Variable Turbine Guide Vanes with Flow Features for Leakage Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Turbochargers with variable turbine geometry face issues of exhaust gas leakage and swirling due to clearance between guide vanes and the vane support ring, leading to reduced efficiency, especially when guide vanes are adjusted between open and closed positions.

Innovation Solution

The guide vanes are designed with first and second flow features to prevent leakage and swirling, where the first flow feature is located on the edges to disturb exhaust gas flow and the second flow feature is on the surfaces to channel the gas, ensuring smooth flow and minimizing leakage and cross-flow when the vanes are in open or closed positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If clearance is provided between guide vane edges and the vane support ring to permit pivotal movement and thermal expansion, then ease of operation and reliability are improved, but exhaust gas leakage increases reducing turbocharger efficiency

Engineering Contradiction:

Improvepivotal movement of guide vanesVSAvoidexhaust gas leakage

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

A seal member is introduced as an intermediary component between the guide vane and the vane support ring. The seal member fills the clearance gap while allowing the guide vane to pivot, thus preventing exhaust gas leakage without restricting the necessary pivotal movement for operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The seal member is designed as a flexible component that can deform to accommodate the pivotal movement of the guide vane while maintaining contact to prevent leakage. The flexibility allows it to adapt to thermal expansion and movement without creating rigid constraints.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If guide vanes are adjusted to open position to decrease boost pressure at high engine speeds, then adaptability is improved, but exhaust gas leakage around edges increases reducing efficiency

Engineering Contradiction:

Improveboost pressure regulationVSAvoidexhaust gas leakage

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The seal member acts as a mediator that maintains sealing effectiveness across all guide vane positions. It prevents exhaust gas from leaking around the edges regardless of whether the vanes are in open, closed, or intermediate positions, thus maintaining efficiency while preserving adaptability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If high and low pressure regions are created between adjacent guide vanes to direct exhaust gas flow, then flow control is improved, but swirling and transverse flow increase reducing smooth flow

Engineering Contradiction:

Improveexhaust gas flow directionalityVSAvoidsmoothness of exhaust gas flow

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The harmful swirling and transverse flow components are extracted or removed from the exhaust gas stream by the flow control features on the guide vane surfaces. These features redirect the flow to eliminate unwanted motion patterns while preserving the necessary directional control.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Flow control features with curved surfaces are used to guide the exhaust gas smoothly. The curvature of these surfaces helps to streamline the flow, reducing swirling and transverse components while maintaining effective directionality toward the turbine wheel.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 design effectively reduces exhaust gas leakage and swirling, enhancing the efficiency and performance of the turbocharger by ensuring that all exhaust gas is directed through the flow channels, thereby improving boost pressure regulation and responsiveness.

Implementation Method 1

A first flow feature is disposed on the first and second edges of each guide vane. The first flow feature is designed to disturb the flow of exhaust gas to prevent leakage of exhaust gas around the first and second edges of the guide vanes.

Methodology Applied

Scientific EffectFlow disturbance: Turbulence

Implementation Method 2

A second flow feature is disposed on the front and rear surfaces of each guide vane. The second flow feature is designed to channel the flow of exhaust gas between adjacent guide vanes from the leading edge to the trailing edge when the guide vanes are in the open position to prevent swirling and/or cross flow of the exhaust gas.

Methodology Applied

Scientific EffectFlow channeling: Laminar Flow

Data Source

PatentUS10138744B2Turbocharger with variable turbine geometry having grooved guide vanes

Publication Date: 2018.11.27 BORGWARNER INC

AI summary

A plurality of guide vanes (34) in a variable turbine geometry turbocharger (10) regulates a flow of exhaust gas. The guide vanes (34) are selectively adjustable between an open position to allow the flow of exhaust gas to drive a turbine wheel (24) and a closed position to block the flow of exhaust gas. A first flow feature (58) is disposed on first (44) and second (46) edges of the guide vanes (34) to disturb the flow of exhaust gas to prevent leakage of exhaust gas around the first (44) and second (46) edges. A second flow feature (64) is disposed on front (60) and rear (62) surfaces of the guide vanes (34) to channel the flow of exhaust gas between adjacent guide vanes (34) when the guide vanes (34) are in the open position to prevent swirling and/or cross flow of the exhaust gas.