Roots-style blower with leakage mechanisms

Abstract

The disclosure concerns a Roots-type blower comprising a housing defining first and second transversely overlapping cylindrical chambers and at least one inlet port and an outlet port; first and second meshed, lobed rotors, each lobe having a top land sealingly cooperating with the cylindrical chambers; a plurality of control volumes for transfer of fluid, each control volume being defined by a pair of adjacent lobes on one of the rotors, and at least one of the cylindrical chambers; and blowholes formed within the cylindrical chambers in connection with meshing of the lobes of the first and second rotors. The blower further comprises at least one backflow slot extending through the housing wall of each cylindrical chamber for effecting a leakage of fluid from downstream the at least one outlet port into a control volume.

Claims

1. A Roots-type blower comprising: a housing defining first and second transversely overlapping cylindrical chambers, the housing comprising a first end wall and a second end wall, and the housing defining at least one inlet port in the first end wall and at least one outlet port at an intersection of the first and second chambers, adjacent the second end wall; first and second meshed, lobed rotors disposed, respectively, in the first and second cylindrical chambers, each rotor including a plurality of lobes, each lobe having first and second axially facing end surfaces sealingly cooperating with the first and second end walls, respectively, and a top land sealingly cooperating with a respective cylindrical chamber, each lobe having its first and second axially facing end surfaces defining a twist angle of at least 90, and each lobe defining a helix angle; a plurality of control volumes for transfer of fluid from the at least one inlet port to the at least one outlet port, each control volume being defined by a pair of adjacent lobes on one of the rotors, and at least one of the cylindrical chambers, the first end wall, or the second end wall; a leakage mechanism for effecting a leakage of fluid between adjacent control volumes, the leakage mechanism including blowholes formed within the cylindrical chambers in connection with meshing of the lobes of the first and second rotors; and an additional leakage mechanism comprising at least two individual backflow slots provided on each side of a center line of the housing, each backflow slot extending through a wall of the housing for effecting a leakage of fluid from downstream of the at least one outlet port into a control volume prior to traversal of boundaries of the at least one outlet port by the top land of a lead lobe of the control volume, wherein the individual backflow slots on either side of the center line are arranged along a slot axis having a slot axis angle to a longitudinal direction of the housing, and wherein the slot axis angle is smaller than the helix angle of the lobes, such that the individual backflow slots along each slot axis sequentially enable a fluid flow passage to a control volume as the top land of the lead lobe of the control volume progressively traverses the slot axis.

2. The Roots-type blower according to claim 1 wherein the additional leakage mechanism comprises at least three individual backflow slots provided on each side of the center line of the housing.

3. The Roots-type blower according to claim 1 wherein each backflow slot has a rectangular shape.

4. The Roots-type blower according to claim 1 wherein each backflow slot has an elongated shape having a length in the range of 3-25 millimeters.

5. The Roots-type blower according to claim 1 wherein each backflow slot has an elongated shape having a length in the range of 4-20 millimeters.

6. The Roots-type blower according to claim 1 wherein each backflow slot is provided on either side of the at least one outlet port.

7. The Roots-type blower according to claim 1 wherein the housing comprises a reinforcing rib projecting outwardly from an exterior surface of the housing and extending in a direction perpendicular to a longitudinal direction, and the at least two individual backflow slots provided on each side of the center line are provided on each side of the reinforcing rib.

8. The Roots-type blower according to claim 1 wherein a blowhole between adjacent control volumes is formed in regions along a longitudinal direction of the blower when the lobe of any rotor is located between an angular position where the top land has passed an outlet cusp and an angular position where the lobe sealingly closes the control volume upon meshing with lobes of the other rotor.

9. A Roots-type blower comprising: a housing defining first and second transversely overlapping cylindrical chambers, the housing comprising a first end wall and a second end wall, and the housing defining at least one inlet port in the first end wall and at least one outlet port at an intersection of the first and second chambers, adjacent the second end wall; first and second meshed, lobed rotors disposed, respectively, in the first and second cylindrical chambers, each rotor including a plurality of lobes, each lobe having first and second axially facing end surfaces sealingly cooperating with the first and second end walls, respectively, and a top land sealingly cooperating with a respective cylindrical chamber, each lobe having its first and second axially facing end surfaces defining a twist angle and each lobe defining a helix angle; a plurality of control volumes for transfer of fluid from the at least one inlet port to the at least one outlet port, each control volume being defined by a pair of adjacent lobes on one of the rotors, and at least one of the cylindrical chambers, the first end wall, or the second end wall; and a leakage mechanism for effecting a leakage of fluid between adjacent control volumes, the leakage mechanism comprising at least one bleed recess provided in the second end wall, wherein the at least one bleed recess provides a passage between the second axially facing end surface of a lobe and the second end wall such that fluid is enabled to leak between adjacent control volumes, and wherein the at least one bleed recess is located to enable a leakage of fluid between adjacent control volumes only after each of the adjacent control volumes is lacking fluid communication with the at least one inlet port.

