U.S. patent application number 14/033347 was filed with the patent office on 2014-04-03 for hydraulic system with modular inserts.
The applicant listed for this patent is Energy Recovery Inc.. Invention is credited to Bart Biche, Jeff Calkins, Eric Kadaj, Prem Krish.
Application Number | 20140093407 14/033347 |
Document ID | / |
Family ID | 49274886 |
Filed Date | 2014-04-03 |
United States Patent
Application |
20140093407 |
Kind Code |
A1 |
Calkins; Jeff ; et
al. |
April 3, 2014 |
HYDRAULIC SYSTEM WITH MODULAR INSERTS
Abstract
A hydraulic turbocharger having replaceable, insertable
components, including volute inserts, vaned diffuser inserts,
nozzle inserts, diffuser inserts, nozzle liners and diffuser
liners, that define the internal passageways of a hydraulic
turbocharger. By making various components of the turbocharger
removably insertable and replaceable, turbochargers can be
manufactured in a cost-effective way to maximize efficiency, obtain
improved performance and make it easier to operate these types of
devices over a wide range of operating conditions. Moreover, the
devices can be readily modified while in the field when operating
conditions change.
Inventors: |
Calkins; Jeff; (Pleasanton,
CA) ; Biche; Bart; (Redwood City, CA) ; Kadaj;
Eric; (Canton, MI) ; Krish; Prem; (Foster
City, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Energy Recovery Inc. |
San Leandro |
CA |
US |
|
|
Family ID: |
49274886 |
Appl. No.: |
14/033347 |
Filed: |
September 20, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61703963 |
Sep 21, 2012 |
|
|
|
Current U.S.
Class: |
417/405 ; 29/428;
415/208.1; 415/214.1 |
Current CPC
Class: |
C08F 8/44 20130101; C08F
8/32 20130101; F01D 15/08 20130101; F04D 29/4293 20130101; F04D
13/043 20130101; F04D 29/426 20130101; Y10T 29/49826 20150115; C08F
8/12 20130101; F04D 29/628 20130101; F04D 29/605 20130101; F01D
25/24 20130101; F05D 2230/51 20130101; C08F 8/34 20130101 |
Class at
Publication: |
417/405 ;
415/214.1; 415/208.1; 29/428 |
International
Class: |
F01D 25/24 20060101
F01D025/24; F04D 29/60 20060101 F04D029/60 |
Claims
1. A system, comprising: a modular hydraulic turbocharger,
comprising: a housing with a pump inlet, a pump outlet, a turbine
inlet, and a turbine outlet; a first cavity within the housing,
wherein the first cavity is in fluid communication with the pump
inlet and the pump outlet; a second cavity within the housing,
wherein the second cavity is in fluid communication with the
turbine inlet and the turbine outlet; a pump impeller coupled to a
shaft, wherein the pump impeller is disposed within the first
cavity of the housing; a turbine impeller coupled to the shaft,
wherein the turbine impeller is disposed within the second cavity
of the housing, and wherein the turbine impeller is responsive to a
motive fluid to drive the pump impeller to pump a fluid through the
modular hydraulic turbocharger; and a first modular insert within
the housing, wherein the first modular insert is interchangeable
with a first plurality of modular inserts, and each of the first
plurality of modular inserts has a different effect on a fluid flow
through the hydraulic turbocharger.
2. The system of claim 1, wherein the first plurality of modular
inserts comprises one or more pump volute inserts, one or more
turbine volute inserts, one or more vane diffuser inserts, one or
more diffuser inserts, or one or more nozzle inserts.
3. The system of claim 1, comprising a second modular insert
interchangeable with a second plurality of modular inserts each
having a different effect on the fluid flow through the hydraulic
turbocharger, wherein the first modular insert is a pump volute
insert and the second modular insert is a turbine volute
insert.
4. The system of claim 1, wherein the turbine outlet is integral
with the housing.
5. The system of claim 1, wherein the first modular insert
comprises a single-piece volute insert.
6. The system of claim 1, wherein the first modular insert
comprises a multi-piece volute insert.
