Patent Publication Number: US-2019178151-A1

Title: Adjustable-trim centrifugal compressor for a turbocharger

Description:
BACKGROUND OF THE INVENTION 
     The present disclosure relates to centrifugal compressors, such as used in turbochargers, and more particularly relates to centrifugal compressors in which the effective inlet area or diameter can be adjusted for different operating conditions. 
     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. 
     Turbochargers typically employ a compressor wheel of the centrifugal (also known as “radial”) type because centrifugal compressors can achieve relatively high pressure ratios in a compact arrangement. Intake air for the compressor is received in a generally axial direction at an inducer portion of the centrifugal compressor wheel and is discharged in a generally radial direction at an exducer portion of the wheel. The compressed air from the wheel is delivered to a volute, and from the volute the air is supplied to the intake of an internal combustion engine. 
     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. 
     Applicant is owner of a number of pending patent applications directed to a turbocharger compressor having an inlet-adjustment mechanism for adjusting the size of the inlet flow area into the compressor, such as U.S. patent applicant Ser. No. 15/446,054 filed on Mar. 1, 2017, which claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 62/324,488 filed on Apr. 19, 2017, the entire disclosures of said applications being hereby incorporated herein by reference. The inlet-adjustment mechanisms described in said applications are effective for shifting the compressor surge line to lower flow rates. 
     BRIEF SUMMARY OF THE DISCLOSURE 
     The present disclosure describes mechanisms and methods for a centrifugal compressor that can enable the surge line for the compressor to selectively be shifted to the left (i.e., surge is delayed to a lower flow rate at a given pressure ratio) while optimizing compressor performance. One embodiment described herein comprises a turbocharger having the following features:
         a turbine housing and a turbine wheel mounted in the turbine housing and connected to a rotatable shaft for rotation therewith, the turbine housing receiving exhaust gas and supplying the exhaust gas to the turbine wheel;   a centrifugal compressor assembly comprising a compressor housing and a compressor wheel mounted in the compressor housing and connected to the rotatable shaft for rotation therewith, the compressor wheel having blades and defining an inducer portion and an exducer portion, the compressor housing having an air inlet wall defining an air inlet for leading air generally axially into the compressor wheel, the air inlet at the inducer portion having a diameter F, the compressor housing further defining a diffuser receiving compressed air from the exducer portion and diffusing and delivering the compressed air into a volute defined by the compressor housing, the exducer portion having a diameter D; and   a compressor inlet-adjustment mechanism disposed in the air inlet of the compressor housing and adjustable between an open position and a closed position, the inlet-adjustment mechanism comprising a plurality of blades disposed about the air inlet, the blades collectively circumscribing an orifice delimited by the blades, the blades being movable radially inwardly through a slot in the air inlet wall so as to adjust a flow area AR circumscribed by the orifice, wherein AR c  denotes the minimum value of AR when the inlet-adjustment mechanism is adjusted to the closed position;   wherein L is an axial distance between a leading edge of the inducer portion and a location where the flow area AR of the orifice is a minimum,   wherein the inlet-adjustment mechanism is configured such that 0.28*π*(F/2)2&lt;AR c &lt;0.95*π*(F/2)2, and   wherein L≤0.4*D.       

     In accordance with one embodiment, L≥G, where G is an axial clearance between the exducer portion of the compressor wheel and the compressor housing. 
     In one embodiment of the invention, each of the blades has an arcuate shape. Each of the blades is pivotable about a pivot pin, and the blades are engaged with a rotatable unison ring that surrounds the orifice, rotation of the unison ring in one direction about an axis thereof causing the blades to pivot to the closed position of the inlet-adjustment mechanism, rotation of the unison ring in an opposite direction causing the blades to pivot to the open position. 
     In accordance with one embodiment, the orifice in the closed position of the inlet-adjustment mechanism is circular. 
     In accordance with another embodiment, the orifice in the closed position of the inlet-adjustment mechanism is non-circular. For example, the orifice in the closed position of the inlet-adjustment mechanism can be elliptical. 
    
    
     
