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: An exhaust gas heat exchanger comprising an external shell (20) extending between two tube plates (30, 31) and defining a coolant chamber; internal tubes (38) forming exhaust gas passages which extend between the tube plates (30, 31); an exhaust gas manifold divided by a baffle plate (29) into first and second chambers (26, 28) with an exhaust gas inlet (25) and outlet (27) respectively. The baffle plate (29) is provided with a valve (51) which can be operated between an open position, which exhaust gas flows along the cooling tubes (38), and a closed position, in which exhaust gas is diverted directly from the first chamber (26) to the second chamber (28).

Abstract: A variable geometry turbocharger assembly employing the present invention includes a center housing, a compressor housing attached to one side of the center housing, and a turbine housing attached to another side of the center housing. A plurality of movable vanes is disposed within the turbine housing, and a unison ring is rotatably disposed within the turbine housing to move the vanes in unison. The turbocharger includes a unison ring assembly of this invention that includes an insert that is separate from and attached to the center housing. The support has one or more surfaces to carry the unison ring, and the unison ring is rotatably positioned on the support. The support further provides a space that isolates the unison ring from making contact with contacting the center housing. A heat shroud optionally extends radially inwardly along the center housing and is retained into position by the support.

Abstract: A method for defining a sliding mode control system for a turbocharger system is provided. The method includes perturbing a turbocharger actuator and measuring turbocharger boost pressure output from the perturbation. The perturbation and measurements are repeated for a plurality of states of operation of the turbocharger. System parameters identified for each of the plurality of states from the plurality of perturbations and measurements. A sliding mode control law may be defined for each of the plurality of states from the system parameters. A sliding mode control system for controlling the boost pressure of a turbocharger is also provided. An actuator for controlling the boost pressure is electrically controlled by a sliding mode controller to stabilize the turbocharger system toward a setpoint on a sliding surface. The control law is determined from a plurality of linear models from a plurality of operating states of the turbocharger system.

Abstract: An internal combustion engine system, dual loop EGR system and method is provided, with a high pressure EGR loop, controlled by a control valve, in fluidic connection with the exhaust outlet of the exhaust manifold and the air inlet of the intake manifold, and a low pressure EGR loop, wherein exhaust, in proportions controlled by a control valve, enters a compressor from a point downstream of an exhaust emissions controller, together with fresh air, the low pressure EGR loop being in fluidic connection with an output of the compressor and the air inlet of the intake manifold.

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: Cylinders of an internal combustion engine are provided with an exhaust port that is opened when the piston approaches bottom dead center. Exhaust in the cylinder at the end of the power stroke flows to an EGR tank for containment and cooling. During the intake stroke as the piston approaches bottom dead center, the exhaust port is reopened allowing gas from the EGR tank to flow into the cylinder as a portion of the charge prior to compression. Alternatively, the exhaust port on a first cylinder is connected to the exhaust port on a second cylinder to allow exhaust gas from the power stroke on the first cylinder to flow into the intake stroke on the second cylinder. Pulsed turbocharger systems comprise an internal combustion engine comprising a piston cylinder and a piston slidably disposed within the cylinder. The cylinder includes an exhaust gas port that is disposed through a wall section of the cylinder.

Abstract: Systems for preventing/controlling compressor surge in an electrically assisted turbocharger comprise a turbocharger having an electric motor disposed around a turbocharger shaft. The electric motor controller is electrically coupled to the electric motor for controlling the rotational movement provided by the electric motor to the turbocharger shaft. A memory is electrically coupled to the electric motor controller and comprises a multi-dimensional map of compressor surge conditions stored therein. Sensors are used to provide desired engine and/or turbocharger operating information for comparing against the stored map data. The sensors are electrically coupled to the electric motor controller. The controller plots the actual operating information provided by the sensors on the stored map to evaluate whether the turbocharger is operating in different operating regions.

Abstract: Turbocharger control systems used with electric assist turbochargers include an electric motor for controlling turbocharger operation. The system comprises an oil pressure sensor attached to the turbocharger for sensing oil pressure for lubricating a shaft bearing assembly. The pressure sensor provides oil pressure information to a control system that controls the operation of the electric motor and/or other operating parameters of the turbocharger and/or the vehicle. The control system regulates operation of the electric motor during operating conditions where a low oil pressure condition is detected when compared to a predetermined minimum. The control system reactivates the electric motor once a desired minimum oil pressure has been detected.

