COMPRESSOR SEAL SYSTEM

Abstract

A seal system for a bearing chamber (22) of a turbomachine includes the baffle element (70) encircling the axis (25) of the machine. The baffle element is formed with front surface including both a recess (73) which defines a circumferentially-extending oil-receiving channel (74), and an oil-deflecting surface (78) on a gutter (77). The channel decreases in cross-sectional area close to the oil-deflecting surface, and a circular line which is within the channel distant from the gutter, intersects with the oil-deflection surface. This forces the oil to change direction at the gutter, and urges the oil radially outward. Thus, a high rotational velocity of the body of oil may be maintained, whilst improving the drainage efficiency of the seal system at the gutter.

Claims

1. A baffle element for a seal system of a turbomachine, the baffle element including: an inner portion defining a circular central opening which in use is positioned on a rotational axis of the turbomachine with a centre of the central opening on the axis and the perimeter of the central opening lying in a plane transverse to the axis; an outer portion encircling the inner portion; and a gutter extending radially-outwardly from the outer portion, and having an oil redirection surface inclined to the plane of the circular central opening; the baffle element having a front surface which in use faces axially forwardly into a bearing chamber, and a rear face which in use faces axially rearwardly towards an oil seal plate, the front surface comprising a recess portion which is axially rearward with respect to portions of the front surface which are respectively radially-inward and radially outward of the recess portion; the recess portion defining an circumferentially-extending oil reception channel which intercepts the oil redirection surface, the channel having varying axial width at different circumferential positions, the axial width of the recess with respect to the circular central opening being greatest at a circumferential position about the axis which is circumferentially spaced from the gutter; whereby in use oil moving circumferentially in the channel encounters the oil redirection surface of the gutter and is deflected radially outwardly.

2. The baffle element of claim 1, the channel having varying cross-sectional area at different circumferential positions, the cross-sectional area at the different circumferential positions being measured as the intersection of the channel with respective planes including the axis, the cross-sectional area being greatest at a circumferential position about the axis which is circumferentially spaced from the gutter.

3. The baffle element of claim 1, in which the channel contains a circle centred on the axis which intercepts the oil redirection surface of the gutter.

4. The baffle element of claim 1, in which there is a circumferential position at which the cross-sectional area of the channel is greatest, and which is on the opposite side of the axis to the gutter.

5. The baffle element of claim 1, in which the outer portion of the baffle element includes a wall radially-outward of the channel and extending forward from the radially-outer edge of the recess portion, the wall including a portion which is opposite to a corresponding portion of the gutter with respect to the axis, and which is closer to the axis than the portion of the gutter.

6. The baffle element of claim 1, in which the gutter is formed without an aperture between the oil redirection surface and a rear surface of the gutter.

7. The baffle element of claim 1, in which the front surface of the baffle element is formed without an aperture between its front face and its rear face.

8. The battle element claim 1, in which the oil redirection surface is substantially flat.

9. The baffle element claim 1, in which the inner portion is substantially flat and has an inner edge defining the circular opening.

10. The baffle element claim 1, in which the recess portion extends to a circumferential position in circumferential register with the oil-deflecting surface.

11. The baffle element claim 1, in which the portion of the front surface of the baffle element axially furthest in the rearward direction is on the opposite side of the axis from the gutter.

12. A seal system for a turbomachine, comprising a baffle element and a seal plate, the baffle element including: an inner portion defining a circular central opening which in use is positioned on a rotational axis of the turbomachine with a centre of the central opening on the axis and the perimeter of the central opening lying in a plane transverse to the axis; an outer portion encircling the inner portion; and a gutter extending radially-outwardly from the outer portion, and having an oil redirection surface inclined to the plane of the circular central opening; the baffle element having a front surface which in use faces axially forwardly into a bearing chamber, and a rear surface which in use faces axially rearwardly towards an oil seal plate, the front surface comprising a recess portion which is axially rearward with respect to portions of the front surface which are respectively radially inward and radially outward of the recess portion; the recess portion defining an circumferentially-extending oil reception channel which intercepts the oil redirection surface, the channel having varying axial width at different circumferential positions, the axial width of the recess with respect to the circular central opening being greatest at a circumferential position about the axis which is circumferentially spaced from the gutter; whereby in use oil moving circumferentially in the channel encounters the oil redirection surface of the gutter and is deflected radially outwardly; and wherein the seal plate comprises: an annular body defining a central seal opening which in use is positioned on a rotational axis of the turbomachine with a centre of the central seal opening on the axis; the annular body having a front surface which in use faces towards the baffle element and the bearing chamber; and the front surface of the annular body comprising (i) a support surface for in use contacting the rear surface of the baffle element, and (ii) a drain surface which in use is in circumferential register with the gutter of the baffle element, and spaced from the rear surface of the baffle element, the drain surface being further from the axis than a corresponding portion of the support surface on the opposite side of the axis.

