Abstract: An exemplary heat exchanger includes increased stiffness to prevent buckling of a core. In some examples, an exemplary heat exchanger includes a core and a shaft at least partially positioned therein to increase stiffness of the core and located to limit movement of a heat exchange portion and to receive loads therefrom. In another example, an exemplary heat exchanger includes a core, a duct in fluid communication therewith, a load bearing member positioned adjacent to the core, and a mount which attaches the duct to the member. By connecting the duct to the member, the duct can transfer loads to the load bearing member. This protects the core being damaged by loads applied to the duct. The mount restrains the duct so to transfer loads, from the duct to the load bearing member. Such loads can be from external sources, such as inertia loads and vibration loads.

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: 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: Improved cambered vanes comprise an inner airfoil surface oriented adjacent a turbine wheel, and an outer airfoil surface oriented opposite the inner airfoil surface. The inner and outer airfoil surfaces define a vane airfoil thickness. A cambered vane leading edge or nose is positioned along a first inner and outer airfoil surface junction, and a vane trailing edge positioned along a second inner and outer surface junction. The vane airfoil surfaces, in conjunction with the vane leading edge, are specifically configured to provide a vane camberline, measured between the airfoil surfaces and extending along a length of the vane, having a gradually curved section and a substantially flat section.

Abstract: An exemplary controller includes a control valve that includes an electric actuator operatively coupled to a valve stem, a piston operatively coupled to one or more hydraulic fluid paths controlled by the control valve and including a piston shaft, a rotatable shaft operatively coupled to the piston shaft and mechanically isolated from the valve stem and capable of adjusting geometry of the variable geometry turbine, and an electronic sensor capable of sensing an angular position of the rotatable shaft. Various other exemplary systems, methods, devices, etc., are also disclosed.

Abstract: A compressor impeller for use with a boreless turbocharger is provided in accordance with this invention. The compressor impeller comprises an integral hub projecting axially therefrom that includes a partial bore therein that extends from an open to a close bore end. The bore includes a threaded portion that is configured to accommodate threaded engagement with an end of a common shaft disposed through a turbocharger housing and attached at an opposite end to a turbine wheel. The hub is specially configured so that the threaded portion has a relatively increased wall thickness when compared to a remaining portion of the bore disposed between the threaded portion and the end of the bore. The bore is configured providing a section having a reduced wall thickness, between the threaded portion and the bore closed end, for purposes of providing a preferential stress relief mechanism.

Abstract: A control system of this invention for use with a variable geometry turbocharger is designed to enable turbocharger control based solely on engine speed. The control system takes measured engine speed and sends the same to an engine control unit (ECU) having an actuator position v. engine speed map. The ECU utilizes only the measured engine speed to determine a desired actuator position from the map, and produces a control signal for effecting actuator operation. The control signal generated by the ECU can be converted to an analog signal by pulse width modulation, for example. The control signal is sent to an actuator for placing the actuator into the desired actuator position. The actuator is connected to a variable geometry member in the turbocharger so that operation and placement of the actuator into the desired actuator position thereby places the variable geometry member into a desired position to effect the desired change in turbocharger operation.

Abstract: Heat exchangers, constructed in accordance with principles of this invention, comprise a plurality of first passages, for transporting a first fluid or gas therethrough, and one or more second passages for transporting a second fluid or gas therethrough. The second passages are positioned adjacent to the first passages to permit a desired transfer of thermal energy from the first passages to the second passages. At least one manifold is placed in communication with one of the first or second passages. The manifold includes an opening disposed therethrough for receiving or dispensing the first or second fluid or gas to or from the first or second passages. The heat exchanger includes a flow director disposed therein for diverting or distributing the flow of first or second fluid or gas in a manner different from a natural fluid or gas flow within the heat exchanger.

Abstract: There is provided a locator device and an associated fixture and method for supporting a rotatable member. The locator device has a base and a plurality of flanges extending from the base in an axial direction and arranged circumferentially to define an aperture for at least partially receiving the rotatable member axially. The flanges defining slots for receiving radial portions of the rotatable member with the radial portions extending radially outward from the flanges. Thus, the locator device can support boreless rotatable members so that a tool can be supported against the radial portions of the rotatable member to thereby form the rotatable member to predetermined dimensions.