10. The Roots-type blower according to claim 9 wherein at least two bleed recesses are provided in the second end wall, and wherein at least one bleed recess is associated with each individual cylindrical chamber.

11. The Roots-type blower according to claim 10 wherein each of the at least two bleed recesses has an angular width greater than an angular width of a lobe.

12. The Roots-type blower according to claim 9 wherein the twist angle of each lobe is at least 120.

13. The Roots-type blower according to claim 9 wherein the twist angle of each lobe is at least 140.

14. The Roots-type blower according to claim 9 wherein the twist angle of each lobe is less than 360.

15. The Roots-type blower according to claim 9 wherein the twist angle of each lobe is less than 300.

16. The Roots-type blower according to claim 9 wherein the twist angle of each lobe is less than 240.

17. A Roots-type blower comprising: a housing defining first and second transversely overlapping cylindrical chambers, the housing comprising a first end wall and a second end wall, and the housing defining at least one inlet port and at least one outlet port; first and second meshed, lobed rotors disposed, respectively, in the first and second cylindrical chambers, each rotor including a plurality of lobes, each lobe having first and second axially facing end surfaces sealingly cooperating with the first and second end walls, respectively, and a top land sealingly cooperating with a portion of the housing that defines a respective cylindrical chamber, each lobe having its first and second axially facing end surfaces defining a twist angle of at least 90, and each lobe defining a helix angle; a plurality of control volumes for transfer of fluid from the at least one inlet port to the at least one outlet port, each control volume being at least partially defined by a pair of adjacent lobes on one of the rotors; a leakage mechanism for effecting a leakage of fluid between adjacent control volumes, the leakage mechanism including blowholes formed within the cylindrical chambers in connection with meshing of the lobes of the first and second rotors; and an additional leakage mechanism comprising at least two individual backflow slots provided on each side of a center line of the housing, each backflow slot extending through a wall of the housing for effecting a leakage of fluid from downstream of the at least one outlet port into a control volume prior to traversal of boundaries of the at least one outlet port by the top land of a lead lobe of the control volume, wherein the individual backflow slots on either side of the center line are arranged along a slot axis having a slot axis angle to a longitudinal direction of the housing, and wherein the slot axis angle is smaller than the helix angle of the lobes, such that the individual backflow slots along each slot axis sequentially enable a fluid flow passage to a control volume as the top land of the lead lobe of the control volume progressively traverses the slot axis.

18. The Roots-type blower according to claim 17 wherein the at least one inlet port is formed in the first end wall, and the at least one outlet port is formed at an intersection of the first and second chambers.

19. The Roots-type blower according to claim 17 wherein the additional leakage mechanism comprises at least three individual backflow slots provided on each side of the center line of the housing.

20. The Roots-type blower according to claim 17 wherein each backflow slot has a rectangular shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the detailed description of the disclosure given below reference is made to the following figures, in which:

(2) FIG. 1 shows a schematic overview of an engine aspiration assembly comprising a Roots-type blower;

(3) FIG. 2 shows an external, perspective view of the inventive Roots-type blower;

(4) FIG. 3 shows a perspective overview of the rotors of the inventive Roots-type blower of FIG. 2;

(5) FIG. 4 shows a longitudinal cross-section of the Roots-type blower shown in perspective in FIG. 2,

(6) FIG. 5 shows a transverse cross-section of the Roots-type blower in FIG. 2;

(7) FIG. 6 shows a cross-section along line A-A in FIG. 5;

(8) FIG. 7 shows a top view of the outlet flange of the inventive Roots-type blower of FIG. 2; and

(9) FIG. 8 shows a transverse cross-section of a second embodiment of the inventive Roots-type blower.

DETAILED DESCRIPTION

(10) As required, detailed embodiments are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary and that various and alternative forms may be employed. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art.

(11) Various aspects of the disclosure will hereinafter be described in conjunction with the appended drawings to illustrate and not to limit the disclosure, wherein like designations denote like elements, and variations of the inventive aspects are not restricted to the specifically shown embodiments, but are applicable on other variations of the disclosure.

