Abstract: A two-stage radial compressor having a ported second-stage shroud, forming a passive surge control system. Thus, some proportion of the fluid is allowed to flow between the second-stage of the compressor in the vicinity of the impeller blade tips, through a port in the shroud into an upstream portion of the compressor flow path that leads into the second-stage impeller inlet. The fluid is allowed to flow in either direction, depending on the pressure difference existing between the two locations. Surge margin at higher pressure ratios is significantly increased by the ported second-stage shroud.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: A multi-stage compressor and associated compressor housing and method are provided. The housing defines an aperture for receiving a compressor wheel for successively compressing a gas in first and second stages. First- and second-stage inlets are fluidly connected to the aperture in generally axial directions, and first- and second-stage volutes extend at least partially annularly therearound so that each volute is configured to receive gas flowing generally radially outward from the compressor wheel. In addition, first and second passages fluidly connect the first-stage volute to the second-stage inlet. Each passage extends from the first-stage volute to a position radially outward of the second-stage volute and therefrom to the second-stage inlet at an axial position opposite the second-stage volute from the first-stage volute.

Abstract: An EGR cooler comprises a cooling core having a plurality of passages for accommodating the flow of exhaust gas therethrough, an exhaust gas inlet chamber connected to the cooling core, for receiving exhaust gas from an internal combustion engine and passing the exhaust gas to the cooling core, and an exhaust gas outlet chamber separate from the exhaust gas inlet chamber and connected to the cooling core for receiving exhaust gas from the core. The cooler further includes means for permitting the controlled passage of exhaust gas from the exhaust gas inlet chamber to the exhaust gas outlet chamber without passing through the cooling core, said means being positioned upstream from the exhaust gas outlet chamber. Configured in this manner, the EGR cooler permits the mixing of cooled exhaust gas with uncooled exhaust to provide a desired exiting gas temperature that is below an exhaust gas dew point.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: Turbochargers comprise a compressor housing having an air inlet passage for receiving inlet airflow, an air outlet passage for passing pressurized air to an engine combustion system, and a compressor impeller rotatably disposed within the housing for receiving air from the air inlet passage, pressurizing the inlet air, and passing the pressurized air to the air outlet passage. An air flow conditioner is placed into air flow communication with the compressor housing air inlet passage, and can be disposed within an air inlet section of the compressor itself, or can be placed within a vehicle air ducting positioned upstream from the turbocharger.

Abstract: An EGR cooler comprises a cooling core having a plurality of passages for accommodating the flow of exhaust gas therethrough, an exhaust gas inlet chamber connected to the cooling core, for receiving exhaust gas from an internal combustion engine and passing the exhaust gas to the cooling core, and an exhaust gas outlet chamber separate from the exhaust gas inlet chamber and connected to the cooling core for receiving exhaust gas from the core. The cooler further includes means for permitting the controlled passage of exhaust gas from the exhaust gas inlet chamber to the exhaust gas outlet chamber without passing through the cooling core, said means being positioned upstream from the exhaust gas outlet chamber. Configured in this manner, the EGR cooler permits the mixing of cooled exhaust gas with uncooled exhaust to provide a desired exiting gas temperature that is below an exhaust gas dew point.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: A flexible gas connection joint for use with an exhaust gas recirculation system is located between an engine exhaust manifold and a turbocharger. The flexible joint comprises a hot pipe for connection with an exhaust gas source. The hot pipe has a first end for connecting with the exhaust gas source, and has a second oppositely positioned end for connecting with an exhaust gas receiving member. The hot pipe second end includes a generally cylindrical outside surface. An adapter is coupled to the hot pipe second end for receiving exhaust gas therefrom. The adapter has a cylindrical inside diameter, and the hot pipe second end is disposed within the cylindrical inside diameter. The hot pipe second end has a radiused outside surface for enabling three-dimensional movement of the hot pipe second end within the adapter. The flexible joint can include a sealing ring interposed between concentric hot pipe and adapter surfaces for providing a leak-tight seal therebetween.

