Abstract: An exemplary noise damper for a compressor of a turbocharger includes a compressor housing comprising a cavity substantially adjacent a gas flow surface of a conduit to a compressed gas outlet of the compressor housing and an insert that spans the cavity and forms a wall of the cavity where the wall includes one or more openings to the cavity to thereby allow acoustic energy to be damped by the cavity. Various other exemplary technologies are also disclosed.

Abstract: A heat exchanger has a shell and tube stack disposed within a shell inner chamber. A coolant chamber extends from a shell end, accommodates a portion of the tube stack, and has a sidewall that extends outwardly from the tube stack. A divider is disposed within the coolant chamber between the sidewall and tube stack, and extends axially along the chamber to the end of the shell splitting the coolant chamber into inlet and outlet coolant passages. For example, a pair of dividers are disposed within the coolant chamber and are attached to a respective sidewall surfaces. A coolant inlet and outlet is in fluid flow communication with respective inlet and outlet coolant passages. A cooling medium within the heat exchanger flows longitudinally within the inlet coolant passage along the tube stack in a direction opposite from the coolant flow path within the outlet coolant passage.

Abstract: The invention proposes a system for driving a compressor, comprising an induction motor (2) for driving the compressor (3), said induction motor including a squirrel cage rotor, and a controller (1) for controlling the induction motor, said controller comprising a memory for storing drive patterns for driving the induction motor, a first frequency generation means for generating a field frequency based on a field command and/or a second field generation means for generating a voltage frequency based on a voltage command, wherein a drive pattern in extracted from the memory based on the generated frequency or frequencies. Alternatively, the invention proposes a system for driving a compressor, comprising an induction motor (2) for driving the compressor (3), said induction motor including a squirrel cage rotor, and a controller (1) for controlling the induction motor, wherein the controller is adapted to distinguish between a steady state and a transient state of the induction motor.

Abstract: A variable nozzle device for a turbocharger comprises an annular arrangement of vanes disposed in a nozzle formed between an inner wall and an outer wall, the outer wall being constituted by an axially displaceable member, wherein the axially displaceable member is displaceable by an action exerted from the side of the inner wall.

Abstract: A heat exchanger includes a shell that has an inner chamber defined by an inside wall surface. A tube stack disposed within the inner chamber and includes a plurality of flat elongated tubes that define a first fluid flow path. The tubes each include a wire that is wound around a tube outside surface and that extends in a helical manner along a tube length. When stacked together, the wires of adjacent tubes connect with one another to form an “X” pattern connection that operates to both distance the adjacent tubes and form a second fluid flow path along the outside surfaces of the tubes. The connection between the wires causes turbulent flow in the coolant that improves the heat transfer characteristic of the coolant, and the connection between the wires provides structural support to the tubes in the tube stack to help reduce vibration induced heat exchanger failures.

Abstract: A turbocharger includes a compressor wheel having back-to-back impellers (i.e., a forward-facing impeller and a rearward-facing impeller) mounted on the same shaft. The two impellers are independently supplied with inlet air via separate inlet ducts and discharge pressurized air to a common volute. The inlet duct for the rearward-facing impeller comprises a generally axially extending tubular conduit having an upstream end and a downstream end, the tubular conduit being bifurcated at the downstream end into a pair of separate duct branches that divide an air stream flowing through the tubular conduit into a pair of separate air streams. The duct branches direct the air streams radially inwardly and then re-join the streams and turn the air to an axial direction into the second impeller.

Abstract: Exemplary vanes for a turbocharger having variable nozzle geometries are disclosed. In one aspect, each of the vanes includes two axial surfaces that are on opposite sides of the vane. The opposite axial surfaces include two corresponding chambers. These chambers are partially exposed to each other through an aperture. Such an aperture allows for some degree of equalization of the pressures in the chambers and, thereby, reduces the axial load exerted by a vane, for example, on the unison ring. In another aspect, each of the vanes includes two opposite airfoil surfaces. At least one of the airfoil surfaces includes a notch that allows a chamber in the nozzle to be pressurized by the exhaust gas. The pressure in the chamber creates a counteracting force that reduces the axial load exerted by a vane.

Abstract: An exemplary heat exchanger includes a heat exchanger core having a core side fluid space and a cover plate and a substantially U-shaped wall fitted at one end with an inlet header and, at an opposing end, with an outlet header, which in combination with the cover plate, define a shell side fluid space. In this example, the cover plate forms two seals with two opposing sides of the U-shaped wall, forms a seal with the inlet header and forms a seal with the outlet header. Such a heat exchange may be suitable for use as an EGR cooler. Other exemplary devices, methods and systems are disclosed.

Abstract: A compressor active surge control system that includes an air recirculation line that has a first end connected downstream of a compressor outlet and a second end connected upstream of a compressor inlet. The gas recirculation line recirculates compressed air from the compressor outlet to the compressor inlet. Also included in the system is a mixer positioned to receive both ambient air and recirculated air. Mixing of the air homogenizes the air prior to its introduction into the compressor. An air cooler may be included that cools the recirculated air prior to its introduction into the compressor. Cooling and mixing of the recirculated air expands the operating range of the compressor by reducing the incidence of surge. Various existing components, such as intercoolers and filters, may serve the additional duty of cooling or mixing the recirculated air.

Abstract: An exemplary vane for a radial turbine assembly includes a hub end and a shroud end that define vane height, a leading edge and a trailing edge that define vane length along a camberline and an inner surface and an outer surface that extend from the hub end to the shroud end and meet at the leading edge and the trailing edge and that define vane thickness wherein, for at least a portion of the vane, vane length and vane thickness vary with respect to vane height. Other exemplary vanes, assemblies, methods, etc., are also disclosed.

