Design and prototyping of micro centrifugal compressor for ultra micro gas turbine

In order to establish the design methodology of an ultra micro centrifugal compressor, which is the most important component of an ultra micro gas turbine unit, a 10 times size of the final target compressor (impeller outer diameter 40 mm, corrected rotational speed 220,000 r/min) was designed. The problems to be solved for downsizing were examined and a 2-dimensional impeller was chosen as the first model due to its productivity. The conventional ID prediction method and CFD were used. The prototyped compressor was tested by using cold air at the reduced speed of 110,000 r/min. Following to the 10 times model, a 5 times size of the final target model having fully 3-dimensional shape (impeller outer diameter 20mm, corrected rotational speed 500,000 r/min) was designed and tested by using hot gas at the reduced speed of 250,000 r/min.     

Investigation of surge behavior in a micro centrifugal compressor

This paper reports the experimental and theoretical study of the surge occurred in prototyping an ultra micro centrifugal compressor. As the first step, the 10 times size model of an ultra micro centrifugal compressor having the 40 mm outer diameter was designed and manufactured. The detailed experimental investigations for the transient behavior of surge with several different values of B parameter were carried out. The experimental results during the surge were compared with those obtained by the non-linear lumped parameter theory in order to validate the effectiveness of the theoretical surge model for the micro centrifugal compressor. As a result, the quite different behavior of the surge appeared for the different values of B both in the experiment and in the analysis.     

Computational and experimental study of an industrial centrifugal compressor volute

IntrotctionThe overall performance of a centrifugal compressoris a combination of the dueller, diffuser, and voluteperformances. Each component has to be designedcarefully in order tO' minimize the losses and maximizethe efficiency. In this paper, a centrifugal compressorvolute (or spiral) is stUdied numerically, and the CFDresults are compared with measured data.A volute is used to collect the flow from a vaned orvaneless diffuser and to gUide it Ollt of the compressor.The volute geometry…     

Hyperbolically Shaped Centrifugal Compressor

Starting from the classical centrifugal compressor, cone shaped in meridional cross section, two modifications are considered on the basis of results from 2D and 3D flow models. The first modification is the change of the meridional cross section to hyperbolically shaped channel. The second modification, proposed on the basis of 2D axisymmetric solution, concerns the shape of blading. On the strength of this solution the blades are formed as 3D shaped blades, coinciding with the recent tendency in 3D designs. Two aims were considered for the change of meridional compressor shape. The first was to remove the separation zone which appears as the flow turns from axial to radial direction. The second aim is to uniformize the flow at exit of impeller. These two goals were considered within the frame of 2D axisymmetric model. Replacing the cone shaped compressor by a hyperbolically shaped one, the separation at the corner was removed. The disc and shroud shape of the compressor was chosen in the way which sat     

Investigation on centrifugal impeller in an axial-radial combined compressor with inlet distortion

Assembling an axial rotor and a stator at centrifugal compressor upstream to build an axial-radial combined compressor could achieve high pressure ratio and efficiency by appropriate size augment.Then upstream potential flow and wake effect appear at centrifugal impeller inlet.In this paper,the axial-radial compressor is unsteadily simulated by three-dimensional Reynolds averaged Navier-Stokes equations with uniform and circumferential distorted total pressure inlet condition to investigate upstream effect on radial rotor.The results show that spanwise nonuniform total pressure distribution is generated and radial and circumferential combined distortion is formed at centrifugal rotor inlet.The upstream stator wake deflects to rotor rotation direction and decreases with blade span increases.Circumferential distortion causes different separated flow formations at different pitch positions.The tip leakage vortex is suppressed in centrifugal blade passages.Under distorted inlet condition,flow direction of centrifugal impeller leading edge upstream varies evidently near hub and shroud but varies slightly at mid-span.In addition,compressor stage inlet distortion produces remarkable effect on blade loading of centrifugal blade both along chordwise and pitchwise.     

Experimental Analysis of the Rotor Stator Interaction Within a High Pressure Centrifugal Compressor

IntroductionThe t1ow field in a multi-row compressor is three-dimensional, turbu1ent, viscous and inherently unsteady.That makes it truly a challenging flow to understand,measure and compute. Attempts are made to increase theunderstanding of the flow in a multi-row environment,notabIy regarding the flow field unsteadiness due to therotor-stator interactions. Several works have beenpublished conceming the mu1ti-stage unsteadycomputational techniques which involve vallous kinds ofhypothesis. Th…     

Performance analysis of a centrifugal compressor with variable inlet guide vanes

The flow in a centrifugal compressor stage with variable inlet guide vanes (VIGVs) is investigated by numerical simulation in this paper. Analysis of the performance curves and relative velocity vectograms indicates that performance curves shift toward small flow domain when VIGVs turn positively, and toward large flow domain when VIGVs turn negatively. Stage efficiency drops quickly after work condition enters a small flow domain through the peak efficiency point. Under the circumstance of large setting angles of the guide vanes, there exist obvious flow separations in guide vane passages within wide flow ranges, and back flow regions can be located at the front of splitter suction surfaces under large flow conditions, while under the condition of small flow, flow separations occur on suction surfaces of long blades. __________ Translated from Journal of Power Engineering, 2006, 26(6): 804–807 [译自: 动力工程]     