7. The system of claim 6, wherein the multi-piece volute insert
comprises axially split sections that form a passage configured to
receive the shaft.
8. The system of claim 6, wherein the multi-piece volute insert
comprises a first volute end cap and a second volute end cap.
9. The system of claim 8, wherein a first diameter of the first
volute end cap is greater than a second diameter of the second
volute end cap.
10. The system of claim 6, wherein the multi-piece volute insert
comprises radially split sections that are different from one
another.
11. The system of claim 1, wherein the first modular insert is a
first diffuser insert disposed within the pump outlet, or a first
nozzle insert disposed within the turbine inlet, or a combination
thereof.
12. The system of claim 11, comprising a first diffuser liner
nested within the first diffuser insert, or a first nozzle liner
nested within the first nozzle insert, or a combination
thereof.
13. The system of claim 1, wherein the first modular insert is a
vane diffuser insert disposed within the first cavity.
14. A system, comprising: a modular pump, comprising: a housing
with a pump inlet and a pump outlet; a first cavity within the
housing, wherein the first cavity is in fluid communication with
the pump inlet and the pump outlet; and a pump impeller, wherein
the pump impeller is disposed within the first cavity of the
housing to pump fluid through the modular pump; a first modular
insert within the housing, wherein the first modular insert is
interchangeable with a plurality of modular inserts, and each of
the plurality of modular inserts has a different effect on a fluid
flow through the modular pump.
15. The system of claim 14, wherein the first modular insert
comprises a vane diffuser insert or a volute insert disposed within
the first cavity.
16. The system of claim 15, wherein the first modular insert is a
one-piece structure.
17. The system of claim 15, wherein the first modular insert
comprises the vane diffuser insert having multiple radial
components that selectively couple together.
18. The system of claim 17, wherein the multiple radial components
of the vane diffuser insert are the same as one another.
19. The system of claim 17, wherein the multiple radial components
of the vane diffuser insert are different from one another.
20. A method, comprising: selectively supporting a modular insert
of a plurality of modular inserts in a housing of a hydraulic
turbocharger, wherein each modular insert of the plurality of
modular inserts has a different effect on a fluid flow through the
hydraulic turbocharger.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and benefit of U.S.
Provisional Patent Application No. 61/703,963 entitled "REPLACEABLE
HYDRAULIC PATHWAYS", filed Sep. 21, 2012, which is herein
incorporated by reference in its entirety.
BACKGROUND
[0002] The present invention relates generally to a hydraulic
system.
[0003] The pump industry now has available computational fluid
dynamic based machine design software that allows pumps to be
designed to achieve various performance parameters. The resultant
designs require a high degree of dimensional precision to obtain
the desired performance characteristics. The challenge is to
convert the complex computer design into actual components.
[0004] To produce the desired geometry for internal casing
components, investment castings are often used. Investment castings
use metal molds that produce a wax pattern that in turn is used to
make a ceramic mold. The wax pattern is then heated so that the wax
melts and is removed which leaves the ceramic mold. The ceramic
mold is then used to produce the metal parts for the pump. The
ceramic mold produces high quality castings having a good surface
finish and dimensional accuracy. However, investment casting
tooling is expensive and is best suited to small size, mass
produced parts. For custom designed pumps, the parameters of the
pump need to match the performance characteristics that are
desired. Flexibility in the design is important to achieving the
performance objectives and this does not fit well with the use of
mass produced parts. Accordingly, custom designed pumps are not a
good fit with investment casting technology.
[0005] The internal casing components, such as the volute and
diffuser, can be machined from solid metal stock. Such machining
can produce precise dimension control and a good surface finish.
However, the cross section of the volute is limited to parallel
wall design configurations as the machining tools must be inserted
and removed from the interior of the casing. There is little
flexibility in the shape that can be machined under such
restrictions. These restrictions on the shape of the internal
chamber of the volute significantly limit the performance and
efficiency characteristics of a pump produced with this
technology.
[0006] Sand castings can also be used to produce pump casings.