Abstract: A charge air condensation separation system for a turbocharged engine, especially suited for engines employing EGR, includes a turbocharger having a compressor providing charge air with a charge air cooler connected to the compressor to cool the charge air. A charge air delivery duct is connected to an outlet of the charge air cooler and a torroidal trap having an annular inlet is disposed in the charge air delivery duct with a sump for collecting condensation integral to the torroidal trap. A drain line for removing condensation from the sump for expulsion to the atmosphere is connected to the trap and a pump or other device for overcoming pressure differential in the drain line is employed in certain embodiments. For EGR systems employing a mixer, the condensation separator can be incorporated adjacent to or integral with the mixer to minimize additional volume requirements in the engine compartment.

Abstract: A charge air condensation separation system for a turbocharged engine, especially suited for engines employing EGR, includes a turbocharger having a compressor providing charge air with a charge air cooler connected to the compressor to cool the charge air. A charge air delivery duct is connected to an outlet of the charge air cooler and a torroidal trap having an annular inlet is disposed in the charge air delivery duct with a sump for collecting condensation integral to the torroidal trap. A drain line for removing condensation from the sump for expulsion to the atmosphere is connected to the trap and a pump or other device for overcoming pressure differential in the drain line is employed in certain embodiments. For EGR systems employing a mixer, the condensation separator can be incorporated adjacent to or integral with the mixer to minimize additional volume requirements in the engine compartment.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: A flexible gas connection joint for use with an exhaust gas recirculation system is located between an engine exhaust manifold and a turbocharger. The flexible joint comprises a hot pipe for connection with an exhaust gas source. The hot pipe has a first end for connecting with the exhaust gas source, and has a second oppositely positioned end for connecting with an exhaust gas receiving member. The hot pipe second end includes a generally cylindrical outside surface. An adapter is coupled to the hot pipe second end for receiving exhaust gas therefrom. The adapter has a cylindrical inside diameter, and the hot pipe second end is disposed within the cylindrical inside diameter. The hot pipe second end has a radiused outside surface for enabling three-dimensional movement of the hot pipe second end within the adapter. The flexible joint can include a sealing ring interposed between concentric hot pipe and adapter surfaces for providing a leak-tight seal therebetween.

Abstract: A combination bearing supporting a shaft interconnecting the turbine and compressor wheels of a turbocharger incorporates a rotating journal bearing, a squeeze film damper with a registration and retention flange, and a ball bearing assembly. The ball bearing assembly has an outer race providing a thrust shoulder and a registration receiver for the damper flange. Ball roller elements are retained by the outer race and engaged between the thrust shoulder on the outer race and an opposing thrust shoulder on the shaft.

Abstract: A combination bearing supporting a shaft interconnecting the turbine and compressor wheels of a turbocharger incorporates a dual film floating journal bearing, a squeeze film damper and ball bearing carrier, and a ball bearing assembly. An angular contact ball bearing with an outer race mounted in the carrier rolls on an inner race mounted against a should on the shaft. The squeeze film damper and ball bearing carrier is pinned to preclude axial or rotational movement. A thrust collar is sandwiched between the ball bearing inner race and the compressor wheel to carry thrust loads.

Abstract: A retractable safety shield is made of a plurality of telescoping support members, each having an identical cross-section and capable of formation by extrusion. Each of the telescoping support members has an elongated slot cut through it for a substantial portion of the length of the support members. Parallel guide grooves are formed in one surface on opposite sides of this slot and mating parallel ribs are formed on the other surface of each of the support members. The members are slidably interconnected with one another by means of rivets through the slots to cause the guide ribs on one support member to slidably nest within the guide grooves of the adjacent support member. Flexible shields are attached to the lower edges of each of the guide members to extend downwardly toward the work surface with which the device is used.