Abstract: A turbine or compressor wheel mounted in a housing. The wheel is carried on two radial bearings both mounted in a wall of the housing. The wall has a venting orifice that is not impeded by moving parts such as bearings. The wall also has a circular seal member extending toward a back-disk of the wheel with only a very small clearance. The seal member is composed of a material significantly softer than the material of the wheel.

Abstract: Turbine assemblies, loss recovery systems, and related fabrication methods are provided for managing temperatures associated with an electrical generator. One exemplary turbine assembly suitable for use in a loss recovery system includes a wheel configured to rotate in response to a portion of a fluid flow bypassing a flow control valve, a generator including a stator assembly disposed about a rotor coupled to the wheel to rotate in response to rotation of the wheel, a conductive structure in contact with the stator assembly, and an insulating structure radially encompassing the conductive structure and the generator. The conductive structure accesses at least a portion of the fluid flow bypassing the flow control valve and impacting the wheel, thereby providing thermal coupling between the stator assembly and the bypass fluid flow to transfer heat from the stator assembly to the bypass fluid flow via the conductive structure.

Abstract: A system can include a shaft and turbine wheel assembly that includes a seal portion; a bearing assembly that includes an outer race and rolling elements that rotatably support the shaft and turbine wheel assembly; a sleeve that includes an outer diameter and a through bore that includes a first inner diameter that accommodates an outer diameter of the outer race of the bearing assembly and a second, smaller inner diameter that accommodates an outer diameter of the seal portion of the shaft and turbine wheel assembly; and a center housing that includes a compressor side, a turbine side and a bore that includes a turbine side bore diameter that accommodates the outer diameter of the sleeve.

Abstract: An electric motor-driven compressor includes a housing assembly comprising a motor housing and a compressor housing mounted thereto. The compressor housing contains a centrifugal compressor wheel that is mounted on a shaft of the motor rotor and also defines an air inlet that leads air into the compressor wheel, and a volute that collects the compressed air. Air bearings rotatably support the shaft. Cooling air passages are defined in the housing assembly for supplying cooling air to the air bearings. A diffuser between the exit of the compressor wheel and the volute serves to diffuse the compressed air. The compressor includes a heat shield formed separately from the compressor housing and the motor housing and disposed between them. The heat shield defines one wall of the diffuser and also cooperates with the housing assembly to define part of the cooling air passages for the cooling air supplied to the bearings.

Abstract: A mechanism for differential pressure sealing for use in a compressor, such as for fuel cell applications, is described. In a dual-stage compressor, a low pressure side and/or a high pressure side of the dual-stage compressor may include a compressor wheel supported by a shaft that can rotate about an axis of the shaft. A seal carrier may be provided that rotates with the compressor wheel and includes a groove for receiving a sealing ring, which may be a split expansion ring. A static seal plate may be positioned around a periphery of a portion of the seal carrier, such that the sealing ring can seal against a contact surface of the static seal plate when received in the groove in order to create a pressure differential seal. The low pressure side may include one sealing ring, whereas the high pressure side may include two sealing rings positioned in series.

Abstract: An electric motor-driven compressor having an electrical terminal block assembly and corresponding method of assembly are provided. The electrical terminal block assembly includes a base plate that has a staging feature for receiving a lug end of a motor stator cable prior to connection of the motor stator cable with a terminal bar of the terminal block assembly. In this way, once the terminal block assembly is lowered into the enclosure and the motor stator cable is no longer visible to the user, a stator cable fastener may be passed through a stator cable mounting hole in the terminal bar to engage the stator cable lug that is being held in the proper position by the staging feature of the base plate. Upon rotation of the stator cable fastener, the stator cable lug may be drawn into conductive engagement with the terminal bar.

Abstract: Turbine assemblies, loss recovery systems, and related fabrication methods are provided for managing temperatures associated with an electrical generator. One exemplary turbine assembly suitable for use in a loss recovery system includes a wheel configured to rotate in response to a portion of a fluid flow bypassing a flow control valve, a generator including a stator assembly disposed about a rotor coupled to the wheel to rotate in response to rotation of the wheel, a conductive structure in contact with the stator assembly, and an insulating structure radially encompassing the conductive structure and the generator. The conductive structure accesses at least a portion of the fluid flow bypassing the flow control valve and impacting the wheel, thereby providing thermal coupling between the stator assembly and the bypass fluid flow to transfer heat from the stator assembly to the bypass fluid flow via the conductive structure.

