The present disclosure relates to compressors, such as used in turbochargers (which broadly includes exhaust gas-driven turbochargers, e-turbochargers that are electric-motor driven or assisted, and superchargers), and more particularly relates to compressors having a variable-geometry mechanism that is adjustable for regulating flow rate through the compressor.
An exhaust gas-driven turbocharger is a device used in conjunction with an internal combustion engine for increasing the power output of the engine by compressing the air that is delivered to the air intake of the engine to be mixed with fuel and burned in the engine. A turbocharger comprises a compressor wheel mounted on one end of a shaft in a compressor housing and a turbine wheel mounted on the other end of the shaft in a turbine housing. Typically the turbine housing is formed separately from the compressor housing, and there is yet another center housing connected between the turbine and compressor housings for containing bearings for the shaft. The turbine housing defines a generally annular chamber that surrounds the turbine wheel and that receives exhaust gas from an engine. The turbine assembly includes a nozzle that leads from the chamber into the turbine wheel. The exhaust gas flows from the chamber through the nozzle to the turbine wheel and the turbine wheel is driven by the exhaust gas. The turbine thus extracts power from the exhaust gas and drives the compressor. The compressor receives ambient air through an inlet of the compressor housing and the air is compressed by the compressor wheel and is then discharged from the housing to the engine air intake.
The operating range of the compressor is an important aspect of the overall performance of the turbocharger. The operating range is generally delimited by a surge line and a choke line on an operating map for the compressor. The compressor map is typically presented as pressure ratio (discharge pressure Pout divided by inlet pressure Pin) on the vertical axis, versus corrected mass flow rate on the horizontal axis. The choke line on the compressor map is located at high flow rates and represents the locus of maximum mass-flow-rate points over a range of pressure ratios; that is, for a given point on the choke line, it is not possible to increase the flow rate while maintaining the same pressure ratio because a choked-flow condition occurs in the compressor.
The surge line is located at low flow rates and represents the locus of minimum mass-flow-rate points without surge, over a range of pressure ratios; that is, for a given point on the surge line, reducing the flow rate without changing the pressure ratio, or increasing the pressure ratio without changing the flow rate, would lead to surge occurring. Surge is a flow instability that typically occurs when the compressor blade incidence angles become so large that substantial flow separation arises on the compressor blades. Pressure fluctuation and flow reversal can happen during surge.
In a turbocharger for an internal combustion engine, compressor surge may occur when the engine is operating at high load or torque and low engine speed, or when the engine is operating at a low speed and there is a high level of exhaust gas recirculation (EGR). Surge can also arise when an engine is suddenly decelerated from a high-speed condition. Expanding the surge-free operation range of a compressor to lower flow rates is a goal often sought in compressor design.
One scheme for shifting the surge line of a centrifugal compressor to the left (i.e., surge is delayed to a lower flow rate at a given pressure ratio) and for shifting the choke flow line to the right (i.e., choke flow increases to a higher flow rate at a given pressure ratio) is to employ a variable-geometry (VG) mechanism in the compressor inlet. The variable-geometry mechanism is adjustable between a maximum flow-area position and a minimum flow-area position. The surge line can be shifted to lower flows by adjusting the VG mechanism to the minimum flow-area position. Applicant is the owner of co-pending applications disclosing various mechanisms of this type, see, e.g., application Ser. Nos. 14/537,339; 14/532,278; 14/642,825; 14/573,603; and 14/551,218; the entire disclosures of said applications (hereinafter referred to as “the commonly owned applications”) being hereby incorporated herein by reference. It is also possible to position the VG mechanism downstream of the compressor and achieve similar results.
The present disclosure describes methods and systems for controlling a variable-geometry mechanism for a compressor. The VG mechanism is located such that fluid passing through the VG mechanism also passes through and is compressed by the compressor. The VG mechanism is adjustable over a range of different setpoints to adjust an effective flow area for the fluid that passes through the VG mechanism and through the compressor, the VG mechanism being adjustable between a minimum flow area setpoint and a maximum flow area setpoint and being adjustable to at least one intermediate flow area setpoint between the minimum and the maximum flow area setpoints. In accordance with one embodiment described herein, the method comprises the steps of:
In some embodiments of the invention, at least some of the VG setpoints in the VG setpoint map are optimized based on compressor efficiency as the predefined optimization criterion.
Optionally, the VG setpoints in a first region of the compressor map can be optimized based on a first optimization criterion, and the VG setpoints in a second region of the compressor map can be optimized based on a second optimization criterion.
In one embodiment, the first optimization criterion comprises compressor efficiency. Whether or not the first optimization criterion comprises efficiency, the second optimization criterion can comprise compressor flow stability.
The method can further comprise employing a predictive scheme to predict the location of the operating point on the compressor map, taking into account a time lag required for adjusting the VG mechanism to a new VG setpoint.
In one embodiment, the VG mechanism is infinitely adjustable between the minimum and maximum flow area setpoints, and the predefined VG setpoint map is configured to accommodate such infinite adjustability.
In another embodiment, the VG mechanism is adjustable to only a plurality of discrete VG setpoints, and the predefined VG setpoint map is configured to accommodate such discrete adjustability.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
The VG mechanism is connected to a suitable actuator 26 that provides the motive force for adjusting the position of the VG mechanism. The actuator may be an electric motor such as a stepper motor, a pneumatic actuator, a hydraulic actuator, or any other suitable type of device capable of regulating the position of the VG mechanism.
