U.S. patent application number 11/051968 was filed with the patent office on 2006-08-10 for axial flow compressor.
Invention is credited to Henry Mitchell Berry.
Application Number | 20060177302 11/051968 |
Document ID | / |
Family ID | 36780115 |
Filed Date | 2006-08-10 |
United States Patent
Application |
20060177302 |
Kind Code |
A1 |
Berry; Henry Mitchell |
August 10, 2006 |
Axial flow compressor
Abstract
An axial flow compressor is disclosed. The axial flow compressor
includes a tapered housing, having a first open end and a second
open end forming a fluid channel therebetween; a shaft, disposed
axially within the tapered housing from the first open end to the
second open end; a plurality of rotors, mounted to the shaft within
the tapered housing for compressing air within the tapered housing;
and a plurality of stators, mounted within the tapered housing;
wherein the plurality of rotors, plurality of stators and tapered
housing are not in physical contact.
Inventors: |
Berry; Henry Mitchell;
(Vereeniging, ZA) |
Correspondence
Address: |
NATIONAL IP RIGHTS CENTER, LLC;SCOTT J. FIELDS, ESQ.
550 TOWNSHIP LINE ROAD
SUITE 400
BLUE BELL
PA
19422
US
|
Family ID: |
36780115 |
Appl. No.: |
11/051968 |
Filed: |
February 4, 2005 |
Current U.S.
Class: |
415/198.1 |
Current CPC
Class: |
F05D 2250/232 20130101;
F02C 6/12 20130101; F01D 25/24 20130101; F04D 29/522 20130101 |
Class at
Publication: |
415/198.1 |
International
Class: |
F01D 1/02 20060101
F01D001/02 |
Claims
1. An axial flow compressor, comprising: a tapered housing, having
a first open end and a second open end forming a fluid channel
therebetween; a shaft, capable of rotation, disposed axially within
the tapered housing from the first open end to the second open end;
a first plurality of rotors, radially mounted to the shaft within
the tapered housing for compressing air within the tapered housing;
and a first plurality of stators, mounted within the tapered
housing; wherein the first plurality of rotors, first plurality of
stators and tapered housing are not in physical contact.
2. The axial flow compressor of claim 1, wherein the first
plurality of rotors include blades and the first plurality of
stators include vanes.
3. The axial flow compressor of claim 2, wherein the blades include
a leading edge and the vanes include a leading edge.
4. The axial flow compressor of claim 3, wherein the leading edge
of the blades are mounted opposite to the direction of the leading
edge of the vanes.
5. The axial flow compressor of claim 2, wherein the tapered
housing is formed of aluminum.
6. The axial flow compressor of claim 2, wherein the stator vanes
are formed of high-density carbon fiber.
7. The axial flow compressor of claim 2, wherein the rotor blades
are formed of high-density carbon fiber.
8. The axial flow compressor of claim 2, wherein the axle is formed
of high speed steel.
9. The axial flow compressor of claim 1, further comprising a
second plurality of rotors and a second plurality of stators.
10. The axial flow compressor of claim 9, further comprising a
third plurality of rotors and a third plurality of stators.
11. The axial flow compressor of claim 10, further comprising a
fourth plurality of rotors and a fourth plurality of stators.
12. The axial flow compressor of claim 1, wherein the first open
end of the tapered housing receives air via ram pressure
recovery.
13. The axial flow compressor of claim 12, wherein the pressure
inside the first open end of the tapered housing returns to ambient
pressure by means of the ram pressure recovery.
14. The axial flow compressor of claim 1, wherein the tapered
housing tapers to between 25% and 35% from the first open end to
the second open end.
15. The axial flow compressor of claim 14, wherein the tapered
housing tapers to 25% from the first open end to the second open
end.
16. The axial flow compressor of claim 14, wherein the tapered
housing tapers to 35% from the first open end to the second open
end.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to compressors, and in
particular to an axial flow compressor for increasing the power
output of an internal combustion engine.
BACKGROUND OF THE INVENTION
[0002] Superchargers are devices for increasing the power output of
internal combustion engines. They achieve this by increasing the
mass of air which is input to the cylinders, thereby increasing the
combustible mass of the air-fuel mixture in each cylinder or
combustion chamber above that which would be compressed by the
piston at atmospheric pressure.