Unsteady Pressure Field in a Vaneless Diffuser of a Centrifugal Compressor: An Experimental and Computational Analysis

Unsteady static pressure was measured and time-accurate numerical simulations were conducted in order to analyze unsteady behaviour of the centrifugal compressor diffuser. The unsteady static pressure was measured at the diffuser inlet and outlet at three different circumferential positions. Operation points near the surge, the design operation point and operation point near the choke were used in measurements. The time-accurate simulations were conducted at the design operation point and operation point near the choke. The whole compressor was modelled and the low Reynolds number k-εturbulence model was utilized in numerical simulations. The gathered numerical and experimental unsteady pressures were compared with each other.     

Unsteady behavior and control of vortices in centrifugal compressor

Two examples of the use of vortex control to reduce noise and enhance the stable operating range of a centrifugal compressor are presented in this paper.In the case of high-flow operation of a centrifugal compressor with a vaned diffuser,a discrete frequency noise induced by interaction between the impeller-discharge flow and the diffuser vane,which appears most notably in the power spectra of the radiated noise,can be reduced using a tapered diffuser vane（TDV） without affecting the performance of the compressor.Twin longitudinal vortices produced by leakage flow passing through the tapered portion of the diffuser vane induce secondary flow in the direction of the blade surface and prevent flow separation from the leading edge of the diffuser.The use of a TDV can effectively reduce both the discrete frequency noise generated by the interaction between the impeller-discharge flow and the diffuser surface and the broadband turbulent noise component.In the case of low-flow operation,a leading-edge vortex（LEV） that forms on the shroud side of the suction surface near the leading edge of the diffuser increases significantly in size and blocks flow in the diffuser passage.The formation of an LEV may adversely affect the performance of the compressor and may cause the diffuser to stall.Using a one-side tapered diffuser vane to suppress the evolution of an LEV,the stable operating range of the compressor can be increased by more than 12 percent,and the pressure-rise characteristics of the compressor can be improved.The results of a supplementary examination of the structure and unsteady behavior of LEVs,conducted by means of detailed numerical simulations,are also presented.     

The change of the inlet geometry of a centrifugal compressor stage and its influence on the compressor performance

The impact on the compressor performance is important for designing the inlet pipe of the centrifugal compressor of a vehicle turbocharger with different inlet pipes. First, an experiment was performed to determine the compressor performance from three cases: a straight inlet pipe, a long bent inlet pipe and a short bent inlet pipe. Next, dynamic sensors were installed in key positions to collect the sign of the unsteady pressure of the centrifugal compressor. Combined with the results of numerical simulations, the total pressure distortion in the pipes, the pressure distributions on the blades and the pressure variability in the diffuser are studied in detail. The results can be summarized as follows: a bent pipe results in an inlet distortion to the compressor, which leads to performance degradation, and the effect is more apparent as the mass flow rate increases. The distortion induced by the bent inlet is not only influenced by the distance between the outlet of the bent section and the leading edge of the impeller but also by the impeller rotation. The flow fields in the centrifugal impeller and the diffuser are influenced by a coupling effect produced by the upstream inlet distortion and the downstream blocking effect from the volute tongue. If the inlet geometry is changed, the distributions and the fluctuation intensities of the static pressure on the main blade surface of the centrifugal impeller and in the diffuser are changed accordingly.     

Development of compressor for ultra micro gas turbine

The major problems for the development of an ultra micro gas turbine system were discussed briefly from thestand point of the internal flow and the performance characteristics.Following to these,the development of ultramicro centrifugal compression systems for the ultra micro gas turbine is explained with the design and the manu-facturing processes.The measured results of ultra micro centrifugal compressors are shown.     

Effects of measuring positions on the measured aerodynamic performance of a centrifugal compressor

This paper performs a numerical simulation of three-dimensional flow field in a centrifugal compressor with long inlet and outlet pipes using CFX software. By arranging virtual probes at different positions in both inlet and outlet planes, the aerodynamic performance of the centrifugal compressor is measured and compared with each other. Then effects of measuring positions on measurement results are discussed. The results show that it will generate notable measuring errors of the pressure ratio and efficiency if the inlet total pressure is measured using a single-point probe. The inlet total pressure data can be accurate when they are measured using a 3-point rake. The outlet total pressure and total temperature data can not be accurate if they are respectively measured at one circumferential position even using a multi-point rake. Increasing tangential measuring positions at the outlet is effective to improve the test accuracy. When the outlet total pressure and total temperature are respectively measured at 3 tangential positions, the data can be almost accurate.     

