1. Field of the Invention (Technical Field)
The present invention relates to compressors, particularly gas compressors, and specifically to a compressor with a geometry variable to adapt the compressor diffuser flow area to differing air mass flow rates.
2. Background Art
A conventional compressor apparatus, for example a turbocharger for use in association with internal combustion engines, includes an exhaust gas driven turbine and an inlet air compressor. The inlet air compressor is driven by power generated by the exhaust gas driven turbine wherein a turbine wheel of the exhaust gas driven turbine is mounted on a common shaft with a compressor impeller of the inlet air compressor.
The conventional compressor apparatus is provided with a housing having an exhaust gas inlet for supplying the exhaust gas to the exhaust gas turbine.
It is known in the art to provide a nozzle in a passage for urging a fluid, e.g. compressed air, toward the inlet of the engine, provides a variable geometry with the vanes in the nozzle being rotatably mounted to provide a variable geometry.
It is the object of the present invention to supply a variable flow nozzle downstream of the centrifugal compressor wheel in a compressor, to provide with a compressor with an improved configuration and an enhanced efficiency.
A variable geometry compressor for use in, for example, a turbocharger. A swing-vane diffuser is provided downstream of the centrifugal compressor wheel. By using optimum vane profiles and controllably pivoting the diffuser vanes at different angles, the cross-sectional diffuser flow area can be regulated at varying values to suit different air mass flow rates, and the flow incidence at diffuser vane leading edges is minimized. A nozzle ring is adjustable mounted in the compressor housing, and defines the nozzle face for the compressor diffuser. No spacers are deployed in the diffuser thereby improving efficiency, yet by stacking only the vanes and the nozzle ring, the diffuser clearances are maintained within strict tolerances. Further, seals, such as o-rings, are situated between the nozzle ring and the compressor housing and back plate to eliminate deleterious gas leaks between the diffuser and the spaces behind the nozzle ring.
The accompanying drawings, which are incorporated into and form a part of the specification, illustrate several embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating a preferred embodiment of the invention and are not to be construed as limiting the invention. In the drawings:
Reference is invited to the drawing figures, showing a preferred embodiment of the present invention.
First, an apparatus according to the present invention, which may be a turbocharger, is explained generally. Referring to the figures, the apparatus is provided with a housing which houses an exhaust gas turbine 35 and an inlet air compressor 30.
The inlet air compressor 30 includes an inlet air compressor wheel or impeller 4. The inlet air compressor impeller 4 is mounted on a shaft which is rotatably supported in a center housing 2 generally according to convention.
The exhaust gas turbine 35 includes an exhaust gas turbine wheel 5 which is mounted on the same shaft as the inlet air compressor wheel 4. Turbine housing 1 defines a turbine flow volute around the turbine wheel 5, all as best seen in
As shown in
Each vane 9 is supported on a shaft 41 (
As best shown in
Each vane 9 is connected by the shaft 41 to a vane arm 8 (
A nozzle ring 7 is mounted in the housing 3, between the housing and the back plate 51. Back plate 51 extends radially out from the center housing 2, and may be integrally molded or machined therewith, or welded thereon, or alternatively may be a separate component bolted or otherwise removably attached to the center housing. Thus, the back plate 51 may be a distinct detachable element. For each vane 9 a separate shaft 41 is provided such that an annular array of shafts is formed. The shafts 41 pass through corresponding holes in the nozzle ring 7, and are rotatable in the holes. Nozzle ring 7 provides the innermost extent of the flow passage, and also defines the nozzle 52 face adjacent to which the vanes 9 pivot, as indicated in
Continuing the reference to
Rotation of the unison ring 6, with the vane arms 8 pivotally attached thereto by their movable engagement in the sockets 37, permits the rotational position of the vanes 9 to be adjustable. The sockets 37 are concavities, but need not have any particular sectional shape; circular sockets suitably receive a knob 27. By adjusting the rotational position of the vanes 9, the fluid passage area, in the diffuser space of the compressor nozzle, can be regulated. That is, the passage area is decreased by moving the vanes 9 in a direction for aligning the vanes with the tangential direction with respect to the compressor impeller or wheel 4, whereas the passage area is increased by moving the vanes 9 to a direction for aligning the vanes with the radial direction of the compressor wheel 4. By a movement of the vanes 9, the component of velocity of the flow between the vanes in the radial and the tangential direction can be adjusted to optimize performance.