[0003] U.S. Pat. No. 6,450,156 is directed towards an air
compressor for charging an internal combustion engine includes a
compressor for blowing compressed air into the intake manifold of
the engine and a gas powered turbine for driving the compressor. In
a first embodiment, the exhaust from a small gas powered turbine is
coupled to the driving turbine of a standard turbocharger. In a
second embodiment, the drive shaft of a small gas powered turbine
is coupled to the drive shaft of a standard supercharger. In a
third embodiment, a compressor turbine having an air intake, a
compressed air outlet, and a bleed air outlet is coupled to a small
gas powered turbine such that the bleed air outlet supplies the
combustor intake of the gas turbine. The gas powered turbine drives
the compressor and receives compressed air from the compressor via
the bleed outlet. The system provides a constant boost, does not
use engine horsepower, is easy to install, and does not need to be
coupled to a rotating shaft or the exhaust system of the
engine.
[0004] U.S. Patent App. No. 20020157397 is directed towards an
exhaust power recovery system for internal combustion engines. The
engine exhaust gases drive a gas turbine that in turn drives a
hydraulic turbine pump pressurizing a hydraulic fluid which then in
turn is the driving source for a hydraulic motor which transmits
power to the engine shaft. In a preferred embodiment the engine
exhaust gases drive a gas turbine with pivotable stator vanes that
in turn drives a hydraulic pump pressurizing hydraulic fluid which
than in turn is the driving source for a hydraulic motor which
transmits power to the engine shaft. The pivotable stator vanes
function as an efficient variable nozzle providing precise gas
turbine control and improved exhaust energy utilization over a wide
range of engine operating conditions. Various embodiments of the
present invention make it applicable to a wide range of engines.
For high power density engines such as 20 kW/Liter and higher, the
engine supercharging system is configured as a combination of
hydraulic supercharger in series with turbocharger, such as in the
previous invention. For low power density engines as 20 kW/Liter
and lower, the supercharging system is configured with either a
hybrid supercharger/turbocharger unit or with a standard commercial
turbocharger
[0005] U.S. Pat. No. 6,328,024 is directed towards a supercharger
employing an axial flow electric compressor or fan with its various
connections to an internal combustion engine to obtain more power
from the engine. A control system is also described to operate the
supercharger from the throttle mechanism to obtain extra power with
the use of the supercharger when the engine is otherwise performing
at its normal full power.
[0006] U.S. Pat. No. 6,751,957 is directed towards an
electronically driven pressure boosting system that is used to
boost the torque output of an internal combustion engine. The
system comprises an electrically driven supercharger, an electrical
supply system for providing electrical power to drive the pressure
charging device including a battery and an engine-driven battery
recharger, a switch to connect and disconnect the battery and
recharger and an engine control system for controlling the switch
and the operation of the pressure charging device. The engine
control system is used to determine a capacity utilization of the
electrical supply system, and then to control the switch to isolate
at least partially the battery from the engine-driven battery
recharger and drive the pressure charging device using the battery
when said capacity utilization is above a first threshold.
[0007] U.S. Pat. No. 6,718,955 is directed towards a multiple
electric motor driven centrifugal air compressor, for example, for
gasoline or diesel engine powered vehicles.
[0008] U.S. Pat. No. 6,135,098 is directed towards an electric air
charger for use with an internal combustion engine is disclosed.
The air charger includes an impeller for supplying air to the
engine. A housing surrounds the impeller and has an air inlet and
an air outlet adapted to couple the air supplied by the impeller to
the engine. The air inlet and the air outlet are substantially
axially aligned. The air charger further includes an electric motor
for controllably rotating the impeller.
[0009] U.S. Pat. No. 5,025,629 is directed towards a turbocharger
for an internal combustion engine can provide a two-stage
compressor with movable stator blades to shift the compressor
performance and match the air output of the turbocharger to varying
air requirements of an internal combustion engine. The turbocharger
can also be provided with a generally optimum boost pressure ratio
of about 4.5:1 to 4.6:1. Such a compressor comprises a first
axial-compressor stage, typically providing a 1.3:1 pressure boost
ratio, and a second radial-compressor stage, typically providing a
pressure ratio of 3.5:1. The turbine of such a turbocharger can be
a combination flow turbine and can be provided with closure means
to vary the turbine geometry and provide more efficient turbine
operation at low-engine speeds. The turbocharger includes a roller
bearing system adapted to accommodate imbalance. A control system
operating in response to engine-operating conditions can operate
the compressor-stator vanes and, if present, the turbine closure
means.