离心压缩机无叶扩压器的改进新方法

研究了某高压比离心压缩机无叶扩压器的性能,提出在无叶扩压器轮盘侧加装一定高度机翼型导叶的改进方法。结果表明,这种扩压器可以改善其内部流动,提高自身的压力恢复系数和效率,从而改善离心压缩机的整级性能。     

Effects of Diffuser Vane Geometry on Interaction Noise Generated from a Centrifugal Compressor

The characteristics of interaction tone noise radiated from a centrifugal compressor with a vaned diffuser are discussed by experiments, including visualization techniques using the oil-film method. Research attention is paid to the leading edge geometries of the diffuser vanes that are deeply related to the generation mechanism of the interaction tone noise. The compressor-radiated noise can be reduced by several decibels by setting some clearances in both the hub and shroud surfaces of the diffuser wall along with some decline in the pressure-rise coefficient. Since the decline turned out to be caused by the flow impingement and also by the secondary flow within the diffuser passages, several new types of diffuser vane geometries which do not detract from both the performance and noise level are developed and utilized for the experiments. The presented diffuser vane geometries will offer a few basic guidelines for the diffuser vane design.     

Optimal r/b ratio of bend channel in centrifugal compressor

A numerical investigation on the flow in a bend channel by coupling the impellerwith the vaneless diffuser in a centrifugal compressor with different r/b ratios (bend radius r to bend channel width b) is presented. The jet-wake effect of the impeller outlet is considered and flow pattern in the bend channel and the performance of the centrifugal compressor stage are investigated. The results indicate that there is an optimal r/b ratio for increasing the stage efficiency to the highest for a specific compressor stage. The change in r/b ratio significantly affects the flow angle of the bend channel outlet. The prime reason for the total pressure loss in the bend channel is the wall friction in the bend channel. __________ Translated from Journal of Engineering Thermophysics, 2008, 29(2): 233–236 [译自: 工程热物理学报]     

Use of partially shrouded impeller in a small centrifugal compressor

Numerical analysis is conducted for the 3-dimensional impeller and vaneless diffuser of a small centrifugal com- pressor. The influence of impeller tip clearance on the flow field of the impeller is investigated. Detailed investigation on the leaking flow across the tip clearance of the impeller shows that the leaking flow rate is higher near the exit of the impeller than that near the inlet of the impeller. Based on this phenomenon, a new partially shrouded impeller is designed. The impeller is shrouded near the exit of the impeller. Numerical results show that the secondary flow region becomes smaller at the exit of the impeller. Better performance is achieved than that with the unshrouded impeller.     

Radial Forces in a Centrifugal Compressor; Experimental Investigation by Using Magnetic Bearings and Static Pressure Distribution

The volute of a centrifugal compressor causes a non-uniform pressure distribution which leads to a radial force on the impeller. This force was measured using magnetic bearings. In addition, the radial force was estimated using the static pressure distribution measured at the impeller outlet. The impeller force was found to be the highest at choke, the lowest at the design flow and moderate at stall. The radial force determined from the pressure measurements was only slightly different from the force obtained from the bearing measurements. The rotational speed was seen to affect the force to some extent.     

Effect of high negative incidence on the performance of a centrifugal compressor stage with conventional vaned diffusers

Three vaned diffusers, designed to have high negative incidence (-8°) at the design operating point, are studied experimentally. The overall performance (efficiency and pressure ratio) are measured at three rotational speeds, and flow angles before and after the diffuser are measured at the design rotational speed and with three mass flow rates. The results are compared to corresponding results of the original vaneless diffuser design. Attention is paid to the performance at lower mass flows than the design mass flow. The results show that it is possible to improve the performance at mass flows lower than the design mass flow with a vaned diffuser designed with high negative incidence. However, with the vaned diffusers, the compressor still stalls at higher mass flow rates than with the vaneless one. The flow angle distributions after the diffuser are more uniform with the vaned diffusers.     

离心式压气机叶片的造型和加工方法

首先分析了离心式压气机工作轮的结构特点,指出随着新的排放标准的逐步实施,米勒定时和可变喷嘴等技术的应用已成为未来的发展方向,直纹曲面径向叶型在离心式压气机未来的发展中将有用武之地。进而针对直纹曲面径向叶型,给出了通过导线构造叶片曲面的造型方法。针对叶片的数控加工方法,提出利用非线性方程组的数值计算方法进行精铣叶片的刀具加工轨迹的求解方法。     

Detailed analysis of the flow in the inducer of a transonic centrifugal compressor

Numerical and experimental investigations were conducted in a transonic centrifugal compressor stage composed of a backswept splittered unshrouded impeller and a vaned diffuser. A detailed analysis of the flow in the inducer (i.e. the entry zone of the impeller between the main blade leading edge and the splitter blade leading edge) is proposed from choke to surge. Steady and unsteady simulations were performed using the code elsA, which uses a multi-domain approach on structured meshes and solves the compressible RANS equations, associated with a two-equation turbulence model k-l in the rotating frame of reference. The 1MW LMFA-ECL test rig was used for carrying out the tests in the compressor stage. Unsteady pressure measurements up to 150 kHz and Laser Doppler Anemometry measurements were performed in the inducer. A good agreement is obtained between the experimental and numerical data even if an over dissipation is noticed in the numerical results. The change in flow pattern from choke to surge is mainly due to a change in the tip leakage flow trajectory which straightens, leading to a flow blockage of an individual passage near shroud. A spectral analysis shows that only the blade passing frequency and its harmonics compose the various spectra obtained from choke to surge.