The present inventions are directed to methods and systems for regulating the position of the VG mechanism for any operating point on the compressor map. A primary objective of such regulation of the VG mechanism is to avoid compressor surge by effectively delaying surge to lower flow rates. As well known to those skilled in the art, a compressor map plots compressor pressure ratio on the vertical axis and corrected flow rate on the horizontal axis.
As described in the commonly owned applications of Applicant, the surge line can be shifted to lower flow rates by using a VG mechanism to reduce the effective flow area through which the fluid is delivered to the compressor wheel. For example, in a compressor such as shown in
In accordance with the present inventions, for every possible operating point on the compressor map (defined by the pressure ratio and corrected flow rate at that point), an optimum position of the VG mechanism is predefined based on an optimization criterion (or multiple criteria).
It will also be appreciated, therefore, that if the VG mechanism is adjustable to a series (possibly of infinite number if the mechanism is infinitely or continuously adjustable over its range) of intermediate positions between the minimum and maximum area positions, there will be a series of lines intermediate between the solid and dashed lines on the map of
In accordance with the present inventions, the predefined set of optimum VG positions can take various forms.
It is not necessary that the same optimization criterion be used for all points on the compressor map. For example, the map can be divided into two or more regions, and in each region a region-specific optimization criterion can be used. As shown in
Regardless of the particular form in which the predefined set of optimum VG positions or setpoints is represented and stored in the memory of the controller, the present inventions are directed to methods and systems in which a location of a current operating point of the compressor on the compressor map is ascertained, an optimum VG setpoint is determined for the operating point based on at least one optimization criterion, and the actuator for the VG mechanism is commanded to adjust the VG mechanism to the optimum setpoint. In accordance with the invention, the optimized VG setpoints are predefined for the entire compressor map and the resulting VG setpoint map is stored for use in regulating the VG mechanism.
Implementation of the above-described control scheme can be accomplished in various ways.
In an embodiment, the ECU may receive inputs from various engine sensors and turbocharger sensors and control various engine and turbocharger actuators. The engine sensors may be disposed at various points in the engine to measure or otherwise determine corresponding engine parameters. Examples of engine sensors may include a throttle position sensor, air temperature sensor, engine revolutions per minute (RPM) sensor, engine load sensor, accelerator pedal position sensor and/or others. The engine actuators may include various relays, solenoids, ignition coils, or other electrically operable devices that may be used to control corresponding engine parameters. The turbocharger sensors may include sensors for measuring turbocharger rotational speed, compressor inlet pressure, compressor discharge pressure, compressor corrected flow rate, and other parameters.
In an exemplary embodiment as shown in
The memory device 60 may include, for example, volatile and/or non-volatile memory. The memory device 60 may be configured to store information, data, applications, modules, instructions, or the like for enabling the apparatus to carry out various functions in accordance with exemplary embodiments of the present invention. For example, the memory device 60 could be configured to buffer input data for processing by the processor 50. Additionally or alternatively, the memory device 60 could be configured to store instructions corresponding to an application for execution by the processor of the control unit 40.
As noted, the processor 50 may be a processor of the ECU or a co-processor or processor of a separate antisurge control module. The processor may be embodied in a number of different ways. For example, the processor may be embodied as a processing element, a coprocessor, a controller, or various other processing means or devices including integrated circuits such as, for example, an ASIC (application specific integrated circuit), FPGA (field programmable gate array) a hardware accelerator or the like. In an exemplary embodiment, the processor may be configured to execute instructions stored in the memory device 60 or otherwise accessible to the processor. As such, whether configured by hardware or software methods, or by a combination thereof, the processor may represent an entity capable of performing operations according to embodiments of the present invention while configured accordingly. Thus, for example, when the processor is embodied as an ASIC, FPGA or the like, the processor may be specifically configured hardware for conducting the operations described herein. Alternatively, as another example, when the processor is embodied as an executor of software instructions, the instructions may specifically configure the processor, which may otherwise be a general-purpose processing element if not for the specific configuration provided by the instructions, to perform the algorithms and/or operations described herein. However, in some cases, the processor 50 may be a processor of a specific device (e.g., the ECU) adapted for employing embodiments of the present invention by further configuration of the processor 50 by instructions for performing the algorithms and/or operations described herein (e.g., by addition of the antisurge control module).
The memory 60 of the control unit stores a compressor map, comprising a predefined set of optimum VG setpoints over the whole operating envelope of the compressor. In
With reference now to
From the foregoing description of certain embodiments of the invention, it will be appreciated that the control methods in accordance with the invention are suitable for either discretely variable or infinitely variable VG mechanisms. A discretely variable VG mechanism having as few as 3 setpoint positions (minimum area, intermediate area, and maximum area) can be used in the present invention. Alternatively, a VG mechanism having a greater number of setpoints, or one having essentially an infinite number (or at least a very large number) of possible setpoint positions can also be used. It is merely necessary to configure the VG setpoint map and the control logic accordingly, depending on which type of VG mechanism is employed. When a discretely variable VG mechanism is employed, the methods and systems in accordance with the invention advantageously can include hysteresis in the regulation of the VG setpoint so as to avoid oscillating behavior of the mechanism when the compressor operating point falls on or close to a boundary between one VG setpoint and an adjacent VG setpoint.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, in the described embodiments, the location of the compressor operating point on the compressor map is determined based on pressure ratio and corrected flow rate. Alternatively, however, the operating point location can be determined in other ways (e.g. using turbocharger speed and flow), as known in the art. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.