13. The seal system of claim 12, in which an oil containment chamber is defined between a portion of the oil seal plate and the rear surface of the baffle element.

14. The seal system of claim 12, wherein the drain surface is inclined to the axis.

15. A turbomachine, comprising: a housing defining a bearing chamber; a shaft having a longitudinal axis, a portion of the shaft being within the bearing chamber; a plurality of bearing elements mounted on the housing within the bearing chamber, the bearing elements supporting the shaft, and permitting the shaft to rotate about the axis; an oil delivery mechanism for supplying oil to the bearing elements; a slinger element coupled to the shaft; and a seal system at one axial end of the bearing chamber; the seal system comprising a baffle element and a seal plate, the baffle element including: an inner portion defining a circular central opening which in use is positioned on a rotational axis of the turbomachine with a centre of the central opening on the axis and the perimeter of the central opening lying in a plane transverse to the axis; an outer portion encircling the inner portion; and a gutter extending radially-outwardly from the outer portion, and having an oil redirection surface inclined to the plane of the circular central opening; the baffle element having a front surface which in use faces axially forwardly into a bearing chamber, and a rear surface which in use faces axially rearwardly towards an oil seal plate, the front surface comprising a recess portion which is axially rearward with respect to portions of the front surface which are respectively radially inward and radially outward of the recess portion; the recess portion defining an circumferentially-extending oil reception channel which intercepts the oil redirection surface, the channel having varying axial width at different circumferential positions, the axial width of the recess with respect to the circular central opening being greatest at a circumferential position about the axis which is circumferentially spaced from the gutter; whereby in use oil moving circumferentially in the channel encounters the oil redirection surface of the gutter and is deflected radially outwardly; and wherein the seal plate comprises: an annular body defining a central seal opening which in use is positioned on a rotational axis of the turbomachine with a centre of the central seal opening on the axis; the annular body having a front surface which in use faces towards the baffle element and the bearing chamber; and the front surface of the annular body comprising (i) a support surface for in use contacting the rear surface of the baffle element, and (ii) a drain surface which in use is in circumferential register with the gutter of the baffle element, and spaced from the rear surface of the baffle element, the drain surface being further from the axis than a corresponding portion of the support surface on the opposite side of the axis.

16. The turbomachine of claim 15 which is a turbocharger.

17. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] A non-limiting embodiment of the disclosure will now be described, for the sake of example only, with reference to the following figures, in which:

[0037] FIG. 1 is a cross-sectional drawing of a known turbocharger;

[0038] FIG. 2 is a cross-sectional view of a portion of a turbomachine which is an embodiment of the disclosure, the portion including a seal system;

[0039] FIG. 3 is an exploded view of the portion of the turbomachine shown in FIG. 2;

[0040] FIG. 4, which is composed of FIGS. 4(a) and 4(b), shows a seal plate of the seal system of the turbomachine of FIG. 2; and

[0041] FIG. 5, which is composed of FIGS. 5(a)-5(f), shows a baffle element of the seal system of the turbomachine of FIG. 2.

DETAILED DESCRIPTION OF THE EMBODIMENT

[0042] Referring firstly to FIG. 2, a portion is shown of a turbomachine which is an embodiment of the present disclosure. The turbomachine may be a turbocharger which is identical to the known turbocharger shown in FIG. 1, except that the seal system which is provided between the bearing chamber 22 and the compressor wheel 6 takes the form explained in the following text, and illustrated with respect to FIGS. 2 to 5. In the following description, the term “front” refers to the direction to the right in FIG. 2, i.e. along the rotational axis towards the turbine wheel, while the term “rear” refers to the direction to the left in FIG. 2, i.e. along the rotational axis towards the compressor wheel.