Abstract: An air bearing assembly is provided that includes a bearing sleeve that has two slots side-by-side having rectangular profiles for engaging the ends of first and second bearing foils for supporting a shaft of a dual-stage compressor. The first rectangular-profile slot, which may be made using a broaching process, is designed to receive first ends of the first bearing foil and the second bearing foil. The second rectangular-profile slot, which may also be made using a broaching process, is designed to receive a second end of the second bearing foil. This dual-slot design replaces the complex “L” shaped single slot design of conventional bearing sleeves, allowing for high-volume, low-cost manufacturing of the bearing sleeves. The dual-slot design also provides for robust engagement of the bearing foils with the bearing sleeves, while allowing easy assembly and installation of the air bearing assemblies.

Abstract: An electric motor-driven compressor having an electrical terminal block assembly and corresponding method of assembly are provided. The electrical terminal block assembly includes a base plate that has a staging feature for receiving a lug end of a motor stator cable prior to connection of the motor stator cable with a terminal bar of the terminal block assembly. In this way, once the terminal block assembly is lowered into the enclosure and the motor stator cable is no longer visible to the user, a stator cable fastener may be passed through a stator cable mounting hole in the terminal bar to engage the stator cable lug that is being held in the proper position by the staging feature of the base plate. Upon rotation of the stator cable fastener, the stator cable lug may be drawn into conductive engagement with the terminal bar.

Abstract: An electric motor-driven compressor includes a motor having a rotor and a stator in a motor housing, a low-pressure compressor mounted to one end of the motor housing, and a high-pressure compressor mounted to the other end of the motor housing, the compressors forming a two-stage compressor. The motor housing defines a convoluted liquid coolant passage having a plurality of axially spaced-apart, convoluted passageways arranged for serial flow of liquid coolant from the passage inlet, then through each of the convoluted passageways one after another, and finally out from the outlet. The coolant passage further defines at least a first bypass passage that intersects with the convoluted passageways and extends in a non-convoluted fashion so as to interconnect the convoluted passageways and provide an alternative flow path for the coolant.

Abstract: An air bearing assembly is provided that includes a bearing sleeve that has two slots side-by-side having rectangular profiles for engaging the ends of first and second bearing foils for supporting a shaft of a dual-stage compressor. The first rectangular-profile slot, which may be made using a broaching process, is designed to receive first ends of the first bearing foil and the second bearing foil. The second rectangular-profile slot, which may also be made using a broaching process, is designed to receive a second end of the second bearing foil. This dual-slot design replaces the complex “L” shaped single slot design of conventional bearing sleeves, allowing for high-volume, low-cost manufacturing of the bearing sleeves. The dual-slot design also provides for robust engagement of the bearing foils with the bearing sleeves, while allowing easy assembly and installation of the air bearing assemblies.

Abstract: An electric motor-driven compressor includes a housing assembly comprising a motor housing and a compressor housing mounted thereto. The compressor housing contains a centrifugal compressor wheel that is mounted on a shaft of the motor rotor and also defines an air inlet that leads air into the compressor wheel, and a volute that collects the compressed air. Air bearings rotatably support the shaft. Cooling air passages are defined in the housing assembly for supplying cooling air to the air bearings. A diffuser between the exit of the compressor wheel and the volute serves to diffuse the compressed air. The compressor includes a heat shield formed separately from the compressor housing and the motor housing and disposed between them. The heat shield defines one wall of the diffuser and also cooperates with the housing assembly to define part of the cooling air passages for the cooling air supplied to the bearings.

Abstract: A mechanism for differential pressure sealing for use in a compressor, such as for fuel cell applications, is described. In a dual-stage compressor, a low pressure side and/or a high pressure side of the dual-stage compressor may include a compressor wheel supported by a shaft that can rotate about an axis of the shaft. A seal carrier may be provided that rotates with the compressor wheel and includes a groove for receiving a sealing ring, which may be a split expansion ring. A static seal plate may be positioned around a periphery of a portion of the seal carrier, such that the sealing ring can seal against a contact surface of the static seal plate when received in the groove in order to create a pressure differential seal. The low pressure side may include one sealing ring, whereas the high pressure side may include two sealing rings positioned in series.

