Pulse energy enhanced turbine for automotive turbochargers

Abstract

A turbocharger with a turbine (10) having a turbine wheel (12) in a turbine housing (14) with an associated manifold (24) having individual ports (22) corresponding to unobstructed passageways (26) from each cylinder of an engine. The ports (22) are substantially equally spaced around a face of the turbine wheel (12) to preserve benefits of pulses without interference.

Claims

1. A turbocharger comprising a turbine (10) having a turbine wheel (12) in a turbine housing (14) with an exhaust manifold (24) having ports (22) spaced around an axis of the turbine wheel (12) that direct separate pulses of exhaust gas to the turbine wheel (12) and a wastegate assembly (40) in the turbine housing (14) for regulating exhaust gas flow, wherein each port (22) has a tapered port edge (28) for residual gas flow in the direction of movement of blades (20) of the turbine wheel (12).

2. A turbocharger comprising a turbine (10) having a turbine wheel (12) in a turbine housing (14) with an exhaust manifold (24) having ports (22) spaced around a face of the turbine wheel (12) that direct separate pulses of exhaust gas to the turbine wheel (12) and a wastegate assembly (40) in the turbine housing (14) for regulating exhaust gas flow, wherein each of the separate pulses of exhaust gas corresponds to one cylinder of an engine associated with the turbocharger and the number of ports (22) is the same as the number of cylinders of the engine.

3. The turbocharger of claim 2 wherein exhaust gas pulsation energy is used to control gas flow in the exhaust manifold (24) with individual unobstructed passageways (26) to each port (22), wherein the exhaust manifold is coupled to the turbine (10).

4. The turbocharger of claim 2 having three ports separated by 120 degrees for the engine having three cylinders.

5. The turbocharger of claim 2 having four ports separated by 90 degrees for the engine having four cylinders.

6. The turbocharger of claim 2 having five ports separated by 72 degrees for the engine having five cylinders.

7. The turbocharger of claim 2 having six ports separated by 60 degrees for the engine having six cylinders.

8. The turbocharger according to claim 2, wherein the ports (22) are spaced around an axis of the turbine wheel (12).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

(2) FIG. 1 is a cross-sectional view of a turbine housing with an axial-flow turbine and a waste gate valve with a closely coupled manifold;

(3) FIG. 2 is a view of a portion of a turbine housing with three ports separated by 120 degrees;

(4) FIG. 3 is cross-sectional view of the turbine housing of Section B-B;

(5) FIG. 4 is cross-sectional view of Section A-A where exhaust pulse affects the axial-flow turbine blades;

(6) FIG. 5 is a view of a portion of a turbine housing with four ports separated by 90 degrees;

(7) FIG. 6 shows a cross-sectional view of a pulse enhanced radial/mixed flow turbine with four ports in an integrated manifold directing gas flow to the turbine wheel;

(8) FIG. 7 shows equally spaced pulsation of the four-port turbine of FIG. 6; and

(9) FIG. 8 shows an expanded turbine portion with the turbine wheel above a spoked support with gaps for gas flow between the spokes.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(10) A turbocharger is generally known and includes a turbine 10 and a compressor, wherein a compressor impeller is rotatably driven via a shaft 16 by a turbine wheel 12. The rotatable shaft 16 passes through a bearing housing between a turbine housing 14 and a compressor housing. The turbine 10 converts exhaust gas pressure into energy to drive the turbine wheel 12, which via the shaft 16 drives the compressor impeller.

(11) In the axial-flow turbine 10 of FIGS. 1-4, gas flows through the turbine wheel 12 in an axial direction. The axial-flow turbine 10 includes the axial-flow turbine wheel 12 substantially within the turbine housing 14. While the axial-flow turbine 10 is the preferred turbocharger, the pulse enhanced turbine can be used with radial or mixed flow turbines as shown in FIGS. 6 and 7.

(12) The axial-flow turbine wheel 12 has a hub 18 and a plurality of axial-flow turbine blades 20 configured to rotate the turbine wheel 12 and the centrally attached rotatable shaft 16 when the turbocharger receives exhaust gas flow from the engine. The axial-flow turbine wheel 12 is designed to react to flow pulsations that are concentrated to impact tips of the blades 20 via substantially equally spaced ports 22 around a face of the turbine wheel 12. Axial-flow turbine wheels 12 may have low-stress small hubs 18 attached to the rotatable shaft 16 by various means. Similarly, a radial or mixed flow turbine wheel 12 has a hub 18 and a plurality of turbine blades 20 configured to rotate the turbine wheel 12 when the turbocharger receives exhaust gas flow from the engine. The radial/mixed-flow turbine wheel 12 would also be designed to react to flow pulsations on the blades 20 radially or mixed between axial and radial via the substantially equally spaced ports 22 around a face of the turbine wheel 12.