[0043] The seal system comprises an oil seal plate 50 (described below in more detail with reference to FIG. 4), and a baffle element 70 (described below in more detail with reference to FIG. 5) which takes the place of the baffle 21 of FIG. 1. The oil seal plate 50 and baffle element 70 both define circular central openings centred on the axis 25, and the seal system comprises a slinger 90 (taking the place of the slinger 17 of FIG. 1) which is positioned within the central openings. The slinger 90 itself defines a central opening centred on the rotational axis 25, and the shaft 8 passes through the central opening of the slinger 90. A seal ring 100 may be positioned between the slinger 90 and the seal plate 50.

[0044] The baffle element has a radially inner portion 71 and a radially outer portion 72 (marked on FIG. 5(e)). On one side of the axis 25, the baffle element comprises a laminar gutter 77 inclined to the rotational axis 25. The front face of the gutter 77 is an oil-deflecting surface 78, which may be substantially flat (planar).

[0045] The seal system comprises a primary cavity 60 defined on the front surface of the baffle element 70. As illustrated, in this embodiment the primary cavity 60 is defined between the baffle element 70 and a thrust bearing 103. On the upper side of the axis 25 (as viewed in FIG. 2), the primary cavity 60 includes a channel 74 defined by a recess portion 73 of the front surface of the baffle element 70. The channel is thus recessed relative to (i.e. axially rearward of) the flat front surface of the inner portion 71 of the baffle which defines the circular central opening. Due to the channel 74 the axial width (i.e. the “depth”) of the primary cavity 60 increases from the radial position of the inner portion 71 of the baffle element to the radial position of the channel 74, providing a large volume for oil collection.

[0046] The axial width, at any given circumferential position where the channel exists, may be defined as the distance the distance from the bottom of the recess (channel) to the flat front surface of the inner portion 71 of the baffle element. This axial width may alternatively be expressed as the distance d between the most axially-rearward part of the back surface of the baffle at the recess, and the flat back surface of the inner portion 71. The baffle element may have equal axial thickness at these points so these two expressions of the axial width are equivalent.

[0047] On the lower side of the axis 25, oil can escape from the primary cavity 60 to the drain by passing between baffle element 70 (i.e. the inner portion 71 and the gutter 77 of the baffle element) and the lower part of the thrust bearing 103.

[0048] The seal system further comprises a secondary cavity 61 defined between the seal plate 50 and the baffle element 70. On the lower side of the axis 25, oil can escape from the secondary cavity 61 to the drain by passing between the rear surface of gutter 77 and a drain surface 57.

[0049] The oil seal plate 50 comprises a radially-outwardly extending lip 52. The slinger 90 includes a radially-outwardly extending secondary fin 91 and radially-outwardly extending primary fin 92. The fins 91, 92 are circularly symmetric about the axis 25, as indeed is the entire radially-outer periphery of the slinger 90. The inner portion 71 of the baffle element 70 is substantially flat and laminar, the central opening of the baffle element 70 being defined by the circular radially-inner edge of the inner portion 71 of the baffle element 70. Note that the inner portion 71 of the baffle element 70 extends radially inwardly of the radially-outermost point of the secondary fin 91, thus limiting flow of oil from between the primary and secondary cavities 60, 61.

[0050] FIG. 3 is an exploded view of the seal system comprising an oil seal plate 50, seal ring 100, slinger 90, and baffle element 70 according to the embodiment. The provision of the seal ring 100 allows for blow-by gas control in the event of gas leakage from the engine to which the turbocharger of FIG. 1 is coupled.

[0051] The inner diameter of the baffle element 70 (i.e., the diameter of the central opening) should be as small as possible, in order to reduce leakage through the central opening. The possible dimensions of the inner diameter will be limited by the clearance for the diameter of the primary fin 92, as the primary fin 92 passes through the central opening of the baffle element 70 during assembly.