       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: 
         FIG. 1  is an end view of a turbocharger in accordance with one embodiment of the invention, looking axially from the compressor end toward the turbine end of the turbocharger; 
         FIG. 2  is a cross-sectional view of the turbocharger along line  2 - 2  in  FIG. 1 ; 
         FIG. 3  is a perspective view of the compressor portion of the turbocharger of  FIG. 1 ; 
         FIG. 4  is a partially exploded view of the compressor portion of  FIG. 3 ; 
         FIG. 5  is a perspective view of an inlet-adjustment mechanism for the compressor, with the top plate of the inlet-adjustment mechanism removed to show details of the blades, illustrating a closed position of the inlet-adjustment mechanism; 
         FIG. 6  is a side view of the inlet-adjustment mechanism; 
         FIG. 7  is a cross-sectional view through the inlet-adjustment mechanism along line  7 - 7  in  FIG. 6 , showing the inlet-adjustment mechanism in an open position; 
         FIG. 8  is a view similar to  FIG. 7 , with the inlet-adjustment mechanism in an intermediate position; 
         FIG. 9  is a view similar to  FIG. 7 , with the inlet-adjustment mechanism in a closed position; 
         FIG. 10  is an axial cross-sectional view of a compressor in accordance with an embodiment of the invention, illustrating several key parameters of the inlet-adjustment mechanism of significance to optimum performance of the compressor; 
         FIG. 11  is an end view of a turbocharger in accordance with a further embodiment of the invention, looking axially from the compressor end toward the turbine end of the turbocharger; and 
         FIG. 12  is an end view of the compressor inlet of the turbocharger of  FIG. 10 , illustrating a non-circular orifice of the inlet-adjustment mechanism. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     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. 
     In the present disclosure, the term “orifice” means “opening” without regard to the shape of the opening. Thus, an “orifice” can be circular or non-circular. Additionally, when the blades of the inlet-adjustment mechanism are described as moving “radially” inwardly or outwardly, the term “radially” does not preclude some non-radial component of movement of the blades (for example, the blades may occupy a plane that is angled slightly with respect to the rotational axis of the compressor, such that when the blades move radially inwardly and outwardly, they also move with a small axial component of motion). 
     A turbocharger  10  in accordance with one embodiment of the invention is illustrated in axial end view in  FIG. 1 , and an axial cross-sectional view of the turbocharger is shown in  FIG. 2 . The turbocharger includes a compressor and a turbine. The compressor comprises a compressor wheel or impeller  14  mounted in a compressor housing  16  on one end of a rotatable shaft  18 . The compressor housing includes a wall that defines an air inlet  17  for leading air generally axially into the compressor wheel  14 . The shaft is supported in bearings mounted in a center housing  20  of the turbocharger. The shaft is rotated by a turbine wheel  22  mounted on the other end of the shaft from the compressor wheel, thereby rotatably driving the compressor wheel, which compresses air drawn in through the compressor inlet and discharges the compressed air generally radially outwardly from an exducer portion  14   e  of the compressor wheel. The compressed air travels through a diffuser  19  into a volute  21  for receiving the compressed air. From the volute  21 , the air is routed to the intake of an internal combustion engine (not shown) for boosting the performance of the engine. 
     The turbine wheel  22  is disposed within a turbine housing  24  that defines an annular chamber  26  for receiving exhaust gases from an internal combustion engine (not shown). The turbine housing also defines a nozzle  28  for directing exhaust gases from the chamber  26  generally radially inwardly to the turbine wheel  22 . The exhaust gases are expanded as they pass through the turbine wheel, and rotatably drive the turbine wheel, which in turn rotatably drives the compressor wheel  14  as already noted. 
     With reference to  FIGS. 1-4 , in the illustrated embodiment, the wall that defines the air inlet  17  is formed in part by the compressor housing  16  and in part by a separate inlet duct member  16   d  that is received into a cylindrical receptacle defined by the compressor housing. The portion of the air inlet  17  proximate the compressor wheel  14  defines a generally cylindrical inner surface  17   i  that has a diameter generally matched to the diameter of an inducer portion  14   i  of the compressor wheel. 
     The compressor housing  16  defines a shroud surface  16   s  that is closely adjacent to the radially outer tips of the compressor blades. The shroud surface defines a curved contour that is generally parallel to the contour of the compressor wheel. 
     In accordance with the invention, the compressor of the turbocharger includes an inlet-adjustment mechanism  100  disposed in the air inlet  17  of the compressor housing. The inlet-adjustment mechanism comprises a ring-shaped assembly and is disposed in an annular space defined between the compressor housing  16  and the separate inlet duct member  16   d . The inlet-adjustment mechanism is operable for adjusting an effective diameter of the air inlet into the compressor wheel. As such, the inlet-adjustment mechanism is movable between an open position and a closed position, and can be configured to be adjusted to various points intermediate between said positions. 
     With reference now to  FIGS. 5 and 6 , the inlet-adjustment mechanism comprises a plurality of blades  102  arranged about the central axis of the air inlet and each pivotable about a pivot pin  104  located at or near one end of the blade. In the illustrated embodiment, the inlet-adjustment mechanism comprises a stand-alone assembly or “cartridge” having a pair of annular end plates  105  and  107 . The pivot pins are secured in the annular end plate  105  and the blades are arranged to rest against the end plate. The assembly of the blades  102  and unison ring  106  is captively retained between the annular end plate  105  and the second opposite annular end plate  107 . The pivot pins  104  can also serve the further function of axially spacing the two end plates apart from each other. A plurality of guides  103  are also secured in the end plate  105 , or optionally can be secured in the other end plate  107  instead, or can be secured to both end plates. The guides are located so as to engage the circular inner periphery of a unison ring  106  that is substantially coplanar with the blades  102 . (Optionally the guides  103  can engage the outer periphery of the unison ring if the end plate diameter is large enough to support the guides radially outward of the unison ring.) The guides  103  serve to guide the unison ring when it is rotated about its central axis (which coincides with the rotational axis of the turbocharger), so that the unison ring remains substantially concentric with respect to the end plate  105 . The guides  103  can comprise rollers or fixed guide pins. The inner periphery of the unison ring defines a plurality of slots  108 , equal in number to the number of blades  102 . Each blade includes an end portion  102   e  that engages one of the slots  108 , so that when the unison ring is rotated about its axis, the blades are pivoted about the pivot pins  104 . 