(12) FIG. 1 shows a schematic overview of an engine aspiration assembly 100 comprising a Roots-type blower 1. Typically, such an engine assembly is found in a motor vehicle, such as for example an automobile, truck, bus or the like. In this example, the Roots-type blower 1 is used in combination with a turbocharger 8 for transferring air into the combustion chambers of the internal combustion engine 10. The transferred volumes of air are greater than the displacement of the engine 10, thereby increasing the air pressure within the combustion chambers which results in greater engine output power. Air is let into the engine aspiration assembly 100 via an air intake 2 and passes via an air filter 3 for removal of particles harmful to the assembly 100. A bypass valve 4 controls if the incoming air is fed via the Roots-type blower 1 or directly to the turbocharger 8. For example, the pumping of the Roots-type blower 1 may be needed at low engine speeds, while being superfluous at higher engine speeds. If the bypass valve 4 is open towards the Roots-type blower 1, air is fed into the Roots-type blower 1 via an inflow duct 5. The pumping mechanism of the Roots-type blower is mechanically driven by a drive belt 7 connected to the engine crankshaft. After being pumped, the air leaves the Roots-type blower 1 via an outflow duct 6 and is passed on to the turbocharger 8 in which the air may be further pumped. After having passed the turbocharger 8, the air is cooled by an intercooler 9 before entering the combustion chambers of the engine 10. After combustion, exhaust gases are ejected from the engine 10. The exhaust gases drive the turbocharger 8 before leaving the engine aspiration assembly 100 via an exhaust outlet 11.

(13) FIG. 2 shows an external, perspective view of a first embodiment of the Roots-type blower 1, according to the present disclosure, having a longitudinal direction A and a transverse direction B. The Roots-type blower 1 includes a housing 20. Air enters the blower 1 via the inlet port 23 which is defined by an opening adjacent one end of the housing 20. An inlet flange 46 surrounds the inlet port 23 and provides means for connection to inflow duct 5. An outlet port 25 is provided on the upper side of housing 20. In this example, the single outlet port 25 is defined partly by an end surface 28 which extends in the transverse direction B and a pair of inclined side surfaces 26, 27, such that the outlet port 25 has a substantially triangular shape. The inclined side surfaces 26, 27 are inclined with respect to the longitudinal direction A. The inclination angle is preferably selected to correspond to the helix angle of two rotors 31, 32 rotatably positioned within the housing 20. An outlet flange 47 surrounds the outlet port 25 and provides means for connection to the outflow duct 6. The outlet flange 47 has a rectangular form and encloses an area significantly larger than the flow area of the outlet port 25. The exterior surface 48 of the housing 20 occupies the area enclosed within the outlet flange 47 that is not part of the outlet port 25. The housing is reinforced by means of a plurality of transversally extending reinforcement ribs 49 that are spaced apart in the longitudinal direction A.

(14) A first rotor 31 and a second rotor 32 are partly glimpsed through the outlet port 25. As the lobed rotors 31, 32 rotate, fluid is trapped in pockets, herein referred to as control volumes, enclosed by consecutive lobes and carried from the inlet port 23 to the outlet port 25 as the rotors rotate. To provide improved pressure equalization between consecutive control volumes prior to opening to the outlet port 25, the housing is provided with backflow slots 29 which allow the control volume to at least partly equalize in pressure with the outflow duct 6 prior to opening to the outlet port 25. The mechanical input to drive the rotors 31, 32 is by means of a pulley 15 adapted for engagement with a driving belt 7.

(15) FIG. 3 shows a cross-section of the blower housing 20 of FIG. 2, as well as the complete rotors 31, 32. The rotors 31, 32 comprise a first and a second rotor shaft 33, 34 respectively. Each rotor shaft 33, 34 is rotatably supported by bearing arrangements in the housing 20. The twist angle of the rotors is in the shown example 160 degrees. The twist angle refers to the difference in angular orientation of any lobe at a first axially facing end surface 61 and a second axially facing end surface 62. In this example, each rotor 31, 32 has four lobes 51, 52. The first rotor 31 is connected to the pulley 21 via a shaft 50.

(16) The internal design of the blower will now be described more in detail, wherein FIG. 4 show a centrally located cross-section of the blower in the longitudinal direction A and FIG. 5 shows a corresponding cross-section of the blower in the transverse direction B. The blower housing 20 defines a pair of transversely overlapping cylindrical chambers 41, 42. The cylindrical chambers 41, 42 overlap at an inlet cusp 40a which is in-line with the inlet port 23 and at an outlet cusp 40b which is in-line with and interrupted by the outlet port 25. At a first end of the cylindrical chambers 41, 42, the housing 20 defines a first end wall 43 which comprises the inlet port 23. At the opposite end of the chambers 41, 42, the housing 23 defines a second end wall 44. The outlet port 25 is formed at an intersection of the first and second chambers 41, 42, adjacent the second end wall 44.