[0052] Preferably, the diameter of the primary fin 92 is kept to a minimum value, as this allows for improved sealing performance. By minimising this diameter, a minimum amount of rotational energy is imparted to the oil as it leaves the slinger, and the circumferential velocity of the oil is reduced.

[0053] FIGS. 4(a) and 4(b) show plan and cross-sectional views of the oil seal plate 50 respectively. The view in FIG. 4(a) is how the oil seal plate 50 appears as viewed in the axial direction towards the turbine (i.e. the direction which is from the left in FIG. 2).

[0054] FIG. 4(a) shows the oil seal plate 50 having a slot 58 formed in its front surface 53. The slot 58 may be used to orient the oil seal plate 50 during a sub-assembly process in which the baffle element 70 and oil seal plate 50 are assembled. Subsequently, when the combination of the oil seal plate 50 and the baffle element 70 are inserted into the bearing housing 3, the slot 58 may also receive a corresponding protrusion from the bearing housing 3 to orient the combination of the baffle element 70 and oil seal plate 50 within the turbocharger. Note that in variations of the embodiment the oil seal plate 50 may additionally or alternatively be provided with a slot which is configured to engage with a corresponding protrusion in the baffle element 70 during assembly. This slot thus serves as an alignment feature which may be used to orientate the oil seal plate 50 with respect to the baffle element 70 and optionally the drain 20 of the turbocharger during assembly.

[0055] FIG. 4(b) shows a cross-sectional view of the oil seal plate 50. This is the same cross-section shown in FIG. 2.

[0056] As mentioned above, the front face of the oil seal plate 50 of the embodiment comprises a drain surface 57. The drain surface 57 is inclined with respect to the axis 25 of the turbocharger. The oil seal plate 50 may be produced by forging, and if so the drain surface 57 may be created in the forging process. The remainder of the oil seal plate 50 may be finish turned, leaving the drain surface 57 unchanged. Alternatively, the oil seal plate 50 could be manufactured by casting, or entirely by machining.

[0057] At a range of angles about the axis 25, the oil seal plate 50 comprises an outer wall 56, configured to engage with a rear surface of the oil seal plate 50. The inner surface of the outer wall 56 provides a support surface 55 for the baffle element 70. The support surface 55 may be circularly symmetric within an angular range of at least 180 degrees about the axis 25 of the turbocharger. Alternatively, the support surface 55 may be circularly symmetric within an angular range of at least 220 degrees about the axis 25 of the turbocharger.

[0058] For a given axial position, the support surface 55 is located closer to the axis than the drain surface 57. This makes it possible, when the support surface 55 is engaged with the rear surface of the baffle 70 (as in, for example, FIG. 2), as described above for a path to exist for oil to escape from the secondary cavity 61 between the drain surface 57 and the gutter 77 to the drain 20, even though the gutter 70 is further radially from the axis 25 than the outer wall 75 at that axial position.

[0059] In the exemplary embodiment, the oil seal plate 50 further comprises an inner wall 54, preventing oil from entering the central seal opening of the oil seal plate 50 and hence leaking to the compressor 2. The sealing performance of the oil seal plate 50 may be further enhanced by the provision of a radially-outwardly extending lip 52, as shown in FIG. 4(b).

[0060] Optionally, the radially-outer portion of the rear surface 53 of the oil seal plate may be axially further from the bearing chamber than the radially-inner portion. For example, the rear surface 53 of the oil seal plate 50 may be frusto-conical, in order to further reduce leakage to the compressor 2 via the central seal opening. Use of a frusto-conical rear surface 53 also serves to increase the size of the secondary cavity 61 defined between the rear surface of the baffle element 70 and the oil seal plate 50 (for a given axial position of the radially-inner part of the oil seal plate 50), allowing more oil to be accommodated within this secondary cavity 61.

[0061] FIGS. 5(a)-5(f) show the baffle element 70. FIG. 5(a) is a perspective view of the baffle element 70, while FIG. 5(b) shows an axial view of the front surface of the baffle element 70 looking from the turbine end of the axis.