Abstract: Thermal indictors of this invention are constructed for use with a heat exchanger generally comprising hot and cold side passages for accommodating a desired heat transfer therebetween. The thermal indicator is disposed at least partially within the heat exchanger and is formed from a material designed to undergo a permanent physical change when exposed to a temperature that is above a heat exchanger design operating temperature.

Abstract: A turbocharger including center housing with a thermally decoupling flange is provided. The flange, which extends generally radially outward from a body of the center housing, has a connection portion that can be used to mount the center housing to a turbine housing of the turbocharger. A curved portion of the flange is disposed between the connection portion and the housing body and provides a thermal decouple for reducing the thermal gradient in the connection portion. The curved portion can also increase the flexibility of the flange to reduce the stresses therein that result from temperature variations in the center housing.

Abstract: A cartridge is formed by an insert fixed to a base to form turbine intake nozzles in which vanes are rotatably mounted, and the base is fixed to a center housing. A separate exhaust housing which is formed from sheet metal is fixed to the cartridge outside of the insert in order to provide an intake and an outlet for exhaust gases driving a turbine wheel on a shaft journaled in the center housing.

Abstract: Exemplary turbine blade outer edges, exemplary vane inner edges, exemplary systems and exemplary methods are disclosed that help to reduce noise in variable geometry turbines and optionally other turbines wherein a turbine blade interacts with an object. Other exemplary turbine-related technologies are also disclosed.

Abstract: Turbochargers of this invention comprise a turbine housing and a turbine wheel rotatably disposed therein. A center housing is connected to the turbine housing, and a compressor housing is attached to the center housing. A compressor is rotatably disposed within the compressor housing, and comprises two impellers placed in back-to-back orientation. A movable member is disposed within the compressor housing to downstream of the compressor to control the flow of air within the compressor housing. The position of the movable member can be operated to control the amount of pressurized air that is produced by one of the compressor impellers to provide enhanced compressor operating efficiency throughout the operating range and mass flow requirements of the engine.

Abstract: There is provided a shaft member such as a bearing, washers, and shaft, having at least one surface defining a plurality of radial grooves for providing radial fluid communication without generating significant thrust loading between the shaft member and an adjacent surface. The grooves can be formed by pressing a die against the surface(s) of the shaft member.

Abstract: A buffer chamber and outlet guide provide an air path from an intake passage in a compressor housing to an upstream position relative to an intake port of the compressor. Surging is minimized during low airflow conditions while cyclic forces on the blades of the impeller are minimized during high airflow conditions. By providing an air path through the buffer chamber and outlet guide, ribs or other supporting structures are eliminated within the air pathway through the intake port and intake passage within the compressor housing.

Abstract: Improved actuation assemblies are used with variable geometry turbochargers comprising a plurality of movable aerodynamic vanes attached to a movable unison ring that is coupled to an actuator. The actuation assembly includes a crank arm that is attached at a first end to the actuator, and at a second end to the unison ring. A first gear member is attached to the crank arm second end and includes teeth. The unison ring includes a second gear member attached thereto that also comprises teeth. The teeth of the first and second gear members are cooperatively engaged with one another. The second gear member is movably attached to the unison ring to maintain predetermined distance between the first and second gear members during operation of the turbocharger and related thermal movement of the unison ring.

Abstract: Exemplary methods, devices, and/or systems are suitable for regenerating a plurality of after-treatment units. An exemplary method includes selecting less than all of a plurality of after-treatment units and adjusting air to fuel ratio for less than all of a plurality of combustion chambers of an engine to thereby cause the selected after-treatment units to receive exhaust having hydrocarbon and oxygen concentrations that favor regeneration of the selected after-treatment units. Other exemplary methods, devices and/or systems are also disclosed.

Abstract: A high temperature prime surface heat exchanger is created using adjacent pairs of plates having braze cladding on a first surface thereof that are formed to create fluid flow passages for coolant and fluid flow passages for hot gas when assembled into a core by stacking the plates. The coolant passages are adjacent the first or clad surface of each formed plate to avoid direct contact with the high temperature gas flowing in the hot gas passages. The adjacent plate pairs are joined by brazing of a contacting portion of the first surface on each plate to form sealed coolant passages the core.

Abstract: A heat exchanger, including a core having a variable size or length and a support structure connected to the core, the support structure accommodating variations in the size of the core.