However, sand casting does not work well for the internal casings
of small pumps or turbines, as the surface finish produced is not
smooth enough for good efficiency. Without the necessary level of
efficiency such small pumps and turbines have a difficult time
being a competitive product. In addition, the cores that are used
to create the internal voids such as the volute can shift during
the molding or pouring process. This results in the void area being
both axially and radially displaced from the desired position. Such
shifting results in uneven flow entrances and a loss of efficiency
for the pump. In addition, the surface finish of such a cast pump
casing is not as smooth as desired to obtain the best flow
characteristics and efficiency. Some of the above deficiencies can
be reduced by grinding or sanding operations on the cast casing
provided that the required tools can fit into the areas that need
further processing.
[0007] The present invention overcomes the deficiencies of the
prior art and allows the construction of pumps that maximize the
efficiency and performance for the pump and allows for the cost
effective production of unique one off design and construction of
volute flow passages.
BRIEF DESCRIPTION
[0008] The present invention relates to improvements to the
invention described in U.S. Patent Application Publication
2006/0013707 describing the use of removable components in the
construction of hydraulic pumps, turbines and turbochargers to
enable such devices to operate effectively over a range of
operating conditions and to enable such devices to be modified in
the field when operating conditions change.
[0009] The present invention includes improvements in the design of
removable components in the construction of hydraulic pumps,
turbines and turbochargers and more specifically relate to
removably insertable components that define the internal hydraulic
passageways of a turbocharger including volute inserts, vaned
diffuser inserts, nozzle inserts, diffuser inserts, nozzle liners
and diffuser liners.
[0010] Detailed descriptions of these improvements are set forth
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0012] FIG. 1 is a cross-sectional view of a hydraulic turbocharger
comprising a pump section and a turbine section, in accordance with
an embodiment;
[0013] FIG. 2 is a perspective view of the hydraulic turbocharger
of FIG. 1, in accordance with an embodiment;
[0014] FIG. 3 is a perspective view of an axially-split volute
insert, in accordance with an embodiment;
[0015] FIG. 4 is a cross-sectional view of a radially-split volute
insert comprising two facing pieces that each have a differently
shaped volute, in accordance with an embodiment;
[0016] FIG. 5 is a radially-split volute insert comprising three
separate pieces, in accordance with an embodiment;
[0017] FIG. 6 is the radially-split volute insert of FIG. 5 shown
with the pieces fastened together, in accordance with an
embodiment;
[0018] FIG. 7 is a cross-sectional front elevation view of a
one-piece volute insert, in accordance with an embodiment;
[0019] FIG. 8 is a cross-sectional side view of a one-piece volute
insert, in accordance with an embodiment;
[0020] FIG. 9 is a cross-sectional side view of a pump vaned
diffuser insert, in accordance with an embodiment;
[0021] FIG. 10 is a front elevation view of the pump vaned diffuser
insert of FIG. 9, in accordance with an embodiment;
[0022] FIG. 11 is a perspective view of the vanes of the pump vaned
diffuser insert of FIG. 9, in accordance with an embodiment;
[0023] FIG. 12 is a cross-sectional view of a hydraulic
turbocharger with an opening in the outlet section that receives a
diffuser insert, in accordance with an embodiment;
[0024] FIG. 13 is a cross-sectional view of a diffuser insert, in
accordance with an embodiment;
[0025] FIG. 14 is a side view of the diffuser insert of FIG. 13, in
accordance with an embodiment;
[0026] FIG. 15 is a cross-sectional view of a hydraulic
turbocharger comprising an installed diffuser inserted in the
outlet section, in accordance with an embodiment;
[0027] FIG. 16 is a cross-sectional view of a hydraulic
turbocharger with an opening in the inlet section that receives a
nozzle insert, in accordance with an embodiment;
[0028] FIG. 17 is a cross-sectional view of a hydraulic
turbocharger with an installed nozzle insert, in accordance with an
embodiment;
[0029] FIG. 18 is a cross-sectional view of a nozzle insert, in
accordance with an embodiment;
[0030] FIG. 19 is a side view of the nozzle insert of FIG. 18, in
accordance with an embodiment;
[0031] FIG. 20 is a hydraulic turbocharger with an installed nozzle
insert liner, in accordance with an embodiment;
[0032] FIG. 21 is a hydraulic turbocharger with an installed
diffuser insert liner, in accordance with an embodiment;
[0033] FIG. 22 is a perspective view of a two-piece hydraulic
turbocharger comprising an outer housing that encloses the pump
section and the turbine section and only one end cap, in accordance
with an embodiment; and
[0034] FIG. 23 is a cross-sectional view of the two-piece hydraulic
turbocharger of FIG. 22, in accordance with an embodiment.
