Centrifugal compressor for a turbocharger, having pressure-balanced adjustable-trim mechanism

Abstract

A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism operable to move between an open position and a closed position. The inlet-adjustment mechanism includes a plurality of blades disposed about the compressor air inlet and located between an upstream wall surface and a downstream wall surface of an annular space within the air inlet wall. The blades are pivotable about respective pivot points such that the blades extend radially inward from the annular space into the air inlet when the blades are in the closed position so as to form an orifice of reduced diameter relative to a nominal diameter of the inlet. Aerodynamic pressure balancing across the blades is achieved by spacing features that space a majority of the upstream surface of each blade from the opposing upstream wall surface.

Claims

1. A turbocharger, comprising: 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 defining an inducer portion, the compressor housing having an air inlet wall defining an air inlet for leading air generally axially into the compressor wheel, the compressor housing further defining a volute for receiving compressed air discharged generally radially outwardly from the compressor wheel, the air inlet wall defining an annular space surrounding the air inlet and open to the air inlet at a radially inner end of the annular space; and a compressor inlet-adjustment mechanism disposed in the annular space of the air inlet wall and movable between an open position and a closed position, the inlet-adjustment mechanism comprising a plurality of blades disposed between an upstream wall surface and a downstream wall surface within the annular space, the blades collectively circumscribing an orifice, an upstream surface of each blade opposing the upstream wall surface and a downstream surface of each blade opposing the downstream wall surface, each blade being pivotable about a pivot point fixed in the compressor housing, the blades pivoting radially inwardly from the annular space into the air inlet when the blades are in the closed position so as to cause the orifice to have a reduced diameter relative to a nominal diameter of the inlet; wherein at least one of the upstream wall surface and the upstream surface of each of the blades includes spacing features that space a majority of the upstream surface of each blade away from the upstream wall surface, enabling pressure communication between the upstream and downstream surfaces of the blades.

2. The turbocharger of claim 1, wherein the spacing features are defined by the upstream surface of each blade.

3. The turbocharger of claim 2, wherein the spacing features comprise raised areas on the upstream surface of each blade that contact the upstream wall surface and space the majority of the upstream surface of each blade from the upstream wall surface.

4. The turbocharger of claim 1, wherein each blade includes a radially inner edge having a circular-arc shape, the blades being configured so that said radially inner edges collectively form the orifice as substantially circular in a selected position of the inlet-adjustment mechanism.

5. The turbocharger of claim 4, wherein said selected position in which said radially inner edges form the orifice as substantially circular is the closed position.

6. The turbocharger of claim 1, wherein the number of said blades is three.

7. The turbocharger of claim 1, wherein the inlet-adjustment mechanism further comprises a unison ring, the unison ring being rotatable about a rotational axis of the turbocharger, wherein each of the blades is engaged with the unison ring such that rotation of the unison ring causes the blades to pivot.

8. The turbocharger of claim 7, wherein each blade includes an end portion that engages a slot defined in an inner periphery of the unison ring.

9. The turbocharger of claim 7, wherein the inlet-adjustment mechanism further comprises a plurality of guides for guiding rotation of the unison ring.

10. The turbocharger of claim 9, wherein the guides are arranged to limit the amount of radially outward pivoting of the blades to the open position.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

(1) 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:

(2) 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;

(3) FIG. 2 is a cross-sectional view of the turbocharger along line 2-2 in FIG. 1;

(4) FIG. 3 is a partially exploded view of the compressor portion of the turbocharger of FIG. 1;

(5) FIG. 4 an isometric view of the compressor portion of FIG. 3, with the compressor cover (inlet duct member) exploded away so that the inlet-adjustment mechanism is visible;

(6) FIG. 5 is an isometric view of a partial assembly of the inlet-adjustment mechanism and the actuator therefore, with the inlet-adjustment mechanism in an open position;

(7) FIG. 6 is a view similar to FIG. 5, with the inlet-adjustment mechanism in a closed position;

(8) FIG. 7 is an isometric view of a blade of the inlet-adjustment mechanism, showing the upstream surface of the blade having spacing features;

(9) FIG. 8 is an isometric view of the blade, showing the downstream surface of the blade; and

(10) FIG. 9 is a cross-sectional view through the compressor housing assembly and inlet-adjustment mechanism of the turbocharger of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

(11) 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.