     As shown in  FIGS. 2 and 4 , the entire assembly is disposed in an annular space defined between the compressor housing  16  and the inlet duct member  16   d . The two end plates  105  and  107  have an inner diameter matched to the diameter of the cylindrical inlet surface  17   i  proximate the inducer  14   i  of the compressor wheel, such that the two end plates are effectively part of the wall defining the air inlet  17 , and such that the axial space between the two end plates effectively forms an opening or slot S ( FIG. 2 ) through the wall of the air inlet. The blades  102  are arranged to pass through this slot. The radially inner edges of the blades  102  include portions that preferably are generally circular arc-shaped and these edges collectively surround and bound a generally circular opening (although the degree of roundness varies depending on the positions of the blades, as further described below). 
     In an alternative embodiment (not shown), instead of a cartridge form of inlet-adjustment mechanism, the inlet-adjustment mechanism can comprise a non-cartridge assembly in which the pins  104  for the blades  102  are secured in the compressor housing  16  and/or the inlet duct member  16   d . Stated differently, the end plate  105  becomes an integral portion of the compressor housing  16  and the other end plate  107  becomes an integral portion of the inlet duct member  16   d.    
     The range of pivotal movement of the blades is sufficient that the blades can be pivoted radially outwardly (by rotation of the unison ring in one direction, clockwise in  FIG. 5 ) to an open position as shown in  FIG. 7 , in which the blades are entirely radially outward of the inner surface  17   i  of the inlet. As such, in the open position of the blades, the inlet-adjustment mechanism does not alter the nominal inlet diameter as defined by the inlet surface  17   i . Optionally, the guides  103  can serve also as stops for limiting the radially outward pivoting of the blades to the open position. 
     The blades can also be pivoted radially inwardly (by rotation of the unison ring in the opposite direction, counterclockwise in  FIG. 5 ) to an intermediate position as shown in  FIG. 8 . In the intermediate position, the circular-arc edges along the radially inner sides of the blades collectively form an orifice OR having a diameter that is less than that of the inlet surface  17   i . This has the consequence that the effective diameter of the inlet is reduced relative to the nominal inlet diameter. Furthermore, the blades can be pivoted an additional amount to a closed position as shown in  FIG. 9 . When the blades are in the closed position, the circular-arc edges of the blades collectively define an opening or orifice OR that is still smaller than the opening for the intermediate position of  FIG. 8 . Thus, the inlet-adjustment mechanism causes the effective diameter of the inlet to be further reduced relative to the intermediate position. In this manner, the inlet-adjustment mechanism is able to regulate the effective diameter of the air inlet approaching the compressor wheel. 
     As previously described, the blades  102  are actuated to pivot between their open and closed positions by the unison ring  106  that is rotatable about the center axis of the air inlet. Referring now to  FIG. 4 , rotational motion is imparted to the unison ring by an actuator  116  that is received into a receptacle  116   a  defined in the compressor housing. The actuator includes an actuator rod  117  that extends through a space defined in the compressor housing and is affixed at its distal end to a pin  118  that engages a slot  109  in the outer periphery of the unison ring  106 . The actuator is operable to extend and retract the rod  117  linearly along its length direction so as to rotate the unison ring  106  and thereby actuate the blades  102 . Extending the rod pivots the blades towards the closed position and retracting the rod pivots the blades toward the open position. 
     As noted, the inlet-adjustment mechanism  100  enables adjustment of the effective size or diameter of the inlet into the compressor wheel  14 . As illustrated in  FIG. 2 , when the inlet-adjustment mechanism is in the closed position, the effective diameter of the inlet into the compressor wheel is dictated by the inside diameter defined by the blades  102 . In order for this effect to be achieved, the axial spacing distance between the blades and the compressor wheel must be as small as practicable, so that there is insufficient distance downstream of the blades for the flow to expand to the full diameter of the inducer portion of the compressor wheel  14  by the time the air encounters it. The inlet diameter is thereby effectively reduced to a value that is dictated by the blades. 
     At low flow rates (e.g., low engine speeds), the inlet-adjustment mechanism  100  can be placed in the intermediate or closed position of  FIG. 8  or  FIG. 9 . This can have the effect of reducing the effective inlet diameter and thus of increasing the flow velocity into the compressor wheel. The result will be a reduction in compressor blade incidence angles, effectively stabilizing the flow (i.e., making blade stall and compressor surge less likely). In other words, the surge line of the compressor will be moved to lower flow rates (to the left on a map of compressor pressure ratio versus flow rate). 
     At intermediate and high flow rates, the inlet-adjustment mechanism  100  can be opened as in  FIG. 7 . This can have the effect of increasing the effective inlet diameter so that the compressor regains its high-flow performance and choke flow essentially as if the inlet-adjustment mechanism were not present and as if the compressor had a conventional inlet matched to the wheel diameter at the inducer portion of the wheel. 
     In accordance with the present invention, performance of the compressor can be optimized through selection of certain geometric characteristics or parameters of the inlet-adjustment mechanism  100 . With reference to  FIG. 10 , a compressor in accordance with an embodiment of the invention is depicted.  FIG. 10  is an enlargement of a portion of  FIG. 2 , and hence the previous description of the compressor in  FIG. 2  applies equally to  FIG. 10 . However,  FIG. 10  includes additional reference characters for explaining how compressor performance is optimized in accordance with the invention. The reference character F denotes the diameter of the air inlet to the compressor at the location of the inducer  14   i , or in other words, the diameter of the inlet surface  17   i  at the inducer. Stated differently, F is the sum of the diameter of the inducer  14   i  and two times the radial clearance between the inducer and the inlet surface  17   i . The reference character AR c  denotes the flow area bounded by the orifice OR of the inlet-adjustment mechanism  100  when it is closed as in  FIG. 10 . The reference character L is the axial spacing between the leading edge of the compressor inducer  14   i  and the axial location where the orifice OR of the inlet-adjustment mechanism is defined (i.e., the axial location where the flow area through the inlet-adjustment mechanism is a minimum). The reference character D is the diameter of the exducer  14   e  of the compressor wheel. The reference character G is the axial clearance between the exducer  14   e  and the compressor housing (i.e., the upstream wall of the diffuser  19 ). 
     In accordance with the invention, performance of the compressor can be optimized by ensuring that the orifice flow area when the inlet-adjustment mechanism is closed, AR c , is greater than 28% of the flow area of the air inlet at the compressor inducer inlet  17   i . A practical maximum upper limit on AR c  is 95% of the inducer inlet flow area. Thus, 
       0.28*π*( F/ 2) 2   &lt;AR   c &lt;0.95*π*( F/ 2) 2 .
 