DETAILED DESCRIPTION
[0035] One or more specific embodiments of the present invention
will be described below. In an effort to provide a concise
description of these embodiments, all features of an actual
implementation may not be described in the specification. It should
be appreciated that in the development of any such actual
implementation, as in any engineering or design project, numerous
implementation-specific decisions must be made to achieve the
developers' specific goals, such as compliance with system-related
and business-related constraints, which may vary from one
implementation to another. Moreover, it should be appreciated that
such a development effort might be complex and time consuming, but
would nevertheless be a routine undertaking of design, fabrication,
and manufacture for those of ordinary skill having the benefit of
this disclosure.
[0036] When introducing elements of various embodiments of the
present invention, the articles "a," "an," "the," and "said" are
intended to mean that there are one or more of the elements. The
terms "comprising," "including," and "having" are intended to be
inclusive and mean that there may be additional elements other than
the listed elements.
[0037] The present invention involves improvements to the invention
disclosed in U.S. Patent Application Publication 2006/0013707 the
content of which is hereby incorporated by reference into this
patent application
[0038] The present invention relates to improvements in the design
of pumps (e.g. modular pumps), turbines (modular turbines), and
modular hydraulic turbochargers and more particularly relates to
improvements in the design of removable, insertable components
(i.e., inserts, modular inserts) in such devices that enable them
to operate more efficiently and under a wide range of operating
conditions. These removably insertable i.e., interchangeable)
components (i.e., inserts, modular inserts) include pump volute
inserts, turbine volute inserts, vane diffuser inserts, diffuser
inserts, nozzle inserts, diffuser liners, and nozzle liners.
Moreover, each of these components (i.e., inserts, modular inserts)
may be one of a plurality of modular inserts that has a different
effect on a fluid flow through a pump (e.g., modular pump), a
turbine (modular turbine), or modular hydraulic turbocharger.
Indeed, each component (i.e., inserts, modular inserts) may be one
of many components (i.e., inserts, modular inserts) in a family
that are interchangeable used to affect a fluid flow.
[0039] The present invention will be understood by those skilled in
the art upon review of the following descriptions and the
accompanying drawings.
[0040] To facilitate the description of the present invention, it
will be described in connection with a hydraulic turbocharger
utilized for energy recovery that comprises a pump section and a
turbine section. However, it should be understood that the present
invention is suitable for use with almost any type of pump, turbine
or hydraulic turbocharger application. Operating features of such
devices are known in the art and will not be described in detail
herein.
[0041] As shown in FIGS. 1 and 2, a hydraulic turbocharger 1 has an
outer housing 2, a first section 3, a turbine end section 4 and a
pump end section 5 wherein the turbine end section and pump end
section are removably secured to the first section of the outer
housing. A securing device such as bolts 6 can be utilized to
removably secure the turbine end and pump end sections to the first
section of the outer housing 2. The first section 3, the turbine
end section 4 and the pump end section 5 of the outer housing 2
define a passageway 7 that extends through the outer housing.
[0042] The outer housing 2, comprising the first section 3, turbine
end section 4 and pump end section 5 is costly to make and requires
significant lead time to design and manufacture. However, the
performance requirement for each hydraulic turbocharger can vary
depending on the parameters of use that are present in a particular
application. This variability in performance characteristic can
produce an almost infinite number of performance curves for the
hydraulic turbocharger. It is not economically feasible to produce
unique components for the outer housing 2 to maximize the
efficiency for the hydraulic turbocharger.