[0010] There is a need, however, for an axial flow compressor that
can easily and quickly be mounted to the engine intake of an
internal combustion engine and has multiple compression stages for
a cascade effect to increase air pressure through the stages. None
of the references mentioned above disclose such a device. The
present axial flow compressor operates on the principle of
acceleration of air followed by diffusion to convert the kinetic
energy to a pressure rise.
OBJECTS AND SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide an axial
flow compressor that spools up to maximum speed immediately to
provide exceptionally quick response.
[0012] It is a further object of the present invention to provide
an axial flow compressor that includes a tapered housing, having a
first open end and a second open end forming a fluid channel
therebetween; a shaft, disposed axially within the tapered housing
from the first open end to the second open end; a plurality of
rotors, mounted to the axle within the tapered housing for
compressing air within the tapered housing; and a plurality of
stators, mounted within the tapered housing; wherein the plurality
of rotors, plurality of stators and tapered housing are not in
physical contact.
[0013] In accordance with a first aspect of the present invention,
a novel axial flow compressor is provided. The novel axial flow
compressor is formed of lightweight materials to allow it to spool
up to maximum speed immediately to provide exceptionally quick
response.
[0014] In accordance with another aspect of the present invention,
a novel axial flow compressor is provided. The novel axial flow
compressor includes a tapered housing, having a first open end and
a second open end forming a fluid channel therebetween; an axle,
disposed axially within the tapered housing from the first open end
to the second open end; a plurality of rotors, mounted to the axle
within the tapered housing for compressing air within the tapered
housing; and a plurality of stators, mounted within the tapered
housing; wherein the plurality of rotors, plurality of stators and
tapered housing are not in physical contact.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The foregoing summary, as well as the following detailed
description of a preferred embodiment of the present invention will
be better understood when read with reference to the appended
drawings, wherein:
[0016] FIG. 1A is a perspective view, in partial cross section, of
the stator vanes in an axial flow compressor in accordance with the
present invention.
[0017] FIG. 1B is a perspective view of a stator vane in accordance
with the present invention.
[0018] FIG. 2 is a perspective view of a rotor assembly of the
axial flow compressor in accordance with the present invention.
[0019] FIG. 3 is a schematic representation of a rotor/stator
arrangement of the axial flow compressor demonstrating the cascade
effect.
[0020] FIG. 4 is a schematic representation of the axial flow
compressor in accordance with the present invention and a graphic
representation of a pressure ratio in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Referring now to the drawings, wherein like reference
numerals refer to the same components across the several views and
in particular to FIGS. 1A, 1B, 2, and 3, an axial flow compressor
10 is depicted. The axial flow compressor 10 includes a tapered
housing 11, having a first open end 12 and a second open end 13. In
operation, air flows into the first open end 12 through the tapered
housing 11 and out of the second open end 13.
[0022] The tapered housing 11 includes a plurality of rotors 20
within it, which have a plurality of blades 25. A plurality of
stators 30 are mounted within the case 11, and are paired with one
of the plurality of rotors 20. Each of the plurality of stators 30
include vanes 35. The speed of the plurality of rotors 20
determines the velocity of air present in each stage and with
increased velocity, kinetic energy is transferred to the air. The
vanes 35 of the plurality of stators 30 are placed between their
respective blades 25 of the plurality of rotors 20 and the second
open end 13 of the tapered housing 11 to receive the air at high
velocity and act as a diffuser, changing kinetic energy to
potential energy in the form of pressure. Secondarily, the
plurality of stators 30 direct air flow to the next stage of
compression at the desired angle.
[0023] The plurality of rotors 20 are mounted to a shaft 40, and
proceed outward radially from the shaft 40. The shaft 40 is
disposed within the tapered housing 11 such that the plurality of
rotors 20 are disposed within a plurality of gaps 31 between each
stage of rotors 20. In this manner, the shaft 40 can be rotated and
the plurality of rotors 20 will rotate within their respective gap
31 compressing air from stage to stage with the plurality of
stators 30 from the inlet 12 to the outlet 13.