Abstract: An electric assisted turbocharger has an electric motor with a stator and a rotor that is coupled to a turbocharger shaft carried by a bearing assembly. The stator has a left-hand winding and a right hand-winding each projecting axially outwardly therefrom. The winds each extend a different distance radially along the motor (and are thus asymmetrical with respect to one another), thereby forming a radial gap along an axial end of the stator. The so-formed stator is disposed within a motor housing and together, the stator and motor housing, facilitate placement center housing axial end therein to minimize turbocharger axial length. The rotor is configured to prevent migration of oil into the motor housing, to improve dynamic balance, and comprises an integral thrust washer for placement against the bearing assembly.

Abstract: A compressor includes first-stage and second-stage impellers arranged back-to-back such that fluid is discharged from the first-stage impeller into a generally annular interstage duct that conducts the fluid into the second-stage impeller and the fluid discharged from the second-stage impeller enters into a volute that is arranged generally concentrically within the interstage duct. A discharge duct from the volute passes through the interstage duct at one circumferential location. An array of non-axisymmetric deswirl vanes is arranged upstream of the second-stage impeller. One of the vanes is thick and envelops the discharge duct. The remaining vanes are thinner and are differently configured about the circumference of the vane array to account for the flowfield effects of the thick vane.

Abstract: A hydrodynamic thrust bearing of this invention comprises a body having a load-bearing surface comprising an oil supply channel and an oil return channel positioned along respective inside and outside body diameters. A number of thrust pads are positioned along the surface that each include an oil supply groove, positioned adjacent a leading edge/upstream portion of each thrust pad and extending radially a distance from the oil supply channel, and an oil return groove, positioned adjacent a trailing edge/downstream portion of each thrust pad and extending radially a distance from the oil return channel. The oil supply grooves are separate from the oil return grooves, and the thrust pads each comprise a series arrangement of three differently configured land or pad sections. Configured in this manner, oil is provided onto the series of land sections by the oil supply groove and is collected after passing over the series of land sections by the separate oil collection groove.

Abstract: An exhaust gas cooler for reducing the temperature of exhaust gases from internal combustion engines, comprising an external tube extending between two tube plates or end walls and defining a coolant chamber, coolant inlet and outlet means communicating with the coolant chamber, and a plurality of internal tubes extending between the end walls and arranged to carry the exhaust gas through the coolant chamber. The external tube has a cross-sectional shape which has a height (H) in the major axis which is greater than its width (W) in the minor axis perpendicular to the major axis, preferably oval, or comprising two semi-circles connected by common straight line tangents parallel to the major axis. Such a cross-sectional shape means that the exterior tube has a planar face which simplifies the fitting of mounting brackets and placement with an engine compartment.

Abstract: An exhaust gas recirculation cooler (1) with a coolant chamber (14), a bypass tube (50) and means (70) to selectively direct exhaust gas through the coolant chamber (14) or bypass tube (50). The bypass tube (50) may be used to direct hot exhaust gases to the engine under low engine temperature/load operating conditions and during start up of the engine; the coolant chamber (14) may be used to cool very hot gases under high engine temperature/load conditions and direct the cooled gas to the engine. The bypass tube (50) is integrally formed with the coolant chamber, reducing space required for the cooler and making for easier installation.

Abstract: A high-pressure ratio turbocharger of this invention has a two-stage compressor section comprising a first-stage compressor impeller rotatably disposed in a first compressor housing, and a second-stage compressor impeller rotatably disposed in a second compressor housing. The first and second stage compressor impellers are attached to a common shaft, and are positioned within respective compressor housing in a direction facing away from one another. A portion of the second compressor housing is formed from a compressor backplate attached to a turbocharger center housing. A scroll seal is disposed between the first and second compressor housings, and is interposed between the impellers to separate outlet air flow between each respective first and second compressor chamber.

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: Heat exchanger header tanks are constructed from a basic set of components. The basic components are castings and simple formed sheet parts. The components are assembled to produce a heat exchanger tank having a desired size and geometry.

Abstract: Variable geometry turbochargers include a turbine housing having an exhaust gas inlet and outlet, a volute connected to the inlet, and typically a nozzle wall adjacent the volute. The turbine housing includes a bypass exhaust gas flow port disposed internally therein having an inlet opening positioned upstream from the turbine wheel, and a outlet opening positioned downstream from the turbine wheel. The inlet opening is exposed for facilitating bypass exhaust gas flow through the turbocharger when a respective vane is actuated or moved into an open position. The turbine housing may also include a specially configured nozzle wall terminal edge designed to work with vanes having a recessed underside surface to permit additional bypass exhaust gas flow within the turbocharger when the vanes are actuated in an open position.