[0043] The present invention allows a standard outer housing to be
designed and produced for a range of potential applications. The
turbine impeller 8, pump impeller 9, pump volute insert 10 and
turbine volute insert 11 can be individually designed to produce
the maximum efficiency for the operational parameters of the
hydraulic turbocharger. In most applications the turbine volute
insert 11 and pump volute insert 10 are designed to cooperate with
the turbine impeller and the pump impeller, respectively, to obtain
the desired performance characteristics for the hydraulic
turbocharger.
[0044] The pump volute and turbine volute inserts can be designed
and manufactured to achieve the desired performance
characteristics. Since the pump and turbine volute inserts are
positioned in the first cavity 12 and second cavity 13
respectively, the pump and turbine volute inserts can be custom
designed to optimize the performance of the hydraulic turbocharger
without requiring a custom design for the entire hydraulic
turbocharger. Additionally, the pump and turbine volute inserts of
the present invention are removable so they can be removed and
modified, or alternatively replaced with new pump and turbine
volute inserts that have new shapes and surface finishes to provide
improved performance characteristics.
[0045] In several preferred embodiments of the present invention,
shown in FIGS. 3-6, the pump volute insert and turbine volute
insert each comprise a plurality of pieces fastened together to
form individual volute inserts that can be removably positioned in
the first cavity 12 or second cavity 13 of the turbocharger. There
are several preferred ways to design volute inserts wherein they
each comprise a plurality of pieces.
[0046] In one preferred embodiment of the present invention, shown
in FIG. 3, a volute insert for a hydraulic turbocharger is axially
split and comprised two facing pieces 20 and 21; and a first volute
end cap 60 and a second volute end cap 61 that are fastened
together to form a pump volute at one end and a turbine volute at
the opposite end. The benefit of the axially-split volute insert
design is a greater flexibility in outer casing design as well as
rotor design. Fastening means (not shown), such as screws or other
devices, can be used to securely fasten and align the axially split
pieces of each of the volute inserts with respect to each other to
ensure the volute inserts provide the desired fluid flow
characteristics through the hydraulic turbocharger.
[0047] In one preferred embodiment of the present invention, shown
in FIG. 4, the pump volute insert and turbine volute insert are
each radially split and each comprises two pieces 22, 23 that are
fastened together to form a pump volute insert or a turbine volute
insert that can be removably positioned in the first cavity 12 and
second cavity 13 of the hydraulic turbocharger, respectively. The
two pieces 22, 23 are non-mirror facing pieces with each piece
having a different volute passageway 24, 25. Fastening means (not
shown), such as screws or other devices, can be used to securely
fasten and align the radially-split pieces of each of the volute
inserts with respect to each other to ensure the volute inserts
provide the desired fluid flow characteristics through the
hydraulic turbocharger.
[0048] In one preferred embodiment of the present invention, shown
in FIGS. 5 and 6, the pump volute insert and turbine volute insert
are each radially split and each comprises three pieces 26-28 that
are fastened together, as shown in FIG. 6, to form a pump or
turbine volute insert 29 that can be removably positioned in the
first cavity 12 and second cavity 13 of the hydraulic turbocharger,
respectively. Additionally, the radially-split pump volute insert
and turbine volute insert may comprise more than three pieces
fastened together. Fastening means (not shown), such as screws or
other devices, can be used to securely fasten and align the
radially-split pieces of each of the volute inserts with respect to
each other to ensure the volute inserts provide the desired fluid
flow characteristics through the hydraulic turbocharger.
[0049] In another preferred embodiment of the present invention, an
additional feature is utilized to position and maintain the
removable volute inserts in the correct position in the hydraulic
turbocharger. 0-rings 17 are utilized between the outer wall of the
pump volute insert 10 and the pump end section 5 and between the
outer wall of the turbine volute insert 11 and the turbine end
section 4. The 0-rings 17 serve to provide a take up of tolerance
and impart a force to help ensure the pump volute insert and the
turbine volute insert are properly positioned and in the optimum
configuration when the securing bolts 6 are utilized to removably
secure the pump end section 5 and turbine end section 4 to the
first section 3 of the outer housing 2. The 0-rings 17 help to
ensure the desired fluid flow characteristics are achieved to
optimize the performance of the hydraulic turbocharger.