     More preferably, the upper limit on AR c  is 90% of the inducer inlet flow area, and still more preferably 85% of the inducer inlet flow area. 
     Furthermore, in accordance with the invention, the axial spacing L between the orifice minimum area location (where AR is defined) and the leading edge of the compressor wheel inducer is not greater than 40% of the compressor exducer diameter D, or 
         L≤ 0.4* D.    
     The axial spacing L preferably is not less than the exducer-compressor housing clearance G, or 
     
       
      
       L≥G.  
      
     
     Accordingly, G≤L≤0.4*D. 
     Preferably, L can be in a range between 5% and 35% of exducer diameter D, more preferably between 5% and 30% of D, and still more preferably between 5% and 25% of D, even more preferably between 5% and 20% of D, and most preferably between 5% and 15% of D. 
     With reference to  FIGS. 11 and 12 , a further embodiment of the invention is depicted, in which the shape of the orifice OR defined by the inlet-adjustment mechanism  100  is non-circular, and specifically is elliptical, in contrast to the circular orifice in the previously described embodiment. 
     Applicant has found that compressor operating range (between the choke line at high flow rates and the surge line at low flow rates) can be widened or expanded by using an inlet-adjustment mechanism such as the type of mechanism described herein. The mechanism is effective to shift the surge line to lower flow rates, thereby expanding the useful operating range. Additionally, the compressor efficiency at what would be near-surge operating conditions (typically low flow rate and moderate to high pressure ratio), for a compressor without an inlet-adjustment mechanism, can be improved by using the inlet-adjustment mechanism to restrict the orifice going into the compressor. However, Applicant has found that the gain in efficiency can be partially or completely lost if the inlet-adjustment mechanism is not designed properly. Applicant has found that the parameters described herein are important in designing the inlet-adjustment mechanism so as to provide the greatest benefit in terms of range extension and efficiency improvement at near-surge conditions. 
     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, although the illustrated embodiment employs three blades  102 , the invention is not limited to any particular number of blades. The invention can be practiced with as few as two blades, or as many as 12 blades or more. 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.