Patent Application
20170328234
The subject matter described herein relates to turbochargers.
Variable geometry turbochargers include turbines that move to change the output of the turbochargers. The moveable turbines address the power needs of the turbochargers at part load operation. For example, as the load placed on the engine that is partially powered by the turbocharger changes, each of the turbines or blades of the turbocharger can move to change the speed at which the turbocharger rotates. This change in rotational speed changes how much air is forced into the engine, thereby changing how much power is generated by the engine.
This type of turbine design avoids the need of using waste gates and can improve engine efficiency by reducing pumping losses associated with an undersized turbine on air handling systems. The variable geometry turbochargers, however, also are expensive and less reliable than other turbochargers due to the large number of moving components.
In one embodiment, a nozzle assembly of a turbocharger includes a nozzle and a ring-shaped body. The nozzle has flow passages extending through the nozzle and configured to direct air received from a volute housing of the turbocharger through the nozzle to turbine blades of the turbocharger. The ring-shaped body is coupled with the nozzle and is configured to rotate around the nozzle. The ring-shaped body includes blocking segments that block the flow of the air and openings between the blocking segments that permit the air to flow through the ring-shaped body. The ring-shaped body is configured to rotate relative to the nozzle to change how many of the flow passages in the nozzle are blocked by the blocking segments of the ring-shaped body.
In one embodiment, an airflow restriction body of a turbocharger includes a first ring, a second ring, and blocking segments. The first ring is configured to be coupled with a nozzle of the turbocharger. The second ring is configured to be coupled with the nozzle of the turbocharger, and is spaced apart from the first ring in a direction that is parallel to a center axis of the nozzle of the turbocharger. The blocking segments extend from the first ring to the second ring and spaced apart from each other by openings. The first and second rings and the blocking segments are configured to rotate around the nozzle of the turbocharger to change which flow passages of the nozzle through which air flows from a volute housing of the turbocharger to blades of the turbocharger are open and which of the flow passages are closed.
In one embodiment, a method includes determining a load placed on one or more of an engine or a turbocharger operatively coupled with the engine and rotating a ring-shaped body around a nozzle of the turbocharger based on the load that is determined. The ring-shaped body has blocking segments that block at least some flow passages of the nozzle through which air flows from a volute housing of the turbocharger to blades of the turbocharger and openings that allow the air to flow from the volute housing of the turbocharger to the blades of the turbocharger. Rotation of the ring-shaped body blocks the air from flowing through at least some of the flow passages in the nozzle with the blocking segments of the ring-shaped body.
The present inventive subject matter will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:
The inventive subject matter described herein provides a nozzle assembly for a turbocharger than includes a ring-shaped body that can rotate around a nozzle of a turbocharger to cover one or more flow passages of the nozzle. This can significantly reduce the number and complexity of the moving parts in the turbocharger relative to some known variable geometry turbochargers, while still providing the flexibility to change the amount of air flowing through the nozzle based on the load placed on the engine receiving air from the turbocharger. The nozzle assembly may be used in fixed geometry turbochargers, or turbochargers having blades or turbines that are fixed in relative positions to each other, to permit fixed geometry turbochargers to change the air flow through the nozzles in the turbochargers in response to changing loads placed on the engines connected with the turbochargers.
The flow passages 210 are openings or ports that extend through the nozzle 202 from the outer surface 212 to the inner surface 214 to allow and direct air to flow through the nozzle 202 from the volume 114 (shown in
A ring-shaped body 204 is coupled with the nozzle 202. The ring-shaped body 204 may be connected with the nozzle 202 and be able to move along the outer surface 212 of the nozzle 202. For example, the ring-shaped body 204 can extend along and around the outer surface 212 of the nozzle 202 and be able to slide along the outer surface 212 of the nozzle 202 around the center axis 216. Similar to the nozzle 202, the ring-shaped body 204 extends around and encircles the center axis 216.
The ring-shaped body 204 includes first and second rings 206, 208 that are axially spaced apart from each other in directions that are parallel to the center axis 216. The rings 206, 208 may have the same shape as the outer surface 212 of the nozzle 202, but be slightly larger along radial directions from the center axis 216 than the outer surface 212 of the nozzle 202 to permit the ring-shaped body 204 to move outside of the nozzle 202, such as by sliding along the outer surface 212 of the nozzle 202 along one or more circumferential directions 220, 222 that are parallel to the outer circumference or perimeter of the outer surface 212 of the nozzle 202.
The ring-shaped body 204 includes blocking segments 218 that extend between the rings 206, 208 of the ring-shaped body 204. For example, the blocking segments 218 may be formed from solid bodies or continuations of the rings 206, 208 that extend from one ring 206 or 208 to the other ring 208 or 206 along axial directions that are parallel to the center axis 216. The blocking segments 218 also partially extend in transverse (e.g., perpendicular) directions, such as directions that are parallel to the circumferential directions 220, 222.
The blocking segments 218 are separated from each other by gaps along the circumferential directions 220, 222 to define open segments, or openings 209, in the ring-shaped body 204. As shown in
The ring-shaped body 204 can be moved relative to the nozzle 202 to position one or more of the blocking segments 218 over the flow passages 210 in the nozzle 202. The blocking segments 218 that are positioned over the flow passages 210 block the flow of air into those flow passages 210 and through the nozzle 202 to the turbines 106 (shown in
For example, in the state or position of the ring-shaped body 204 in
But, rotation of the ring-shaped body 204 from the position shown in
In the illustrated embodiment, the blocking segments 218 are the same size as each other and the openings 209 are the same size as each other. Alternatively, two or more blocking segments 218 may have different sizes and/or two or more of the openings 209 may have different sizes. This can result in the blocking segments 218 blocking less or more of one or more of the flow passages 210 in the nozzle 202. Additionally, in the illustrated embodiment, the ring-shaped body 204 is disposed on and moves along the outer surface 212 of the nozzle 202. Alternatively, the ring-shaped body 204 may be disposed on and move along the inner surface 214 of the nozzle 202. Placing the body 204 on the inner surface 214 may reduce inlet losses.
