Abstract: A turbocharger includes a compressor, a turbine, a shaft coupling the compressor to the turbine, and a turbo casing configured to improve pressure recovery and reduce energy loss from exhaust flow. In one embodiment, the turbo casing may include a geometry configured to improve exhaust flow towards an exhaust outlet. The turbo casing may include a torus shaped chamber having a cross-sectional area that progressively increases in an annular direction of the flow towards the exhaust outlet.

Abstract: A turbocharger system, in certain embodiments, includes a compressor, a turbine, a shaft of common diameter coupling the compressor to the turbine, and a first fluid film bearing disposed about the shaft at a compressor end portion of the shaft. The system also includes a second fluid film fixed pad bearing disposed about the shaft at a turbine end portion of the shaft, wherein the first and second fluid film fixed pad bearings have different clearance ratios, effective lengths, or both, relative to one another. The system, in some embodiments, includes a compressor fluid film fixed pad bearing and a turbine fluid film fixed pad bearing, wherein the compressor and turbine fluid film fixed pad bearings have different clearance ratios and effective lengths, relative to one another.

Abstract: A turbine system for a multistage turbocharger and a method for utilizing the same are disclosed. The turbine system includes a high pressure turbine having an inlet for receiving a flow of fluid, and an outlet for passing the flow on extraction of work from the high pressure turbine. The system further includes a low pressure turbine, having an inlet for receiving a flow of fluid from the high pressure turbine. A diffuser connects the outlet of the high pressure turbine and the inlet of the low pressure turbine. The system also includes a bypass channel for bypassing a portion of the flow around the high pressure turbine, from upstream of the high pressure turbine to downstream of the high pressure turbine. The system includes an injector to input the bypass flow in the diffuser in a manner to reduce flow separation in the diffuser.

Abstract: A system is provided for monitoring radial motion of a rotating shaft of a turbocharger. The turbocharger includes a compressor and a turbine coupled to opposing ends of the shaft. The system includes a thrust collar including a cylindrical portion and a flange configured to radially extend from one end of the cylindrical portion. The thrust collar is configured to rotate with the shaft. A sensor is positioned within a separation of an outer surface of the thrust collar flange, and the sensor is configured to monitor the separation as indicative of the radial motion of the shaft. Additionally, a method is provided for monitoring radial motion of a rotating shaft of a turbocharger.

Abstract: A turbocharger system, in certain embodiments, includes a compressor, a turbine, a shaft coupling the compressor to the turbine, and a turbo casing configured to improve pressure recovery, wherein the turbo casing includes a non symmetrical geometry configured to improve flow towards an exhaust outlet.

Abstract: A turbocharger system, in certain embodiments, includes a compressor, a turbine, a shaft of common diameter coupling the compressor to the turbine, and a first fluid film bearing disposed about the shaft at a compressor end portion of the shaft. The system also includes a second fluid film fixed pad bearing disposed about the shaft at a turbine end portion of the shaft, wherein the first and second fluid film fixed pad bearings have different clearance ratios, effective lengths, or both, relative to one another. The system, in some embodiments, includes a compressor fluid film fixed pad bearing and a turbine fluid film fixed pad bearing, wherein the compressor and turbine fluid film fixed pad bearings have different clearance ratios and effective lengths, relative to one another.

Abstract: A system is provided for monitoring radial motion of a rotating shaft of a turbocharger. The turbocharger includes a compressor and a turbine coupled to opposing ends of the shaft. The system includes a thrust collar including a cylindrical portion and a flange configured to radially extend from one end of the cylindrical portion. The thrust collar is configured to rotate with the shaft. A sensor is positioned within a separation of an outer surface of the thrust collar flange, and the sensor is configured to monitor the separation as indicative of the radial motion of the shaft. Additionally, a method is provided for monitoring radial motion of a rotating shaft of a turbocharger.

Abstract: Disclosed herein are turbocharger systems and methods for their operation. In one embodiment a turbocharger system is disclosed. The turbocharger system comprises a turbine, a compressor, an air inlet, a first sensor, a second sensor, and a controller. The turbine is mechanically connected to the compressor and the air inlet is connected in fluid communication to the compressor. The first sensor and the second sensor are connected in operational communication with the air inlet and disposed a sufficient distance from one another to be capable of measuring a temperature differential caused by a hot boundary layer. The controller is connected in operational communication with the first sensor and the second sensor, and the controller is configured to detect surge precursors.

Abstract: A diffuser (30) for a centrifugal compressor (60) having a flow slot (34) formed between the leading edge portion (36) of a diffuser vane (32) and an adjoining diffuser wall (70) for the passage of working fluid (67) over the vane from the pressure side ((40) to the suction side (42) of the vane. The portion (38) of the working fluid passing over the vane is injected into the flow boundary region (43), thereby minimizing the growth of a flow separation zone (58) along the suction side.

Abstract: Compressor wheel and techniques for manufacturing such a wheel are provided. The wheel may include a hub with a counterbore internally treated to impart residual compressive stresses for enhanced endurance to stress-induced fatigue. The surface treatment allows extending the counterbore relatively closer to a plane of typical maximum stress of the wheel. This design flexibility advantageously allows avoiding or reducing overhang of the compressor wheel, thereby improving rotor dynamics and reducing the axial length of the hub, and the overall foot print of the compressor wheel.