(12) 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 pivoting 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 pivot radially inwardly and outwardly, they also move with a small axial component of motion).

(13) 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 the compressor wheel 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.

(14) 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.

(15) 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 cover or inlet duct member 16d 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 17i that has a diameter generally matched to the diameter of an inducer portion 14i of the compressor wheel.

(16) The compressor housing 16 defines a shroud surface 16s 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.

(17) 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 16d. The annular space is bounded between an upstream wall surface 105 and a downstream wall surface 107. 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.

(18) With reference now to FIGS. 3, 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 located at or near one end of the blade. In the illustrated embodiment, the pivot pins for the blades are secured in the downstream wall surface 107 of the compressor housing. The blades are arranged between the upstream wall surface 105 and the downstream wall surface 107, with a small amount of axial clearance or play for the blades between those wall surfaces, so that the blades can freely pivot without binding.

(19) The inlet-adjustment mechanism further comprises a unison ring 106 for imparting pivotal movement to the blades. The unison ring surrounds the assembly of the blades 102 and is substantially coplanar with the blades, and is rotatable about an axis that coincides with the rotation axis of the compressor wheel. The unison ring includes a plurality of recesses 108 in its radially inner periphery, and each blade includes an end portion 102e that is engaged in a respective one of the recesses 108. Accordingly, rotation of the unison ring in one direction causes the blades 102 to pivot radially inwardly, and rotation of the unison ring in the other direction causes the blades to pivot radially outwardly. The assembly of the blades 102 and unison ring 106 is captively retained between the upstream wall surface 105 and the downstream wall surface 107.

(20) A plurality of guides 103 are also secured in the downstream wall surface 105, or optionally can be secured in the upstream wall surface 107 instead, or can be secured to both wall surfaces. The guides are located so as to engage the circular inner periphery of the unison ring 106. The guides 103 serve to guide the unison ring when it is rotated about its central axis, so that the unison ring remains substantially concentric with respect to the compressor wheel. The guides 103 can comprise rollers or fixed guide pins.

(21) It is advantageous to include some kind of mechanism stop(s) for limiting the radially outwardly pivoting of the blades 102 in the fully open position of the inlet-adjustment mechanism. Various ways of providing stops can be employed in the practice of the invention. As one example, illustrated in FIG. 5, the radially inner periphery of the unison ring 106 acts as the stop. Alternatively, a machined feature at the inner diameter of the compressor housing 16 could serve as the stop. A still further alternative is to configure the guides 103 to serve double-duty as unison ring guides and mechanical stops for the blades. Other variations could be envisioned within the scope of the invention.

(22) 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 or orifice (although the degree of roundness varies depending on the positions of the blades, as further described below).

(23) 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. 5, in which the blades are entirely radially outward of the inner surface 17i (FIG. 2) 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 17i. As noted, in this particular embodiment, the blades pivot out against the stop formed by the radially inner periphery of the unison ring.

(24) The blades can also be pivoted radially inwardly (by rotation of the unison ring in the opposite direction, counterclockwise in FIG. 5) to a closed position as shown in FIG. 6. In the closed position, the circular-arc edges along the radially inner sides of the blades collectively form an orifice. In the illustrated embodiment the orifice is substantially a circle in the closed position, having a diameter that is less than that of the inlet surface 17i. (Substantially a circle in the present disclosure means that the circular-arc edges all lie on the same circle and collectively occupy at least 80% of the circumference of that circle.) This has the consequence that the effective diameter of the inlet is reduced relative to the nominal inlet diameter. Furthermore, in a non-illustrated embodiment the blades can be pivoted an additional amount to a super-closed position in which there is some degree of overlap of adjacent blades, which is made possible by forming the respective overlapping edge portions of adjacent blades as complementing or male-female shapes. When the blades are in the super-closed position, the circular-arc edges of the blades collectively define an opening or orifice that is not perfectly circular but is effectively even smaller than the opening for the closed position of FIG. 6. Thus, the inlet-adjustment mechanism causes the effective diameter of the inlet to be further reduced relative to the closed position. In this manner, the inlet-adjustment mechanism is able to regulate the effective diameter of the air inlet approaching the compressor wheel.

