, but the device complexity and cost increase due to numerous moving parts, bushings, bearings, and seals
Solution Approach 1:
The nozzle is divided into multiple individual nozzles arranged circumferentially, with each nozzle containing multiple blades (first set and second set). This segmentation allows independent control of each nozzle while reducing the complexity of individual nozzle components compared to conventional rotatable vanes.
Solution Approach 2:
At least one nozzle is configured to be movable relative to the turbine wheel, enabling dynamic adjustment of the nozzle position to vary the effective nozzle throat area and control turbine operating characteristics across different load conditions.
2Reliability
If conventional variable geometry turbochargers implement each nozzle airfoil as a separate rotating piece, then the nozzle throat area can be varied, but the reliability decreases due to the large number of seals and moving parts
Solution Approach 1:
The nozzle system is segmented into multiple stationary nozzles with selective movability, reducing the number of rotating seals and moving parts while maintaining the capability to vary the effective nozzle throat area by moving at least one nozzle relative to the turbine wheel.
Solution Approach 2:
The design replaces the conventional mechanical rotatable vane system with a simplified nozzle movement mechanism, reducing reliance on complex mechanical seals and bearings while maintaining adaptability through selective nozzle positioning.
3Productivity
If fixed geometry turbochargers are designed for a specific operating condition, then the device complexity is reduced, but the performance deteriorates during part load operation
Solution Approach 1:
The nozzle system incorporates dynamic adjustability where at least one nozzle can move relative to the turbine wheel, enabling the effective nozzle throat area to be varied across different operating conditions including part load and full load, thereby maintaining high performance across the operating range.
Solution Approach 2:
The nozzle design with multiple nozzles and selective movability provides universal applicability across different operating conditions, allowing the same nozzle structure to serve both part load and full load requirements through positional adjustment rather than requiring multiple fixed geometry configurations.
Data Source
AI summary
The method includes moving at least one of a first support and a second support to vary a position of the plurality of main blades and tandem blades relative to each other to control one or more flow control characteristics across the turbine. The turbine includes a nozzle having the plurality of main blades and tandem blades. The plurality of main blades are coupled to the first support and the plurality of tandem blades are coupled to the second support disposed spaced apart from the first support.