[0050] In a preferred embodiment of the present invention, as shown
in FIGS. 7 and 8, a pump or turbine volute insert is formed of a
single piece of material (i.e., a single-piece volute, one-piece
volute) and wherein the one-piece pump or turbine volute insert 30
is removably positioned (see FIG. 1) in the first cavity 12 to form
a pump volute and in the second cavity 13 to form a turbine volute.
The pump volute insert and turbine volute insert can be machined to
the desired geometry and surface finish prior to being installed in
the first cavity 12 and the second cavity 13, respectively. The
volute inserts may be fabricated out of any materials familiar to
those skilled in the art that provide the desired efficiency and
flow characteristics. Forming the pump and turbine volute inserts
out of single pieces of material allows for fewer components to be
used in the pump construction. Moreover, forming the pump and
turbine volute inserts out of single pieces of material eliminates
the need to align two mirror pieces, like the volute inserts
described in detail in the above-mentioned mentioned '707 patent
application.
[0051] The one-piece removable pump insert volute 30 (shown in
FIGS. 7 and 8) is held in place in the cavity (see FIG. 1) between
the first section 3 and the pump end section 5 of the outer housing
2. The pump volute insert 30 is in fluid communication with the
pump impeller 9 and the inlet 15 (i.e., pump inlet) formed by the
passageway 7. A pump outlet 18 is positioned in the first section 3
of the outer housing 2 and the pump outlet 18 is also in fluid
communication with the first cavity 12 defined by the pump volute
insert 10.
[0052] The one-piece removable turbine insert volute 30 (shown in
FIGS. 7 and 8) is held in place in the cavity between the first
section 3 and the turbine end section 4 of the outer housing 2. The
turbine volute insert 16 is in fluid communication with the turbine
impeller 8 and with the discharge 14 (i.e., turbine outlet) formed
by the passageway 7. The turbine volute insert 11 is also in fluid
communication with the turbine inlet 19 formed in the first section
3 of the outer housing 2.
[0053] The size and shape of the turbine and pump volute inserts is
complex and varies to achieve the desired performance
characteristics for the hydraulic turbocharger. The one-piece pump
volute insert and one-piece turbine volute insert can be machined
or otherwise formed to have characteristics that provide the
desired fluid flow, optimize efficiency and maximize performance of
the turbocharger. The one-piece volute inserts can be removed and
then modified or replaced with new one-piece volute inserts in
order to change the performance characteristics of the hydraulic
turbocharger.
[0054] As shown in FIGS. 9-11, in another preferred embodiment of
the present invention, removable vaned diffuser inserts 31 for the
pump side of the turbocharger are utilized as an alternative to the
use of pump volute inserts described hereinabove. As shown in FIG.
11, the vaned diffuser inserts 31 have a series of vanes 32 that
serve to direct fluid flow between the components along the
internal passageways of the hydraulic turbocharger.
[0055] A pump side diffuser insert may be utilized to direct fluid
flow between the pump impeller 9 and the pump outlet 18.
[0056] The pump vaned diffuser insert is machined or otherwise
formed to have a shape and surface finish to direct the fluid flow
in a way that optimizes the performance of the hydraulic
turbocharger. The removable vaned diffuser inserts can be removed
and then modified or replaced with new vaned diffuser inserts to
change the performance characteristics of the hydraulic
turbocharger.
[0057] In a preferred embodiment of the invention a pump diffuser
insert comprising vanes is formed of a single piece of material
(i.e., one-piece structure, single-piece), as shown in FIG. 10, and
wherein the one-piece pump diffuser insert is removably positioned
(not shown) in the first cavity 12 to form the hydraulic passageway
between the pump impeller and the pump outlet. The pump vaned
diffuser insert can be machined to the desired geometry and surface
finish prior to being installed in the first cavity 12. The vaned
diffuser insert may be fabricated out of any materials familiar to
those skilled in the art that provide the optimum efficiency and
flow characteristics. Forming the pump diffuser insert out of
single pieces of material allows for fewer components to be used in
the pump construction and eliminates the need to align multiple
pieces.
