Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening for receiving the valve shaft. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle such that the spindle is disposed between the valve body and the washer. The spindle head or the washer includes a raised lip extending towards the other of the spindle head or the washer, with the other of the spindle head or the washer defining a notch configured to at least partially receive the raised lip and configured to cooperate with the raised lip to shield the biasing member from exhaust gas and high temperatures.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. A plurality of cup springs is disposed between the spindle and the washer. The plurality of cup springs includes at least a first cup spring and a second cup spring, with the first cup spring supported on the spindle head and the second cup spring orientated substantially identical to the first cup spring and disposed directly on the first cup spring.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening and including a flat surface. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. The washer defines a bottom washer surface facing the flat surface of the spindle head, with the bottom washer surface including a flat region and a beveled region. A biasing member is disposed between the flat surface of the spindle and the flat and beveled regions of the washer. The beveled region extends oblique relative to the flat region for minimizing contact between the washer and the biasing member beyond the flat region.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening for receiving the valve shaft. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle such that the spindle is disposed between the valve body and the washer. The spindle head or the washer includes a raised lip extending towards the other of the spindle head or the washer, with the other of the spindle head or the washer defining a notch configured to at least partially receive the raised lip and configured to cooperate with the raised lip to shield the biasing member from exhaust gas and high temperatures.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening and including a flat surface. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. The washer defines a bottom washer surface facing the flat surface of the spindle head, with the bottom washer surface including a flat region and a beveled region. A biasing member is disposed between the flat surface of the spindle and the flat and beveled regions of the washer. The beveled region extends oblique relative to the flat region for minimizing contact between the washer and the biasing member beyond the flat region.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. A plurality of cup springs is disposed between the spindle and the washer. The plurality of cup springs includes at least a first cup spring and a second cup spring, with the first cup spring supported on the spindle head and the second cup spring orientated substantially identical to the first cup spring and disposed directly on the first cup spring.

Abstract: A method for enclosing a rotating assembly of a turbocharger including providing at least two bearing housing segments which together form a bearing housing including a bearing bore and an insert bore. The method can include machining complementary mating faces of the segments, machining features as required for alignment and fastening of the segments to each other, machining the bearing bore and the insert bore, and machining oil feed passages and oil drain features into at least one segment. The at least one oil feed bore is drilled from the radially inner surface of the corresponding bearing housing segment. The method can further include balancing a rotating assembly, installing the rotating assembly into one of the bearing housing segments, and joining the segments together to enclose the rotating assembly.

Abstract: A turbocharger including a rotating assembly having a compressor wheel and a turbine wheel mounted on opposite ends of a shaft. A bearing housing supports the rotating assembly and comprises at least two segments. Each segment has an opening large enough to radially receive the rotating assembly. The bearing housing segments are fastened together and a flexible seal may be provided between the segments. The bearing housing may house rolling element bearings or journal bearings, for example. The bearing housing is split axially into an upper segment and a lower segment. Alternatively, the bearing housing is split axially into a left segment and a right segment. The turbocharger may further comprise an electric motor stator disposed in the bearing housing. The bearing housing may also include a defined passageway extending around the stator and configured to receive a cooling liquid.

Abstract: The disclosure describes a compressor housing for a turbocharger system. A scroll section of a collecting volute may be defined by a wall of the compressor housing. The scroll section may extend around the axis of the compressor from an inlet of the volute to a scroll discharge stage. A plate section of the compressor housing may extend from the wall in a radial direction outward from the axis and may extend in a circumferential direction around a substantial portion of the collecting volute. The plate section may be configured to shield heat and may advantageously be formed integral with the compressor housing.

Abstract: The disclosure describes a compressor housing for a turbocharger system. A scroll section of a collecting volute may be defined by a wall of the compressor housing. The scroll section may extend around the axis of the compressor from an inlet of the volute to a scroll discharge stage. A plate section of the compressor housing may extend from the wall in a radial direction outward from the axis and may extend in a circumferential direction around a substantial portion of the collecting volute. The plate section may be configured to shield heat and may advantageously be formed integral with the compressor housing.

Abstract: A turbocharger (102, 202, 302) including a rotating assembly (114, 214, 314) having a compressor wheel (120, 220, 320) and a turbine wheel (110, 210, 310) mounted on opposite ends of a shaft (112, 212, 312). A bearing housing (160, 260, 360) supports the rotating assembly (114, 214, 314) and comprises at least two segments (189, 190; 289, 290; 389, 390). Each segment (189, 190; 289, 290; 389, 390) has an opening large enough to radially receive the rotating assembly (114, 214, 314). The bearing housing segments (189, 190; 289, 290; 389, 390) are fastened (193) together and a flexible seal may be provided between the segments. The bearing housing (160, 260, 360) may house rolling element bearings (325) or journal bearings (149), for example. The bearing housing (160, 260, 360) is split axially (101, 201, 301) into an upper segment (189, 289, 389) and a lower segment (190, 290, 390). Alternatively, the bearing housing (160, 260, 360) is split axially (101, 201, 301) into a left segment and a right segment.