The flow passages 210 extending through the nozzle 202 may be the same size (or approximately the same size, such as where differences in size are within manufacturing tolerances of the nozzle 202). The flow passages 210 may be centered around or on, and be elongated along, directions 300 (shown in
In one embodiment, the directions 300 along which the flow passages 210 are centered and extend along are oriented at the same angle with respect to the outer surface 212 of the nozzle 202 and/or are oriented at the same angle with respect to the inner surface 214 of the nozzle 202. For example, the flow passages 210 may all direct air along paths having the same orientation relative to the nozzle 202.
For example, the flow passages 400 are centered on and elongated along first directions or axes 404 and the flow passages 402 are centered on and elongated along different, second directions or axes 406. The first directions 404 of the flow passages 400 are oriented at obtuse angles 408 with respect to the outer surface 212 of the nozzle 202 and the second directions 406 of the flow passages 402 are oriented at obtuse angles 410 with respect to the outer surface 212 of the nozzle 202. As shown in
In the illustrated embodiment, the flow passages 400, 402 alternate with each other around the circumference of the nozzle 202 such that each flow passage 400 has a flow passage 402 on each side of the flow passage 400 and each flow passage 402 has a flow passage 400 on each side of the flow passage 402. Alternatively, a larger number of flow passages 400 and/or 402 may be disposed between pairs of the flow passages 402 and/or 400.
The flow passages 400, 402 having the different orientations may represent different sets of the flow passages 210. The flow passages 400 may be included in one set of the flow passages 210 and the flow passages 402 may be included in a different, second set of the flow passages 210. The blocking segments 218 (shown in
For example, the ring-shaped body 204 may be rotated relative to the nozzle 202 to a first position to cause none of the blocking segments 218 to block the flow of air through any flow passages 210 (or 400, 402). The ring-shaped body 204 may be rotated to a different, second position to cause the blocking segments 218 to block the flow of air through the flow passages 210 in the first set (e.g., the flow passages 400) while not blocking the flow of air through the flow passages 210 in the second set (e.g., the flow passages 402). The ring-shaped body 204 may be rotated to a different, third position to cause the blocking segments 218 to block the flow of air through the flow passages 210 in the second set (e.g., the flow passages 402) while not blocking the flow of air through the flow passages 210 in the first set (e.g., the flow passages 400).
This allows for the ring-shaped body 204 to be used to control the flow of air through the nozzle 202 based on the position of the ring-shaped body 204 relative to the nozzle 202. In the first position described above, more air flows through the nozzle 202 than the second or third positions. In the second position described above, less air flows through the nozzle 202 than the first position, but more air flows through the nozzle 202 than the third position. In the third position described above, less air flows through the nozzle 202 than the first or second positions. More air may flow through the nozzle 202 when the ring-shaped body 204 blocks the flow passages 400, or in other words, the obtuse angle 410 being smaller than the obtuse angle 408. Optionally, the cross-sectional area of the flow passages 400, 402 may be different to allow different amounts of air to flow through the nozzle 200. For example, the flow passages 400 may be wider than the flow passages 402 (or vice-versa) to allow more air to flow through the passages 400 than the passages 402.
The actuation assembly 500 includes connectors 502 that are coupled with the ring-shaped body 204 in one or more locations. The connectors 502 are coupled with elongated rods 504, which are in turn connected with pivot plates 506. The pivot plates 506 are pivotally connected with a fixed body, such as a part of the housing of the turbocharger 100 that does not move relative to the nozzle 202. The pivot plates 506 include pivot points 600 (shown in
This pivoting of the pivot plates 506 is converted or translated by the rods 504 and connectors 502 into rotation of the ring-shaped body 204 on the nozzle 202. The actuation assembly 500 may move the ring-shaped body 204 in this manner in order to change which flow passages 210, if any, are blocked to prevent the flow of air there through.
If the air flow is to be changed in response to a change in the load, then flow of the method 700 can proceed toward 706. Otherwise, if the air flow is not to change in response to a change in the load, then flow of the method 700 can proceed toward 708. At 706, a change in which flow passages through a nozzle of the turbocharger are open and/or closed is made. For example, if the load has decreased, then more flow passages may be blocked and/or a different set of the flow passages may be blocked to reduce the air flowing through the nozzle to the turbine and to the engine. On the other hand, if the load has increased, then fewer or different flow passages may be blocked or no flow passages may be blocked to increase the air flowing through the nozzle to the turbine and to the engine. The change in which flow passages are blocked or open may be performed by rotating the ring-shaped body relative to the nozzle, as described above.
At 708, air is directed through the turbocharger to the engine via the flow passages that are open. For example, if no flow passages are blocked by the blocking segments of the ring-shaped body, then air may flow through many or all of the flow passages in the nozzle from the volute to the turbines, and then to the engine. If some flow passages are blocked by the blocking segments, then the air may flow through the other flow passages that are not blocked from the volute to the turbines, then to the engine. Flow of the method 700 may return toward 702 or may terminate.
As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the presently described subject matter are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter set forth herein without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the disclosed subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
This written description uses examples to disclose several embodiments of the subject matter set forth herein, including the best mode, and also to enable a person of ordinary skill in the art to practice the embodiments of disclosed subject matter, including making and using the devices or systems and performing the methods. The patentable scope of the subject matter described herein is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
