Abstract: A turbocharger can include a center housing; a bearing disposed in a through bore of the center housing where the through bore of the center housing defines a longitudinal axis; a shaft rotatably supported by the bearing; a compressor wheel operatively coupled to the shaft; a turbine wheel operatively coupled to the shaft; and a turbine housing assembly operatively coupled to the center housing where the turbine housing assembly includes: a turbine housing; and a cartridge that includes a nozzle wall component and a plate component that are spaced axially by spacers, where the nozzle wall component includes spacer bores for the spacers and where the nozzle wall component has a non-circular outer perimeter defined at least in part by arcs where adjacent arcs intersect at intersection points, and where each of the intersection points is radially outwardly from a respective one of the spacer bores.

Abstract: An adjustment mechanism for an air inlet flow section of a compressor wheel of a turbocharger. The adjustment mechanism defines a variable inlet diameter for an axial air flow to the compressor wheel. The adjustment mechanism has a unison ring and a plurality of vanes. An actuator is used for providing a first pivoting motion to the unison ring about a central axis and thereby providing a second pivoting motion to the plurality of vanes. At least one elastic biaser is arranged, such that it provides, upon the pivoting motion to the unison ring, a restoring force to the unison ring and/or the plurality of vanes. The pivoting motion of the vanes adjusts the inlet diameter of the axial air flow to the compressor wheel.

Abstract: Turbine housing assemblies and related turbocharger systems are provided. One exemplary turbine housing assembly includes a core structure having a voided inner region defining an axial outlet and an outer surface defining an inner contour of a volute and an inner sheet metal shell having an inner base portion defining an inlet in fluid communication with the volute and a volute portion defining an outer contour of the volute, wherein at least a portion of the core structure defining the axial outlet extends in an axial direction through an opening in the inner sheet metal shell defined by the volute portion. The turbine housing assembly also includes an outer sheet metal shell surrounding the volute portion and including an outer base portion circumscribing the inner base portion.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism operable to move between an open position and a closed position. The inlet-adjustment mechanism includes a plurality of blades disposed about the compressor air inlet and located between an upstream wall surface and a downstream wall surface of an annular space within the air inlet wall. The blades are pivotable about respective pivot points such that the blades extend radially inward from the annular space into the air inlet when the blades are in the closed position so as to form an orifice of reduced diameter relative to a nominal diameter of the inlet. Aerodynamic pressure balancing across the blades is achieved by spacing features that space a majority of the upstream surface of each blade from the opposing upstream wall surface.

Abstract: A system and approach for catalyst model parameter identification with modeling accomplished by an identification procedure that may incorporate a catalyst parameter identification procedure which may include determination of parameters for a catalyst device, specification of values for parameters and component level identification. Component level identification may be of a thermal model, adsorption and desorption, and chemistry. There may then be system level identification to get a final estimate of catalyst parameters.

Abstract: An engine system includes an internal combustion engine, at least one turbocharger, and a catalytic treatment device. The engine includes an exhaust manifold system having a main exhaust manifold and a bypass exhaust manifold. A partial-engine bypass valve system is positioned between the engine and the exhaust manifold system. The bypass valve system when placed in a non-bypass position directs all of the engine exhaust gases to the turbine wheel of the turbocharger, and after passing through the turbine wheel the gases proceed to the catalytic device. In a bypass position of the bypass valve system, a bypass portion of the total exhaust gases is made to bypass the turbine wheel and proceed to the catalytic device, while the remainder first passes through the turbine wheel before going to the catalytic device.

Abstract: An austenitic stainless steel alloy and turbocharger kinematic components are provided. An austenitic stainless steel alloy includes, by weight, about 23% to about 27% chromium, about 18% to about 22% nickel, about 0.5% to about 2.0% manganese, about 1.2% to about 1.4% carbon, about 1.6% to about 1.8% silicon, about 0% to about 0.5% molybdenum, sulfur in an amount of less than about 0.01%, phosphorous in an amount of less than about 0.04%, and a balance of iron, and other inevitable/unavoidable impurities that are present in trace amounts. The turbocharger kinematic components are made at least in part using this stainless steel alloy.

Abstract: A method of manufacturing a variable vane mechanism includes arranging a vane and a spacer between a first support structure and a tool member of a tool. The method also includes abutting a first inner surface of the first support structure against a first side surface of the vane and a second side surface of the vane against an opposing surface of the tool member, leaving a control surface of the spacer projecting from the first support structure at a predetermined distance. The method further includes fixedly attaching the spacer to the first support structure with the control surface of the spacer projecting from the first support structure at the predetermined distance. The method further includes abutting a second support structure on the control surface of the spacer to define a gap between the first support structure and the second support structure with the vane disposed within the gap.

Abstract: Systems and methods are provided for preheating emissions control devices prior to engine startup using a heating element and a flow control device operable to provide a fluid flow, such as a compressor or a turbine. One exemplary method of heating an emissions control component prior to engine startup involves opening or otherwise operating a valve to provide a path for fluid flow to the emissions control component, operating a flow control device to provide the fluid flow through the path, and activating a heating element upstream of the emissions control component to heat the fluid flow to the emissions control component.

Abstract: An assembly can include a turbine housing that includes a bore, a wastegate seat, wastegate passages that extend to the wastegate seat and a divider wall disposed between the wastegate passages where the divider wall includes a divider wall surface; a rotatable wastegate shaft configured for receipt by the bore; a wastegate arm extending from the wastegate shaft; and a wastegate plug extending from the wastegate arm where the wastegate plug includes a contact portion that contacts the wastegate seat to cover the wastegate passages in a closed state and a mesh that contacts the divider wall surface in the closed state.

