Staged turbocharger

• US 7,269,950 B2
• Filed: 05/05/2004
• Issued: 09/18/2007
• Est. Priority Date: 05/05/2004
• Status: Expired due to Fees

• Current Assignee: Precision Industries, Inc. (Freudenberg & Company KG)
• Original Assignee: Precision Industries, Inc. (Freudenberg & Company KG)
• Inventors: Benson, Steven R., Pedersen, Melvin H.
• Primary Examiner(s): TRIEU, THAI BA
• Application Number:
  US10/839,771
• Publication Number:
  US 20050247058A1
• Time in Patent Office: 1,231 Days
• Field of Search: 606/02, 417/406, 415/203, 415/205, 123/559.1
• US Class Current: 60/602
• CPC Class Codes: F01D 17/14 varying effective cross-sectional area of nozzles or guide conduits
• CPC Class Codes: F01D 17/143 the shiftable member being a wall, or part thereof of a radial diffuser
• CPC Class Codes: F01D 17/145 by means of valves, e.g. for steam turbines valves in general F16K
• CPC Class Codes: F01D 17/148 by means of rotatable members, e.g. butterfly valves
• CPC Class Codes: F01N 13/10 of exhaust manifolds with cooling jacket F01N3/046
• CPC Class Codes: F01N 13/107 More than one exhaust manifold or exhaust collector
• CPC Class Codes: F02B 29/0406 Layout of the intake air cooling or coolant circuit
• CPC Class Codes: F02B 37/02 Gas passages between engine outlet and pump drive, e.g. reservoirs
• CPC Class Codes: F02B 37/025 Multiple scrolls or multiple gas passages guiding the gas to the pump drive
• CPC Class Codes: F02B 37/183 Arrangements of bypass valves or actuators therefor
• CPC Class Codes: F02B 37/22 by varying cross-section of exhaust passages or air passages , e.g. by throttling turbine inlets or outlets or by varying effective number of guide conduits F02B37/24 takes precedence
• CPC Class Codes: F02C 6/12 Turbochargers, i.e. plants for augmenting mechanical power output of internal-combustion piston engines by increase of charge pressure
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A turbocharger comprising a turbine, director, and compressor. The turbine may be formed as a turbine wheel surrounded by at least two scrolls. The at least two scrolls may direct exhaust gases supplied thereto toward the turbine wheel to cause rotation thereof. The director may control distribution of the exhaust gases between the at least two scrolls to optimize circumferential velocity in the scroll or volute, and thus impingement velocity on the turbine. The compressor may be driven by the turbine.

Claims

1. A turbocharger using the energy contained in an exhaust flow to compress an intake flow, the turbocharger comprising:

a turbine comprising a turbine wheel surrounded by at least two scrolls, the at least two scrolls each shaped to direct and deliver the exhaust flow supplied thereto directly against the turbine wheel to cause rotation thereof;

a channel to conduct the exhaust flow;

a director selectively moving through a range of motion bounded by a first position, wherein the director forms a wall of the channel to gradually converge the exhaust flow substantially exclusively into one of the at least two scrolls, and a second position, wherein the director is withdrawn substantially completely from within the exhaust flow, the range of motion including an intermediate position located between the first and second positions;

a bypass providing a conduit bypassing the turbine;

the director in the first position, in the intermediate position, and in all positions therebetween covering the bypass and resisting entrance of the exhaust flow into the bypass;

the director in the intermediate position being out of the channel, leaving the channel unobstructed to conduct the exhaust flow substantially exclusively into the at least two scrolls;

the director in the second position exposing the bypass and permitting entrance of exhaust flow into the bypass; and

a compressor driven by the turbine.

2. The turbocharger of claim 1, wherein the turbine includes only a single turbine wheel.

3. The turbocharger of claim 2, wherein the director comprises a gate maintaining, in the first position, a monotonically reducing cross-section in the flow up to entry thereof into the one of the at least two scrolls.

13. The turbocharger of claim 1, wherein the director gradually converges exhaust flow substantially exclusively into the one of the at least two scrolls when the pressure of the exhaust flow is below a first value.

14. The turbocharger of claim 13, wherein the director aims exhaust flow into more than one of the at least two scrolls when the pressure of the exhaust flow is above the first value.

15. The turbocharger of claim 1, wherein the director comprises a pivoting gate formed as a single rigid structure.

16. The turbocharger of claim 1, wherein the director exposes a bypass when the pressure of the exhaust flow is above a threshold value.

17. The turbocharger of claim 1, wherein the director is selected from the group consisting of a poppet valve, translating valve, and pivoting valve.

18. The turbocharger of claim 1, wherein the director comprises a pivoting gate and a controller controlling the position of the pivoting gate.

19. The turbocharger of claim 18, wherein the controller operates using a mechanism selected from the group consisting of hydraulic, pneumatic, mechanical, and electrical actuators, and operates based on a sensed pressure selected from the group consisting of intake manifold pressure, exhaust manifold pressure, and rotational speed of an engine.

4. The turbocharger of chain 3, wherein the range of motion comprises a third position where the director aims the exhaust flow into at least two of the at least two scrolls.

5. The turbocharger of claim 4, wherein the director further comprises a controller to control the position of the gate.

6. The turbocharger of claim 5, wherein the controller pivots the gate in accordance with pressure of the exhaust flow.

7. The turbocharger of claim 6, wherein the controller positions the gate to gradually converge exhaust flow exclusively into one of the at least two scrolls when the pressure of the exhaust flow is less than a first value.

8. The turbocharger of claim 7, wherein the controller positions the gate to aim exhaust flow into more than one of the at least two scrolls when the pressure of the exhaust flow is above the first value.