(17) Referring now primarily to FIG. 5, it may be seen that disposed within the first cylindrical chamber 41 is a first rotor 31 and disposed within the second cylindrical chamber 42 is a second rotor 32. When viewing the rotors from the inlet as in FIG. 5, the first rotor 31 rotates clockwise while the second rotor rotates counter-clockwise. The first rotor 31 includes four lobes 51 and the second rotor 32 includes four lobes 52. The first and second axially facing end surfaces 61, 62 of the lobes sealingly cooperate with the first and second end walls 43, 44 of the housing 23, and the top land 53, 54 of each lobe sealingly cooperate with the cylindrical chambers 41, 42 which is well known in the art. Air which flows into the cylindrical chambers 41, 42 via the inlet port 23 will flow into a volume, which is defined by two consecutive adjacent lobes 51, 52 of the same rotor 31, 32. As used herein, such a volume is referred to as a control volume. The air contained in a control volume will be carried by its respective lobes as the rotor rotates until the control volume is in communication with the outlet port 25. In other words, the term control volume refers, primarily, to the region or volume between two adjacent unmeshed lobes, after the trailing lobe has traversed the inlet cusp 40a, and before the leading lobe has traversed the outlet cusp 40b. A more detailed description of the movements of the lobes and the corresponding control volumes is provided in for example US 2006/0263230 A1.

(18) FIG. 6 shows a cross-sectional cut along line A-A in FIG. 5 for illustrating the internal leakage that inherently results from a Roots-type blower having a relatively large twist angle. As the rotors 31, 32 rotate, the lobes 51, 52 move into and out of mesh. In connection with meshing of two lobes 51, 52, one or more blowholes 55, sometimes referred to as a backflow ports, are formed along the outlet cusp 40b. A blowhole 55 is an opening through which a preceding control volume is permitted to communicate with an adjacent control volume. Consequently, blowholes 55 provide a possibility for a control volume to equalize in pressure with an adjacent control volume prior to opening to the outlet port 25. As understood by those skilled in the art, the formation of blowholes 55 occurs in a cyclic manner, i.e., one blowhole 55 is formed by two meshing lobes 51, 52. The blowhole 55 moves linearly in a direction towards the outlet port 25 as the lobe mesh moves linearly in the same direction. There can be several blowholes 55 present in the Roots-type blower 1 at any one time. The greater the twist angle of the lobes 51, 52, the more blowholes 55 will be present at the same time, and each blowhole will exhibit a larger area. Also, a greater twist angle means a greater helix angle HA of the lobes 51, 52 if the length of the rotors is kept constant. As the helix angle HA increases the linear velocity of the lobe mesh decreases and consequently the linear velocity of the blowholes 55 decreases. This results in each blowhole 55 being present during a longer period of time which means that there is longer time for pressure equalization between adjacent control volumes. Also, many blowholes 55 present at the same may provide pressure equalization between a plurality of adjacent control volumes. Hence, an increased helix angle, which usually is enabled by increased twist angle, provides improved pressure equalization between the control volumes prior to opening to the outlet port 25.

(19) In FIG. 6, a leakage flow 60 is illustrated entering the outlet port 25 and flowing through a first blowhole 55 formed between a first lobe 51a of the first rotor 31 and a first lobe 52a of the second rotor 32, thereby enabling a certain level of pressure equalization between the pressure downstream the outlet port 25 and a first control volume 70, which is defined by a first and second lobe 51a, 51b of the first rotor 31. The leakage flow 60 may subsequently continue from the first control volume 70 to a second control volume 71, which is defined by a first and second lobe 52a, 52b of the second rotor 32, thereby enabling a certain level of pressure equalization between the pressure downstream the outlet port 25 and the first and second control volumes 70, 71. The top land of the first lobe 52a of the second rotor 32 has in this example not yet traversed the boundary of the outlet port 25. A third control volume 72 trailing the first control volume 70 of the first rotor 31 is still closed to the leakage flow 60.