(25) It should be noted, however, that it is not essential that the orifice defined by the inlet-adjustment mechanism be circular in the closed position. Alternatively, the orifice can be non-circular. The invention is not limited to any particular shape of the orifice.

(26) As previously described, the blades 102 are actuated to pivot between their open and closed (and, optionally, super-closed) positions by the unison ring 106 that is rotatable about the center axis of the air inlet. Referring now to FIGS. 4-6, rotational motion is imparted to the unison ring by an actuator 116 that is received into a receptacle 116a 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 (FIG. 3) 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.

(27) 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.

(28) At low flow rates (e.g., low engine speeds), the inlet-adjustment mechanism 100 can be placed in the closed position of FIGS. 2 and 6. 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).

(29) At intermediate and high flow rates, the inlet-adjustment mechanism 100 can be partially opened or fully opened as in FIG. 5. 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.

(30) In accordance with the invention, frictional forces resisting pivotal movement of the blades 102 are significantly reduced by the provision of spacing features that space a majority of the upstream surface 102u of each blade from the adjacent upstream wall surface 105. With reference to FIGS. 5 through 9, in one embodiment the spacing features R comprise raised areas (for example, without limitation, ribs, ridges, dimples, and the like) that contact the upstream wall surface 105. The spacing features R collectively constitute a minor fraction of the total upstream surface 102u of each blade, so that a majority of the upstream surface area of each blade is spaced from the upstream wall surface 105. (The phrase the upstream surface area of each blade means the surface area of the blade that would make frictional contact with the upstream wall surface 105 but for the provision of the spacing features.) Alternatively, the spacing features can be defined in or by the upstream wall surface 105.

(31) With reference to FIG. 9, the net aerodynamic loading on the blades 102 acts in the upstream axial direction (to the left in FIG. 9) to automatically space the downstream surfaces 102d of the blades from the downstream wall surface 107, on account of the axial clearance for the blades that is designed into the inlet-adjustment mechanism, as previously described. The spacing features R at the upstream side of the blades ensure that there is also an air space between the blades and the upstream wall surface 105, thereby enabling pressure communication between the upstream and downstream surfaces of the blades. Accordingly, the pressures on those surfaces are more-nearly balanced. Thus, the net aerodynamic load on the blades in the axial direction is substantially reduced relative to a comparable design that lacks the spacing features. The spacing features R also substantially reduce the total surface area of the blades 102 in contact with the upstream wall surface 105. The reduction in aerodynamic load and reduction in contact surface area together result in substantially lower frictional forces resisting the pivoting of the blades. Accordingly, the invention substantially mitigates or eliminates any tendency for the blades to fail to move outwardly, or to move too sluggishly, when starting from the closed position of the inlet-adjustment mechanism during operating conditions near surge (low engine speed and high compression ratio).

(32) 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. The greater the number of blades, the more-nearly circular the opening circumscribed by the blades can be (although generally the opening can be circular in only one position of the blades). Accordingly, the number of blades can be selected as desired, taking into account the greater complexity with a greater number of blades, which may offset the advantage of increased circularity. Additionally, in the illustrated embodiment the blades are configured so that the opening circumscribed by the blades is approximately circular when the blades are in the closed position. Alternatively, however, the blades can be configured so that the opening is non-circular in the closed position. Moreover, while blades with circular-arc edges have been illustrated and described, the blades do not have to have circular-arc edges. Blades with edges of different shapes (linear, elliptical, etc.) are also included within the scope of the invention. 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.