9. The turbocharger of claim 8, wherein the controller positions the gate to expose the bypass when the pressure of the exhaust flow is above a second value, greater than the first value.

10. The turbocharger of claim 9, wherein the turbine comprises a turbine wheel encircled by only two scrolls.

11. The turbocharger of claim 10, wherein the two scrolls are symmetric.

12. The turbocharger of claim 10, wherein the two scrolls are asymmetric.

20. A turbocharger comprising:

a turbine comprising a turbine wheel surrounded by two scrolls, the two scrolls each directing and delivering exhaust gases supplied thereto directly against the turbine wheel to cause rotation thereof;

a channel to conduct the exhaust gases;

a director forming a wall of the channel to gradually converge the exhaust gases into substantially exclusively the first scroll when the pressure of the exhaust gases is below a first value and withdrawing substantially completely from within the exhaust gases when the pressure of the exhaust gases is above a second value, greater than the first value;

a bypass providing a conduit bypassing the turbine;

the director covering the bypass and resisting enhance of the exhaust gases into the bypass whenever the pressure of the exhaust gases is below an intermediate value between the first and second values;

the director, when the pressure of the exhaust gases is at the intermediate value, covering the bypass and being out of the channel, leaving the channel unobstructed to conduct the exhaust gases substantially exclusively into the two scrolls;

the director exposing the bypass and permitting entrance of exhaust gases into the bypass when the pressure of the exhaust gases is above the second valve; and

a compressor driven by the turbine.

21. The turbocharger of claim 20, wherein the director aims the exhaust gases into both of the two scroll when the pressure of exhaust gases is between the first and second values.

22. The turbocharger of claim 20, wherein the bypass relieves gases entrapped behind the director.

23. A system comprising:

an internal combustion engine having an intake conduit and an exhaust conduit, the internal combustion engine receiving air through the intake conduit and discharging exhaust gases through the exhaust conduit;

a turbine comprising a turbine wheel surrounded by at least two scrolls, the at least two scrolls each directing and delivering exhaust gases supplied thereto by the exhaust conduit directly against the turbine wheel to cause rotation thereof;

a director selectively moving through a range of motion bounded by a first position, wherein the director forms a wall of the exhaust conduit to gradually converge the exhaust gases substantially exclusively into one of the at least two scrolls, and a second position, wherein the director is withdrawn substantially completely from within the exhaust gases, the range of motion including an intermediate position located between the first and second positions;

a bypass providing a conduit bypassing the turbine;

the director in the first position, in the intermediate position, and in all positions therebetween covering the bypass and resisting entrance of the exhaust gases into the bypass;

the director in the intermediate position being out of the exhaust conduit, leaving the exhaust conduit unobstructed to conduct the exhaust flow substantially exclusively into the at least two scrolls;

the director in the second position exposing the bypass and permitting entrance of exhaust gases into the bypass; and

a compressor driven by the turbine to deliver air at greater than ambient pressure to the intake conduit.

24. The system of claim 23, wherein the turbine comprises a turbine wheel surrounded by two scrolls.

25. The system of claim 24, wherein the two scrolls are symmetric.

26. The system of claim 25, wherein the two scrolls are asymmetric.

27. A system comprising:

an internal combustion engine having an intake conduit and an exhaust conduit, the internal combustion engine receiving air through the intake conduit and discharging exhaust gases through the exhaust conduit;

a turbine comprising a turbine wheel surrounded by two scrolls, the two scrolls each directing exhaust gases supplied thereto by the exhaust conduit directly against the turbine wheel to cause rotation thereof, the two scrolls being asymmetric;

a director selectively moving through a range of motion bounded by a first position, wherein the director forms a wall of the exhaust conduit to gradually converge the exhaust gases into substantially exclusively one of the at least two scrolls, and a second position wherein the director is withdrawn substantially completely from within the exhaust gases, the range of motion including an intermediate position located between the first and second position;

a bypass providing a conduit bypassing the turbine;

the director in the first position, in the intermediate position, and in all positions therebetween covering the bypass and resisting entrance of the exhaust gases into the bypass;

the director in the intermediate position being out of the exhaust conduit, leaving the exhaust conduit unobstructed to conduct the exhaust gases substantially exclusively into the two scrolls;

the director in the second position exposing the bypass and permitting entrance of exhaust gases into the bypass;

the bypass relieving gases entrapped behind the director, and

a compressor driven by the turbine to deliver air at greater than ambient pressure to the intake conduit.

28. A system comprising:

an internal combustion engine having an intake conduit and an exhaust conduit, the internal combustion engine receiving air through the intake conduit and discharging exhaust gases through the exhaust conduit;

a turbine comprising a single turbine wheel surrounded by a first scroll and a second scroll, each of the first and second scrolls directing exhaust gases supplied thereto by the exhaust conduit directly against the single turbine wheel to cause rotation thereof;

a director comprising a gate manipulated by a controller, the controller positioning the gate to form a wall of the exhaust conduit to gradually converge the exhaust gases substantially exclusively into the first scroll when a pressure of the exhaust gases is below a first value, and withdrawing the gate substantially completely from within the exhaust gases when the pressure is above a second value, greater than the first value;

a bypass providing a conduit bypassing the turbine;

the director covering the bypass and resisting entrance of the exhaust gases into the bypass whenever the pressure is below an intermediate value between the first and second values;

the director, when the pressure of the exhaust gases is at the intermediate value, covering the bypass and being out of the exhaust conduit, leaving the exhaust conduit unobstructed to conduct the exhaust gases substantially exclusively into the first and second scrolls;

the director exposing the bypass and permitting entrance of exhaust gases into the bypass when the pressure is above the second value;

the bypass relieving gases entrapped behind the director; and

a compressor driven by the turbine to deliver air at greater than ambient pressure to the intake conduit.