[0024] The blades 35 are reduced in size from the first stage
beginning proximate to the first open end 12 of the tapered housing
11 to the last stage mounted proximate to the second open end 13 of
the tapered housing 11 to accommodate the taper of the tapered
housing 11 that houses them. The blades 35 include a vane shank 37
which is mounted to the interior of the tapered housing 11 and a
vane tip 38.
[0025] Referring now to FIG. 3, the high pressure zone air of the
first stage blade 25 is depicted being pumped into the low pressure
zone of its associated stator vane 35. A leading edge 36 of the
stator vane 35 faces the opposite direction of its associated rotor
blade 25 leading edge 26, thereby causing the pumping action to
occur. The high pressure zone of the 1.sup.st stage stator vane 35
then pumps into the low pressure zone of the 2.sup.nd stage rotor
blade 25 (not shown). This cascade progress continues through to
the last stage of compression. The shaft 40 rotates in the
direction of the arrow R to produce this effect, and the flow of
air F proceeds through the inlet vanes 50 to be compressed into the
axial flow compressor 10.
[0026] FIG. 4 depicts the taper of the tapered housing 11. In
general, according to Bernoulli's principle, as pressure builds up
in the rear stages of the compressor, velocity tends to drop
accordingly. In order to stabilize the velocity the shape of the
compressor fluid path converges from the first open end 12 to the
second open end 13. This taper allows the amount of space that the
compressed air can occupy. The shaft 40 traverses the tapered
housing 11 from the first open end 12 to the second open end 13 and
has mounted on it the plurality of rotors 20 to rotate the rotors
20. Each set of blades 25 accelerate the air through the tapered
housing 11 while the stator vanes 35 increase the pressure of the
air through the different stages using the principle of convergent
and divergent effect. The vanes 35, in a preferred embodiment of
the present invention are capable of variable angles.
[0027] In particular, when the air leaves the compressor blades 25,
it flows into a row of stator vanes 35. The stator vanes 35 also
form diverging ducts which decrease the velocity of the air and
increase the static pressure. The compressor blade and stator vane
action continues through all the stages of the axial flow
compressor 10.
[0028] When the air leaves the axial flow compressor 10, it will
have approximately the same velocity with which it started, but a
much greater static pressure. A particular molecule of air would
probably rotate no more than 180.degree. through the axial flow
compressor 10 due to the straightening effect. And since the last
compression stage followed by a stationery vane set, called exit
guide vanes, the airflow is turned completely back to an axial
direction on its way to the combustor of the engine.
[0029] The axial flow compressor 10 makes use of ram pressure
recovery. As the vehicle moves forward a condition known as ram
pressure recovery takes place where the pressure inside the first
open end 12 returns to ambient value. The engine thereby takes
advantage of this process with a corresponding increase in
compressor pressure ratio, thus requiring less fuel expenditure to
create more power.
[0030] As pressure builds in the rear stages of the compressor,
velocity tends to drop in accordance with Benoullis Theory. This is
not desirable because, in order to create pressure the compressor
operates on a principle of velocity change in air flow. In order to
stabilize the velocity, the shape of the compressor gas path
converges, reducing to approximately 25% to 35% of the inlet flow
area, however, any taper known to one of ordinary skill in the art
may be employed as the taper. This tapered shape provides the
proper amount of space for the compressed air to occupy.
[0031] In view of the foregoing disclosure, some advantages of the
present invention can be seen. For example, a novel axial flow
compressor is provided. The novel axial flow compressor includes
rotors and stators that are not in physical contact with one
another to limit wear and tear, and are formed of materials light
enough to allow for maximum spool up. In this manner, multiple
stages are used to provide a cascade effect to increase air
pressure through the stages, which is the only use of such an axial
flow concept on ground vehicles.
[0032] While the preferred embodiment of the present invention has
been described and illustrated, modifications may be made by one of
ordinary skill in the art without departing from the scope and
spirit of the invention as defined in the appended claims. For
example, in a preferred embodiment of the present invention, the
tapered housing is formed of aluminum, the axle is formed of steel,
and the stators and blades are formed of high-density carbon fiber.
However, any material know to one of ordinary skill in the art may
be employed to form the tapered housing, axle, stators and blades.
Additionally, in a preferred embodiment of the present invention,
there are four stages to the compressor, however, any number of
stages can be employed, known to one of ordinary skill in the
art.
* * * * *