Abstract: A turbine or compressor wheel mounted in a housing. The wheel is carried on two radial bearings both mounted in a wall of the housing. The wall has a venting orifice that is not impeded by moving parts such as bearings. The wall also has a circular seal member extending toward a back-disk of the wheel with only a very small clearance. The seal member is composed of a material significantly softer than the material of the wheel.

Abstract: A system can include a shaft and turbine wheel assembly that includes a seal portion; a bearing assembly that includes an outer race and rolling elements that rotatably support the shaft and turbine wheel assembly; a sleeve that includes an outer diameter and a through bore that includes a first inner diameter that accommodates an outer diameter of the outer race of the bearing assembly and a second, smaller inner diameter that accommodates an outer diameter of the seal portion of the shaft and turbine wheel assembly; and a center housing that includes a compressor side, a turbine side and a bore that includes a turbine side bore diameter that accommodates the outer diameter of the sleeve.

Abstract: A turbocharger rotating assembly includes a bearing; a shaft and turbine wheel assembly supported by the bearing; a seal ring disposed about the shaft; and a sleeve that supports the bearing and that includes a compressor end and a turbine end, a bore extending axially from the compressor end to the turbine end, a first counter bore that forms an axial face that axially locates the bearing in the bore, a second counter bore disposed axially between the first counter bore and the turbine end wherein the second counter bore comprises a seal surface that forms a lubricant and exhaust seal with the seal ring disposed about the shaft, and a securing feature to secure the sleeve with respect to a turbocharger housing. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A diffuser divider shaped as disc with a central axis, a leading edge disposed at an inner radius about the central axis, a trailing edge disposed at an outer radius about the central axis, an upper surface disposed between the leading edge and the trailing edge, a lower surface disposed between the leading edge and the trailing edge and one or more mounting features configured to mount the disc in a diffuser section configured to receive air compressed by two compressor wheel faces and to direct the compressed air to a volute. Such a divider can define throats in a diffuser section of a compressor assembly. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbocharger rotating assembly includes a bearing; a shaft and turbine wheel assembly supported by the bearing; a seal ring disposed about the shaft; and a sleeve that supports the bearing and that includes a compressor end and a turbine end, a bore extending axially from the compressor end to the turbine end, a first counter bore that forms an axial face that axially locates the bearing in the bore, a second counter bore disposed axially between the first counter bore and the turbine end wherein the second counter bore comprises a seal surface that forms a lubricant and exhaust seal with the seal ring disposed about the shaft, and a securing feature to secure the sleeve with respect to a turbocharger housing. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A diffuser divider shaped as disc with a central axis, a leading edge disposed at an inner radius about the central axis, a trailing edge disposed at an outer radius about the central axis, an upper surface disposed between the leading edge and the trailing edge, a lower surface disposed between the leading edge and the trailing edge and one or more mounting features configured to mount the disc in a diffuser section configured to receive air compressed by two compressor wheel faces and to direct the compressed air to a volute. Such a divider can define throats in a diffuser section of a compressor assembly. Various other examples of devices, assemblies, systems, methods, etc., are also disclosed.

Abstract: A turbocharger with a two-stage compressor having first- and second-stage impellers mounted on a common shaft in a back-to-back configuration. The first-stage impeller has a boreless configuration, defining an unthreaded pilot hole receiving an unthreaded end of the shaft so as to establish a coaxial relationship between the impeller and the shaft. The first impeller further defines a hollow cylindrical pilot member that projects from the back of the impeller and is received in a portion of the bore through the second-stage impeller to position the impellers coaxially with each other. The shaft passes through the pilot member and is externally threaded for engaging threads on the inner surface of the pilot member to secure the impellers to the shaft. The bore of the second impeller has a second portion that engages an outer cylindrical surface of the shaft to establish a coaxial relationship between the shaft and impeller.