Abstract: A turbine housing assembly includes a tubular piston disposed in a bore of a turbine housing and axially slidable between a closed position and an open position for blocking a nozzle by an amount dependent on axial positioning of the piston. A bypass control member is disposed in the turbine housing and is slidable between a no-bypass position closing a bypass passage and a open bypass opening the bypass passage. The piston is structured and arranged to slide relative to the bypass control member for a part of a full stroke of the piston from the closed position toward the open position thereof, and then to engage the bypass control member and cause the bypass control member to slide together with the piston as the piston further slides toward the open position thereof such that the bypass control member is moved toward the bypass position.

Abstract: A method for operating a turbocharged internal combustion engine having an after-treatment device for treating exhaust gas discharged from the turbocharger, wherein exhaust gas from the engine is passed through a variable-geometry mechanism for regulating power produced by the turbine.

Abstract: A heat exchanger comprises a shell formed from two joined-together shell members. Each shell member includes a tube plate that is integral with each respective shell member and that defines an axial end of the shell member. The shell members are joined along respective open ends. A plurality of tubes is disposed within the shell, and the tube ends are connected with the respective tube plates. A baffle is disposed within the shell and directs the path of coolant flow therein and over the tubes. One shell member includes a fluid inlet and the other a fluid outlet for directing coolant into and out of the shell. The heat exchanger includes an inlet manifold connected to one end of the shell and an outlet manifold connected to an opposite end of the shell.

Abstract: An exemplary housing for a turbocharger includes a substantially cylindrical bore having a longitudinal axis, an inner diameter, a proximate end and a distal end; a counterbore positioned at the distal end, substantially centered on the longitudinal axis and having an inner diameter; a plate attachment mechanism at the proximate end for attachment of a plate including an opening substantially centered on the longitudinal axis and having an inner diameter wherein the inner diameter of the cylindrical bore exceeds the inner diameter of the counterbore and the inner diameter of the opening of the plate; and a pin opening to the cylindrical bore positioned substantially at the inner diameter of the bore, the pin opening capable of receiving a pin. Various exemplary bearing cartridges, housings, assemblies, etc., are also disclosed.

Abstract: An exemplary separator for coupling to a compressor includes a separation region substantially defined by an outer wall, part of an inner wall and an intermediate wall and an open region substantially defined by the inner wall and the intermediate wall and adjacent an outlet in the inner wall wherein the outlet provides passage to an air inlet of the compressor. Various other exemplary methods, devices, systems, etc., are also disclosed.

Abstract: An exhaust gas recirculation cooler, typically of the drawn cup design, with a bypass and control valve is disclosed. The control valve can direct a proportion of the exhaust gas to the cooler and a proportion to bypass the cooler depending on the input temperature of the exhaust gas and the required temperature of the exhaust gas. The proportion of the exhaust gas directed to the cooler/bypassing the cooler can be varied as required and so the temperature of the exhaust gas can be controlled. One benefit of certain embodiments of the invention is that engine damaging chemicals, such as sulphuric acid, which result from over-cooling the exhaust gas are reduced.

Abstract: A charge air cooler with an integral precooler is disclosed which cools charge air by using both liquid coolant and air coolant. The charge air path is not affected by the use of the liquid coolant. The charge air cooler disclosed can cool particularly hot charge air without a significant drop in pressure.

Abstract: EGR systems for an internal combustion engine configured to operate using multiple-staged turbochargers, or a pair of single stage turbochargers, to provide exhaust gas recirculation to meet emissions requirements while not affecting engine performance. One or two EGR loops operating at low, intermediate, or high pressures may be employed. EGR exhaust gases may be taken directly from the exhaust manifold, or after the exhaust stream has passed through a turbocharger turbine. EGR exhaust gases may be injected at an intermediate pressure between stages of a multiple stage turbocharger, or alternatively between a low pressure turbocharger compressor and high pressure turbocharger compressor, before being boosted to a pressure high enough to ensure the desired mass flow to the engine and delivered to the intake manifold. Intake air may be pressurized prior to mixing with the EGR exhaust gases.

Abstract: An exemplary thrust collar for a turbocharger includes a substantially annular body that includes an axis of rotation, a bore, opposing end surfaces where one of the end surfaces is substantially normal to the axis of rotation and capable of seating a back end of compressor wheel, and a surface disposed in the bore where the surface is substantially normal to the axis of rotation and capable of seating a surface of a turbocharger shaft. The axial distance between the end surface for seating a back end of a compressor wheel and the surface disposed in the bore for seating a surface of a turbocharger shaft is selected to improve balancing of a rotating assembly. Various other exemplary devices, systems, methods, etc., are also disclosed.

Abstract: A titanium-aluminide turbine wheel (120, 220, 320, 420) is joined to the end of a shaft (110, 210, 310, 410) by utilizing a titanium surface on the end of the shaft to be joined to the wheel, and electron-beam welding the wheel onto the titanium surface on the shaft. A steel shaft (110, 310, 410) can have a titanium-containing end piece (130, 330, 430) mechanically joined (by brazing, bonding, or welding) to the end of the shaft, and the end piece can be directly electron-beam welded to the wheel. Alternatively, the shaft (210) can be formed as a titanium member and the end (212) of the shaft can be directly electron-beam welded to the wheel (220). In another embodiment, a ferrous end piece (330) is mechanically joined to the titanium-aluminide turbine wheel (320) and then the end piece is directly electron-beam welded to the end of a steel shaft (310). Alternatively, a silver-titanium alloy member (430) is sandwiched between the wheel (420) and a steel shaft (410) and is melted to join the parts together.