Novel Centrifugal Compressor Architecture for Wide-Range Operation: A Feasibility Assessment
Turbocharger compressor performance plays a critical role in the ability of advanced Internal Combustion Engines (ICE) to meet the required fuel economy and drivability targets. Increased use of exhaust gas recirculation (EGR) combined with engine downsizing has pushed compressor operation towards — and often beyond — the stability boundary. However, certain applications and market trends require that no compromise be made to the rated power conditions. This has led to a highly disparate set of requirements for a single turbocharger system resulting in much of the compressor map, including the highest-efficiency area, unused or underutilized. A large percentage of the drive cycle is spent operating the compressor at low flow rates and low pressure ratios, near the compressor surge line, in an area of low efficiency. Compromises in efficiency in critical regions of engine operation result from balancing the disparate requirements. A current approach to meeting these disparate flow targets is the use of two turbochargers in series that are sized such that the operating compressor efficiency is markedly improved. This paper introduces a novel, hybrid single-stage compressor architecture which aerodynamically matches the functions of a series sequential dual turbocharger compression system. The use of a variable flow rate inducer bypass can provide a throttleable work-adding alternate flowpath for high-flow conditions, essentially emulating an efficient large compressor when the bypass is open and a small compressor when the bypass is closed. Using the variable bypass, the low-flow performance improves through an aerodynamically regulated inducer that is tailored to this flow regime. An engineering feasibility assessment supported by CFD, vector diagram analysis, and structural FEA suggest a substantial potential for improved performance across a wide flow range with this novel architecture.