[0058] In another embodiment of the present invention, as shown in
FIG. 11, the pump vaned diffuser insert, instead of being formed of
single pieces of material, comprise two pieces that are radially
split and fastened together to form a pump vaned diffuser insert
that can be removably positioned in the first cavity 12 of the
hydraulic turbocharger. The two-piece pump vaned diffuser insert
can be radially split into two facing mirrored pieces (i.e., same
as one another) or, alternatively, can be radially split to form
into two non-mirror facing pieces (i.e., different from one
another). In another embodiment of the present invention, the
radially-split pump vaned diffuser insert comprises more than two
pieces. Fastening means such as screws or other devices can be used
to securely align the diffuser insert pieces with respect to each
other to form diffuser inserts that provide the desired fluid flow
characteristics through the hydraulic turbocharger.
[0059] In another embodiment of the present invention (not shown),
the vaned diffuser inselts, instead of being formed of single
pieces of material, are formed from a plurality of pieces fastened
together. In one embodiment of the present invention (not shown),
the pump diffuser insert comprises two pieces that are axially
split and fastened together to form a diffuser insert that can be
removably positioned in the first cavity 12 of the hydraulic
turbocharger. Fastening means such as screws or other devices can
be used to securely align the diffuser insert pieces with respect
to each other to form diffuser inserts that provide the desired
fluid flow characteristics through the hydraulic turbocharger.
[0060] As shown in FIG. 12, in a preferred embodiment of the
present invention the outlet section 18 of the pump is designed to
be capable of receiving removable diffuser inserts and comprises
straight sidewalls 33.
[0061] As shown in FIGS. 13 and 14, a removable diffuser insert 35
comprises a straight outer wall 36 that substantially aligns with
the inner wall 33 of the outlet section 18 of the pump (shown in
FIG. 12) when the diffuser insert is removably inserted into the
outlet section of the pump. As shown in FIG. 15, when the removable
diffuser insert is installed the tapered inside wall 37 of the
diffuser insert reduces the velocity of the fluid moving through it
as it moves from the pump volute towards the outlet section 18 of
the pump.
[0062] In a preferred embodiment, a means is provided to hold the
diffuser insert 35 in place inside the turbocharger and ensure the
diffuser insert remains in alignment with the volute insert to
direct fluid flow from the volute insert to the pump discharge
outlet. One preferred retention means comprises a groove 38 around
the outer diameter of the diffuser insert 35 that receives a
retaining ring 39 (shown in FIG. 15) to keep the diffuser insert 35
in position relative to the outlet section 18 of the pump after it
is installed.
[0063] As shown in FIG. 16, in a preferred embodiment of the
present invention, a hydraulic turbocharger has a turbine side that
includes an inlet section 40. FIG. 17 shows the nozzle insert 41
after it is installed in the inlet section 40 on the turbine side
of the turbocharger. The nozzle insert serves to direct fluid flow
between the inlet section 40 of the turbine and the turbine
volute.
[0064] In a preferred embodiment, a means is provided to hold the
removable nozzle insert 41 in place inside the turbocharger and
ensure the nozzle insert remains in proper alignment to direct
fluid flow from the turbine inlet 40 to the turbine volute. As
shown in FIGS. 18 and 19, in one preferred the retention means
comprises a groove 42 around the outer diameter of the nozzle
insert 41 that receives an 0-ring to keep the nozzle insert 41 in
position relative to the inlet section 40 on the turbine side of
the turbocharger.
[0065] To allow for greater flexibility in the design of nozzle
inserts the nozzle centerline can be off-center of the outside
diameter of the nozzle insert as shown in FIG. 18.
[0066] In another preferred embodiment of the present invention, as
shown in FIG. 20, nozzle insert liners 43 can be inserted into
previously installed nozzle inserts in a hydraulic turbocharger in
a nesting configuration to modify the fluid flow through the
internal passageways of the hydraulic turbocharger.
[0067] In practical application, when using a nozzle insert liner,
previously installed nozzle inserts are left in place and a new
nozzle insert liner fabricated to have an outside shape that aligns
substantially with the already installed nozzle insert and an
inside shape and surface finish that provides the desired fluid
flow and performance characteristics through the pump inlet is
inserted. Additional nozzle insert liners with different
characteristics can be installed into previously inserted nozzle
insert liners in a nesting configuration.