The unison ring 6 is operable by a crank mechanism 40 operably connected to the unison ring. The more fundamental elements of the invention are useable with any crank mechanisms known in the art. A preferred embodiment includes the innovative crank mechanism seen best in
Diffuser clearance is improved in the invention without the use of spacers commonly employed in variable geometry compressors known in the art. Combined reference is made to
As best seen in
The nozzle ring 7 and the diffuser surface 53 are substantially parallel and are separated by clearance dimension as depicted in
It is seen thus that in the inventive variable geometry compressor, the compressor housing 3 has the annular, preferably substantially planar, surface 53 therein, while the nozzle ring 7 is seated on the housing. The nozzle ring 7 defines the annular nozzle face 52 in spaced-apart relation from the face or surface 53, as the diffuser space is defined between the nozzle face and the diffuser surface. In this assembly, the one or more pivotal diffuser vanes 9 in the diffuser space are as proximate to the nozzle face 52 as to pivot slidably against it. As seen in the Figures, the nozzle face 52 and the diffuser surface 53 are substantially parallel and spaced-apart by the diffuser clearance distance. The diffuser clearance distance d is adjustable by modifying the position of the nozzle ring in relation to the diffuser surface.
Notably, the invention is not limited to the components orientation depicted in the drawing figures. The apparatus can be configured, in an alternative embodiment, in a reversed or “mirror image” configuration. Thus, an alternative embodiment of the claimed invention may feature an “inverted” layout, to be semi-symmetrical to the version depicted in the drawings, relative to a radial plane through the diffuser. Such a reversed embodiment could, for example, place the nozzle ring where the present drawing figures show the diffuser face located, place the unison ring, vane arms, etc. around the compressor inlet, and have the opposite face simply flat machined in the center housing back plate. Thus, it is intended to cover in the appended claims any alternative embodiments of the invention which employ any such a “flipped” or reversed design, where the alternative embodiment is reflected in a radial plane.
An advance of the invention is the minimization of the diffuser clearance without spacers. Spacers, commonly used in the art, ordinarily are within the diffuser region of the compressor, and thus cause aerodynamic losses, and may generate controllability problems. In contrast, in the present invention the vanes 9 pivot against the nozzle face 52 on the nozzle ring 7 (the nozzle ring being removably seated on the compressor housing). Advantageously, the diffuser clearance (i.e. difference between the height of a vane 9 and the diffuser clearance distance d) is controlled and determined by a single, and only one, compressor dimension—the clearance distance d. Meticulous machining of the vanes 9 permits the vane height to be fixed, while the axial position of the nozzle ring 7 (and thus the nozzle face 52) is established by its controlled and firmly secured disposition in the housing 3 held in place by the back plate 51. In one embodiment of the invention, by way of example, the diffuser clearance dimension d is 2.875±0.30 mm, while the vane height is 2.800±0.012 mm. Consequently, the vanes 9 effectively rotate against the nozzle face 52. The careful fashioning and placement of the nozzle ring 7 in relation to the diffuser face 53 permits the diffuser clearance dimension d to be finely tuned for improved diffuser clearances generally, eliminating the use of problematic spacers altogether to improve compressor performance at possibly reduced cost. As a result, the diffuser clearance dimension d is the only dimension that must be stacked up with the vane height.
Thus the vanes 9 have a uniform height dimension, and the arithmetic difference between the vane height dimension and the diffuser clearance distance d is deemed the vane end clearance, the latter being determined solely from the vane height dimension and the diffuser clearance distance.
The inventive apparatus therefore permits an extremely fine vane-to-compressor housing clearance, that is, the diffuser clearance, to be closely controlled. Spacers are not needed, due to the fact that only two dimensions (vane height and diffuser clearance) are the only parts of the stack-up. This enables smaller axial clearance for the vanes to enhance efficiency. The elimination of spacers in other known compressor designs necessitates additional machining of the housing nozzle (with the attendant increased cost), adversely affecting the components stack-up and resulting in increased diffuser clearance and decreased efficiency.
The actuating mechanism, including the crank control 22 and crank mechanism 40, can be provided with a control means for adjusting the position of the vanes 9 in the passage and thereby adjusting the passage area. The control can be performed based on, for example, pressures which are measured and monitored at the inlet and at the outlet of the compressor. Furthermore, the control can include the processing of other signals from the engine system, in manners known in the art.