[0062] The baffle element 70 is formed without an aperture between its front and rear faces. This allows the baffle element 70 to more effectively contain and direct oil in the bearing housing (compared to certain baffles known in the prior art), since fewer leak paths exist between the primary and secondary cavities. In this document, the term ‘aperture’ means an opening having a closed (i.e. endless) boundary surface contained entirely within the element in which the aperture is formed.

[0063] FIG. 5(b) shows a circle 80 centred on the axis 25 and contained in the circumferentially-extending oil reception channel 74 (e.g. a circle which lies on the recess portion 73 of the front surface of the baffle element 70). At a first circumferential position 81, which is on the opposite side of the axis 25 from the gutter 77, the oil reception channel 74 has a first cross-sectional area as measured in a plane passing through the axis 25. In fact, the channel 74 has the same cross-sectional area at every angular position about the axis 25 within a range of angles which is centred at the position 81 and subtends at least about 220 degrees about the axis 220. Throughout this range of angles, the channel 74 is rotationally symmetric about the axis 25. At second circumferential positions 82, 83 the oil reception channel 74 has a second cross-sectional area. The second cross-sectional area is smaller than the first cross-sectional area. Thus, as oil moves circumferentially in the oil reception channel 74 towards the gutter 77, it is forced to change direction and expelled from the baffle element.

[0064] At either end of region 84, the circle 80 intersects the oil redirection surface 78 of the gutter 77. Within the region 84 the circle 80 is rearward of the oil redirection surface 78. Hence, oil moving along the circle 80 is expelled from the oil reception channel 74, urged onto the oil redirection surface 78, and directed the oil redirection surface 78 towards the drain 20 of the turbocharger.

[0065] FIG. 5(c) shows a rear perspective view of an embodiment of the baffle element 70. The measurements included are exemplary and should not be taken as limiting the scope of the claims. The central opening of the baffle element 70 is centred on the rotational axis 25 of the turbine wheel 4 in use. To either side of the gutter 77, an indent 79 is located between the outer wall 75 and the gutter 77, facilitating bending of the gutter 77 from a flat laminar blank during manufacturing of the baffle element 70. The gutter 77 may be substantially laminar and flat.

[0066] FIG. 5(d) is a plan view of the baffle element 70. The plane X-X shown intersects, on the left-hand side of FIG. 5(d), the portion 81 of the oil reception channel 74 having a first cross-sectional area, and, on the right-hand side of FIG. 5(d), the portion 84 of the oil reception channel 74 and the gutter 77. The plane Y-Y shown intersects two portions of the oil reception channel 74 having the first cross-sectional area.

[0067] FIG. 5(e) is a cross-sectional view of the baffle element 70, viewed perpendicular to the plane X-X indicated in FIG. 5(d). The measurements included are exemplary and should not be taken as limiting the scope of the claims. A recess portion 73 of the front surface of the baffle element 70, is included in the outer portion 72 of the baffle element. The recess portion 73 of the front surface of the baffle element is axially rearward of both (i) a portion of the baffle element 70 which is radially inward of the recess portion 73 (i.e. the inner portion 71 of the baffle element 70), and (ii) a portion of the baffle element 70 which is radially outward of the recess portion 73 (i.e. the radially-outer part of the wall 75). The recess portion 73 defines the oil reception channel 74. It can be seen from FIG. 5(e) that the cross-sectional area of the oil reception channel 74 is reduced almost to zero on the right-hand side of the figure, at an angular position about the axis in circumferential register with the gutter 77. Indeed, in a variation of the embodiment, the recess portion 73 may not exist at that angular position. Preferably, the channel 74 extends to the gutter 77, and at circumferential positions which are circumferentially in register with the gutter the gutter 77 preferably provides a border (edge) of the channel 74.

[0068] FIG. 5(f) is a cross-sectional view of the embodiment of FIG. 5(c), viewed perpendicular to the plane Y-Y indicated in FIG. 5(d).

[0069] Although only one embodiment of the baffle element and seal system has been described, many variations are possible within the scope of the disclosure as will be clear to a skilled reader. For example, the baffle element and seal system may be employed in a different sort of turbo-machine, such as one which does not include a turbine wheel, or one which does not include a compressor wheel.