Abstract: An e-charger includes an outer housing and a rotor supported for rotation within the outer housing. A motor assembly is housed within the outer housing and includes an electric motor and a motor case. The electric motor is encased within the motor case. The electric motor is configured to drivingly rotate the rotor within the outer housing. Furthermore, the e-charger includes a cooling system configured to receive a coolant. The cooling system includes a manifold passage defined in the outer housing. The cooling system includes a first motor cooling circuit and a second motor cooling circuit that are cooperatively defined by the outer housing and the motor case. The first motor cooling circuit and the second motor cooling circuit are fluidly connected to the manifold passage. The manifold passage is configured to distribute a flow of the coolant between the first motor cooling circuit and the second motor cooling circuit.

Abstract: An engine system incorporating an intake manifold, a compressor, and a controller. The compressor may provide air to the intake manifold and the controller may be connected to the intake manifold and the compressor. The controller may receive a control signal and control air flow from the compressor to the intake manifold based on the received control signal. The controller may control the air flow from the compressor to the intake manifold based on a first equation when a value related to the control signal is on a first side of a threshold and according to a second equation when the value is on a second side of the threshold. The controller may control the air flow between the compressor and intake manifold according to the second equation to prevent the compressor from operating at a surge condition when controlling the air flow according to the first equation.

Abstract: A method for controlling a VG mechanism for a compressor employs a predefined VG setpoint map comprising optimum VG setpoints for the VG mechanism based on at least one predefined optimization criterion. The VG mechanism has at least three different setpoints ranging between a minimum flow area setpoint and a maximum flow area setpoint. A location of an operating point of the compressor on its compressor map is determined. Based on the location of the operating point, the VG setpoint map is consulted and an optimum VG setpoint is determined. A predictive scheme can be included for accounting for time lag of the VG mechanism's response.

Abstract: A turbocharger system includes a manifold system that maintains separation between flow paths of different manifold arrangements. One manifold arrangement directs flow from a first group of combustion chambers to a first volute passage of a turbine section of a turbocharger. Another manifold arrangement directs flow from a second group of combustion chambers to a second volute passage of the turbine section of the turbocharger. The system also provides selective variation of the available volume for exhaust flow through the manifold arrangements.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism in an air inlet for the compressor, operable to move between a closed position, an open position, and a super-open position. The compressor also includes a ported shroud system. The inlet-adjustment mechanism includes a plurality of blades disposed about the air inlet and movable radially inwardly and outwardly for defining the various positions. In the closed position, the effective diameter of air inlet is reduced and the blades block flow through the ported shroud system. In the open position, the blades still block the ported shroud but the effective inlet diameter is increased relative to the closed position. In the super-open position, the blades unblock the ported shroud so that an additional amount of flow can pass through the ported shroud, thereby shifting the compressor's choke flow line to higher flow rates.

Abstract: A turbocharger system includes a wastegate with a bypass passage and a valve assembly. The valve assembly includes a poppet with an axis. The valve assembly also includes an arm that is attached to the poppet and that supports movement of the poppet between a closed position and an open position. Additionally, the valve assembly includes a plurality of biasing members that are disposed within a joint between the poppet and the arm. The plurality of biasing members provides a biasing force directed in a radial direction relative to the axis. The plurality of biasing members is disposed substantially symmetrically with respect to a first radial line of symmetry and a second radial line of symmetry.

Abstract: A centrifugal compressor for a turbocharger includes an inlet-adjustment mechanism operable to move between an open position and a closed position. The inlet-adjustment mechanism includes a plurality of blades disposed about the compressor air inlet and located within an annular space within the air inlet wall. The blades are pivotable about respective pivot points such that the blades extend radially inward from the annular space into the air inlet when the blades are in the closed position so as to form an orifice of reduced diameter relative to a nominal diameter of the inlet. The blades include lever arms that engage the outer periphery of a rotatable unison ring that is linked to a linear actuator for rotating the unison ring so as to pivot the blades.

Abstract: A turbine housing assembly seal can include a cylindrical portion that defines an opening having an axis where the cylindrical portion is disposed at a cylinder radius from the axis; a lower edge disposed at a lower edge radius that exceeds the cylinder radius; an sloped annular portion that extends radially inwardly from the lower edge; a lower bend that extends from the sloped annular portion to a lower axial position of the cylindrical portion; an upper bend that extends from an upper axial position of the cylindrical portion; and an upper edge that extends radially outwardly from the upper bend to an upper edge radius that exceeds the cylinder radius and that is less than the lower edge radius.

Abstract: A turbocharger assembly can include a shaft sleeve that includes a bore that extends between a compressor end and a turbine end, outer threads that extend to a first axial position from the compressor end, and an outer shoulder at a second, greater axial position from the compressor end; a lock nut that includes inner threads that mate with the outer threads of the shaft sleeve and an axial length that is less than a distance between the compressor end and the first axial position; and a bearing assembly that includes at least one inner race axially located by the outer shoulder of the shaft sleeve and axially located by the lock nut.

Abstract: An assembly can include a turbine housing that includes a bore, a wastegate seat and a wastegate passage that extends to the wastegate seat; a bushing disposed at least in part in the bore; a rotatable wastegate shaft received at least in part by the bushing; a wastegate plug that extends from the wastegate shaft; a control arm operatively coupled to the wastegate shaft; a control link operatively coupled to the control arm; a pin that forms a joint between the control arm and the control link; and a biasing element coupled to the pin and to the control link.