(13) In conjunction with each cylinder of a reciprocating engine, a manifold 24, such as a closely coupled separate manifold or an integrated exhaust manifold, will have individual unobstructed passageways 26 to direct individual pulsations from each cylinder onto the turbine wheel 12. Each individual cylinder passageway 26 is preferably sized for an area whose sum is equal to that of a fixed single nozzle turbine housing. The passageways 26 end at each port 22, which may have a tapered port edge 28 as shown in FIG. 4 for residual exhaust gas flow in the direction of movement of the blades 20. An integrated manifold may have passageways 26 integrated into the turbine housing 14, rather than a separate exhaust manifold, to all or part way to the engine cylinders.

(14) The turbine housing 14 preferably attaches directly to a mounting flange 30 without a fixed stator or collector volume to direct exhaust gas flow into the leading edge of the blades 20 of the turbine wheel 12. As such, the individual streams shot at the turbine wheel 12 can maintain the pulse energy without a detrimental effect on exhaust gas flow.

(15) Exhaust gas flow exiting the turbine stage is preferably directed to a collector via a heat shield and volute passage.

(16) A wastegate assembly 40 (in communication with the volute passage in the turbine housing 14) may include a control valve 42 that is selectively opened by a linkage connected to an actuator. Exhaust gas flow is regulated (i.e. some bypassing) though the turbine stage, in order to limit/control turbine work, thus selectively using a fraction of the available exhaust energy. The wastegate port 44 allows bypass gas flow to control the maximum boost pressure.

(17) The wastegate bypass port 44 includes a specifically sized flow gap 46 between the cylinder head or manifold 24 with a flow area that is greater than the bypass port area. As an example of FIG. 1, the flow gap 46 used with the wastegate assembly 40 can be up to two times the bypass port area, with a preferred flow gap approximately 1.2 times that of the bypass port area. This allows gas flow to be equally drawn from each cylinder's flow. FIG. 1 shows the flow gap 46 as part of the exhaust area between a cylinder head and the turbine housing 14.

(18) The pulse energy enhanced turbine 10 with a turbine wheel 12 reacts to separate individual pulses of exhaust gas flow from ports 22 in a manifold 24 that are substantially equally spaced around the face of the turbine wheel 12. Each port 22 directs individual pulsations onto the turbine 10 with resulting alternate pulsations across the face of the turbine wheel 12. Exhaust pulsation energy can be used in a closely coupled manifold 24 to deliver both higher efficiency and low inertia without a fixed stator to control flow.

(19) The turbine 10 receives individual pulses via equidistant ports 22 around the face of the turbine wheel 12. The number of ports 22 in the manifold 24 preferably corresponds with the number of cylinders, and the separation and arrangement of ports 22 depends on the number of ports. For example, a three-cylinder engine has three ports separated by approximately 120 degrees as shown in FIGS. 2-3. Similarly, as shown in FIGS. 5 and 7, a four-cylinder engine has four ports separated by approximately 90 degrees, a five-cylinder engine by approximately 72 degrees, and a six-cylinder engine by approximately 60 degrees. The arrangement of individual ports 22 will be fixed by the physical layout of the exhaust and to alternate pulsations across the face of the turbine wheel 12.

(20) FIG. 8 shows the turbine wheel 12 in an expanded relation to a support 50 for the contour. The support 50 as shown has three spokes 52 as a preferred embodiment, but other numbers of spokes could be used. The spokes 52 are preferably aerodynamically angled in a curved radial position with gaps for gas flow between the spokes 52. The support 50 is particularly useful with inserting the turbine wheel 12 into a turbine-integrated manifold wherein the gaps between the spokes 52 preferably align with the volute of the turbine housing 14 as shown in FIG. 6. As shown, the base of the support 50 can form a portion of the volute passage, and the base can be secured to the turbine housing 14.

(21) The invention has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of words of description rather than limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically enumerated within the description.