The driving engagement of the internal arm 18 with the unison ring 6 is depicted in
According to the invention, therefore, the crank control 22 is actuated in response to signals from pressure monitors in the compressor inlet and outlet. The crank control revolves in response to the control signals, thereby translating the crank arm 21 via the connection maintained by the retaining ring 23. The shifting movement of the crank arm 21 induces pivotal movement in the crank linkage 15 (the crank linkage 15 being pivotally connected to the crank arm 21 by the external crank pin 16), which in turn imparts rotary motion to the internal crank pin 17. Because the internal crank pin 17 is fixedly attached to the internal arm 18, so that the internal arm 18 rotates together with the internal crank pin, the rotation of the internal crank pin causes the internal arm 18 to pivot (about an axis defined by the internal crank pin 17). The pivotal movement of the internal arm 18, which swings its distal end through a defined arc, causes the unison ring 6 to rotate about its axis due to the engagement of the distal knob of the internal arm within a socket 43 in the unison ring (
Turbochargers for use in vehicles are subject to load states which differ depending on the operational state of the engine. In a state of a low rotational speed of the engine, the flow rate of inlet air is low. Furthermore, the requirement of the pressure at the inlet of the engine depends on the required power output from the engine. In such circumstances, the vanes 9 are adjusted to a position which decreases the passage area (i.e. the cross-sectional area of flow of the compressor nozzle).
Conversely, in a state of high rotational speed of the engine, the mass flow of inlet air also increases. In this condition, the vanes 9 are adjusted to a position which increases the passage area of the compressor nozzle.
By adjusting the positions of the vanes 9 continuously in view of the engine load state and the engine rotational speed, undesirable compressor surge can be avoided (or at least delayed). An added advantage is that the compressor choke flow also is increased. Stated differently, the vane assembly (including the plurality of vanes 9 as driven by the rotatable unison ring 6) is closed by rotating the unison ring 6 to pivot simultaneously all the vanes 9 so as to incline with respect to the tangential direction of the annular arrangement, and is opened by rotating the vanes 9 towards the opposite direction. In a low-load and low-rotational speed range of the engine, the vane assembly is closed. The vane assembly is rotated towards the opened direction in a high-load and high-rotational speed range of the engine. Consequently, the operating range of the compressor is increased.
In sum, therefore, the flow passage area in the diffuser is adjustable by adjusting the pivotal position of at least one, preferably all, the diffuser vanes 9, and preferably pivoting all the vanes a uniform amount or degree. The plurality of vanes 9 is disposed in a circular array about an imaginary central axis, with the annular unison ring 6 rotatable about that same imaginary array axis. Each vane arm 8 of the plurality of vane arms is pivotally connected to a corresponding diffuser vane 9 and also pivotally connected to the unison ring 6; accordingly, the crank mechanism 20 controllably rotates the unison ring 6, so that controlled rotation of the unison ring simultaneously pivots the vanes in the diffuser space. The crank mechanism includes the rotatable internal arm 18 pivotally connected to the unison ring 6, so that rotation of the internal arm imparts rotary motion in the unison ring.
The operation of the compressor wheel 4 of course generates pressure differences along the gas flow path from the inflow volute 31 to the diffuser exit at the outflow volute 47. Undesirable gas leaks are possible between the vane suction and pressure sides, and from the diffuser space, along the vane arms 8, to behind the nozzle ring 7, and also and most significantly along and behind the nozzle ring 7, from the diffuser exit in outflow volute 47 back toward the diffuser inlet (in inflow section 31) upstream of the vanes 9. Such parasitic losses at the diffuser inlet are detrimental to performance because they modify the air incidence in the variable geometry vanes 9.
Reference is made to
Helpful reference is made particularly to
The foregoing leakages are ameliorated or prevented altogether by the o-rings 12, 13. The inner o-ring 12 prevents leakage between the inner end 49 of the nozzle ring 7 and the center housing 2. The outer o-ring 13 prevents leakage between the outer end 50 of the nozzle ring 7 and the back plate 51. Suitable grooves or ledges may be machined in the nozzle ring 7, the housing 3, and/or the back plate 51 as seats for receiving and holding the O-rings 12, 13.
Thus, the back plate 51 helps hold the nozzle ring 7 against the housing 3 while there is provided a seal means for preventing gas leakage from the vicinity of the diffuser space past the nozzle ring 7. The means for sealing may be one or more resilient inner o-rings 12 disposed between the center housing and the inner end of the nozzle ring, and/or one or more resilient outer O-rings 13 disposed between the compressor housing back plate 51 and the outer end of the nozzle ring.
Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2004/014919 | 11/8/2004 | WO | 00 | 6/6/2007 |
Publishing Document | Publishing Date | Country | Kind |
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WO2006/048042 | 5/11/2006 | WO | A |
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Number | Date | Country | |
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20080118349 A1 | May 2008 | US |