Water-Cooled Compressor Housing Assembly
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Solution Overview
Problem
Conventional compressor housings face challenges in forming complex coolant passages required for efficient cooling, especially under stringent packaging constraints and increasing compressor pressure ratios, making it difficult to effectively cool the compressor housing using sand casting techniques without a coolant passage core.
Innovation Solution
A liquid-cooled compressor housing assembly with a separate cover that defines a coolant passage, bounded by the compressor housing and cover components, allowing for coolant circulation and effective cooling of the diffuser-defining wall without the need for a coolant passage core, utilizing sand casting or die casting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coolant passage core is used in sand casting to form complex coolant passages, then cooling efficiency is improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The invention extracts and removes the coolant passage core from the sand casting process. Instead of using a complex core to form the coolant passage, the patent uses a separate mold cavity approach where the coolant passage is formed by the mold itself without requiring internal cores, thereby simplifying manufacturing while maintaining cooling efficiency
Solution Approach 2:
The invention segments the coolant passage formation from the main housing casting. The coolant passage is formed as a separate feature within the mold cavity, allowing for simplified core removal and easier manufacturing. This segmentation enables the use of standard sand casting techniques without requiring complex core assemblies
2Temperature
If coolant passage geometries become more complex to meet cooling efficiency targets, then cooling performance is improved, but sand filling completeness deteriorates
Solution Approach 1:
The invention changes the dimensional approach to forming coolant passages. Instead of using three-dimensional complex cores that are difficult to fill, the patent uses a two-dimensional mold cavity approach where the coolant passage is formed by the external mold geometry. This dimensional change makes sand filling much easier and more complete while still achieving the required cooling performance
3Adaptability or versatility
If compressor pressure ratio is increased to meet emissions limits, then emissions compliance is improved, but housing temperature increases
Solution Approach 1:
The invention introduces coolant as an intermediary substance to transfer heat from the compressor housing. The coolant passage allows engine coolant to circulate through the housing, absorbing heat and preventing temperature rise. This intermediary cooling system enables the compressor to operate at higher pressure ratios for emissions compliance without excessive housing temperatures
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 solution enables the manufacture of compressor housings that meet cooling efficiency targets and packaging constraints, effectively cooling the compressor housing and reducing temperature rise, while simplifying the manufacturing process by eliminating the need for a coolant passage core.
Implementation Method 1
a liquid coolant passage (80) through which a liquid coolant can be circulated to cool the compressor housing (36)
Data Source
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AI summary
A water-cooled compressor housing assembly for a turbocharger includes a compressor housing that defines an open-ended cavity extending axially downstream into the compressor housing, and a separately formed cover that is affixed to the compressor housing so as to close the open end of the cavity and thereby define a coolant passage for a liquid coolant to be circulated through. A coolant inlet and a coolant outlet are provided for supplying coolant into and exhausting coolant from the coolant passage. The compressor housing has a simplified geometry that is manufacturable by sand casting without needed a sand core for the coolant passage, or by die casting.