[0068] In another preferred embodiment of the present invention, as
shown in FIG. 21, diffuser insert liners 44 can be inserted into
previously installed diffuser inserts in a hydraulic turbocharger
in a nesting configuration to modify the fluid flow through the
internal passageways of the hydraulic turbocharger.
[0069] In practical application, when using a diffuser insert
liner, previously installed diffuser inserts are left in place and
a new diffuser insert liner fabricated to have an outside shape
that aligns substantially with the already installed nozzle insert
and an inside shape and surface finish that provides the desired
fluid flow and performance characteristics through the pump inlet
is inserted. Additional diffuser insert liners with different
characteristics can be installed into previously inserted diffuser
insert liners in a nesting configuration.
[0070] The use of an axially-split volute insert design provides
particular advantages in the construction of hydraulic
turbochargers having different designs than the design shown in
FIG. 1.
[0071] In a preferred embodiment of the present invention, as shown
in FIGS. 22 and 23, a hydraulic turbocharger 45 comprises an outer
housing 46 and only one end cap 47 removably secured to the outer
housing with the turbine discharge (i.e., turbine outlet) being
integral to the housing 46. A securing device such as bolts (not
shown) can be utilized to removably secure the end cap to the outer
housing. The outer housing 46 of the turbocharger comprises a pump
section that includes a pump inlet 48, a pump discharge 49, a pump
impeller 50 and a pump volute forming a first cavity 51 and a
turbine section that includes a turbine inlet 52, a turbine
discharge 53, a turbine impeller 54 and a turbine volute forming a
second cavity 55. A shaft 56 is connected between the pump impeller
50 and the turbine impeller 54.
[0072] Removably positioned inside the outer housing of the
turbocharger is a removable pump and turbine volute insert that can
be machined to the desired geometry and surface finish prior to
being installed. The axially-split facing pieces of the pump volute
insert and turbine volute insert are fastened together to define
volutes that direct fluid flow through the internal passageways of
the turbocharger. The volutes are stationary pump and turbine flow
passages whose changing shape and flow area convert fluid velocity
into pressure on the pump side and fluid pressure to velocity on
the turbine side.
[0073] In operation, fluid at high pressure enters the turbine
inlet and is directed to the turbine volute formed by the turbine
volute insert. The fluid is directed from the turbine volute to the
impeller, which is caused to rotate by impulse and reaction effects
of the fluid on the vanes of the turbine impeller. The rotating
turbine impellers power output is transmitted through the rotatable
shaft to the pump impeller. The turbine impeller decreases the
pressure on the fluid that enters the turbine side of the hydraulic
turbocharger and the fluid is discharged through discharge opening
on the passageway.
[0074] In operation, fluid at low pressure enters the inlet of the
passageway and enters the pump impeller. The rotating impeller
vanes cause the fluid to accelerate towards the periphery of the
impeller. The high velocity fluid exits the impeller to enter the
volute, where the increasing flow area of the volute collects the
impeller flow. The fluid leaves the volute and then enters the pump
discharge where increasing area produces a reduction in fluid
velocity and increase in fluid pressure.
[0075] In practice it has been found that it can be difficult to
remove the various components, like the ones described in this
specification, that are designed to be removed, modified or
replaced with different components, from the interior cavities and
other sections of hydraulic turbochargers. For example, due to
close tolerances it may be difficult to get tools into the interior
cavities to remove replaceable volute inserts and vaned diffusers.
The nozzle inserts and diffuser inserts may also be difficult to
remove from a pump or hydraulic turbocharger.
[0076] In a preferred embodiment of the present invention (not
shown), additional features are utilized to make it easier for
operators to remove the various removable components from the
interior sections of a pump or hydraulic turbocharger of the type
described in the present invention.
[0077] Means are provided for each of the removable components,
either integrated into the design of the components themselves or
separately attached to the components, to make it easier for
operators to remove each of the removable, insertable components
from the pump or hydraulic turbocharger.
[0078] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
* * * * *