(20) FIG. 7 shows a top view of the first embodiment of the Roots-type blower 1. In this example, three backflow slots 29 are provided on each side of an axially extending center line CL in a wall of the housing 20, i.e. in total six backflow slots. The center line CL extends in the longitudinal direction A in the center between the first and second rotor 31, 32, as viewed from the outlet port side of the housing in FIG. 7. Each backflow slot 29 is an opening extending through the housing 20 for effectuating a leakage of fluid between a control volume and a volume outside of the outlet port 25. At each side of the outlet port 25, the three backflow slots are provided substantially along a slot axis 22 which makes an angle to the longitudinal direction A of the housing 20. The slots 29 may have their elongation axis arranged parallel with the associated slot axis 22. The center of each slot 29 may be located on the slot axis. Alternatively, the center of one or more slots 29 may be slightly displaced from the slot axis 22. The longitudinal direction A of the housing 20 coincides with a longitudinal axis of the rotors 31, 32. In this example, the slot axis angle is smaller than the helix angle HA of the lobes 51, 52 such that the backflow slots 29 one after the other are brought into contact with the control volume as the top land 53, 54 of the lead lobe 51, 52 of the control volume progressively traverses the slot axis 22. Consequently, the two backflow slots 29 located closest to the inlet port will first provide a backflow passage, thereafter the four backflow slots 29 located closest to the inlet port will provide a backflow passage, and thereafter all six backflow will provide a backflow passages. In this example, there are six backflow slots 29 located in a V-shaped formation around the outlet port 25. Each backflow slot 29 has an elongated, substantially rectangular shape. The backflow slot 29 has an elongated shape and a length L1 in range of 3-25 millimeters, preferably 4-20 millimeters, and more preferably 4-15 millimeters. Furthermore, the backflow slot 29 has preferably a width L2 in range of 1-5 millimeters, more preferably 1-3 millimeters. However, other numbers, shapes and positions of backflow slots 29 are also possible. Preferably, the design, disclosure, number, size, shape, and position, of the backflow slots 29 is adapted to minimize noise in the specific environment of the Roots-type blower, disclosure, in a specific model of a vehicle. The frequency of the fundamental tone of the noise generated by the Roots-type blower corresponds to the rotational frequency of the rotors 31, 32. Several overtones, i.e., multiples of the fundamental frequency, are also generated. The size and shape of the backflow slots 29 effect which overtones that are generated. The inclination angle of the side surfaces 26, 27 is here indicated.

(21) FIG. 8 shows a transverse cross-section of a second embodiment of the Roots-type blower according to the disclosure. In this embodiment, the second end wall 44 of the cylindrical chambers 41, 42 is provided with two bleed recesses 45, one in each cylindrical chamber 41, 42. Each bleed recess 45 has typically a depth of a few millimeters, disclosure, 2-10 mm, but smaller, larger or variable depths are also possible. The angular width w of the bleed recess 45 is larger than the angular width lw of the lobes 51, 52, such that the bleed recess 45 provides a passage between the end surface of the lobe 51, 52 and the second end wall 44. This passage enables fluid to leak between two adjacent control volumes. The angular width w of the bleed recess 45 is typically in the range of 1.1-2.0 times larger than the angular width lw of the lobes 51, 52. The angular width of a lobe 51, 52 or bleed recess 45 is defined as the average width of the lobe 51, 52 or bleed recess 45. The width w of the bleed recess 45 is typically smaller than the lobe pair width lpw, i.e. the total width of a pair of lobes, in order not to provide passage between three control volumes. The position, size and form of the recess is selected according to the specific circumstances. A three lobed rotor generally requires a wider bleed recess due the wider lobe width lw, etc. The positioning and size of the bleed recess is preferably also selected to avoid that working fluid may bleed from the outlet port to the inlet port. In the specific example shown in FIG. 8, the bleed recess may have a width w in the range of 45-90 degrees, preferably in the range of 60-80 degrees. An angle between an angular center 64 of the bleed recess 45 and a position where the lobe is directed towards the outlet port, in the direction of rotation, may be in the range of 90-180 degrees, preferably in the range of 110-150 degrees. The second embodiment may be successfully implemented on blowers having a large variety of twist angles and a helix angles HA, for example with a twist angle in the range of 0-360 degrees.

(22) The term helix angle herein referrers to the angle between a lobe and the axis of the rotor on which the lobe is provided. The helix angle is typically calculated at the pitch circle (or pitch diameter) of the rotors. The term twist angle herein refers to the angle described by a lobe when travelling from one end surface to the other end surface of the rotor.

(23) As will be realized, the disclosure is capable of modification in various obvious respects, all without departing from the scope of the appended claims. For example, each bleed recess may be divided into two or more bleed recesses having different angular extensions and/or positions, the location of the inlet port and outlet port may be modified. Accordingly, the drawings and the description thereto are to be regarded as illustrative in nature, and not restrictive. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.