Abstract: A variable-geometry turbocharger (1) with a vane lever (11) that provides a stop function at full open position of the guide vanes (8). The integrated vane-open stop controls the full open position of the VTG mechanism. A vane lever (11) preferably has an integrated protrusion (50) that functions as a vane-open stop that contacts an adjacent vane lever (11), an integrated bolt (56), or the upper vane ring (16) at the full open position to regulate maximum exhaust gas flow to the turbine wheel (5).

Abstract: A vane pack assembly (14) for a variable turbine geometry turbocharger is a stand-alone assembly and can be assembled and transported apart from the turbocharger. The vane pack assembly (14) includes a plurality of guide vanes (16) spaced apart in a circumferential direction and a plurality of pivot centers (38). Each one of the pivot centers (38) corresponds with one of the guide vanes (16). A location of the pivot centers (38) relative to the guide vanes (16) changes as an angular position of the guide vanes (16) is adjusted.

Abstract: Turbochargers typically have separate hydrodynamic journal and thrust bearings. A turbocharger thrust bearing for a turbocharger is provided that merges the function of a journal bearing into a thrust bearing while maintaining the thrust bearing function to produce a turbocharger with a reduced axial space envelope. Such a thrust bearing includes a bore contoured to have a plurality of taper-land pairs distributed circumferentially about the bore. As a result, the axial length of the turbocharger bearing housing and shaft can be reduced.

Abstract: A system and method is provided in which a turbocharger includes a heat shield wall that is formed together with the bearing housing as a unitary structure. The wall can extend from a main body portion of the bearing housing in a generally radially outward direction. The wall can be spaced from the main body and attached by a plurality of ribs such that chambers are defined therebetween. A circumferential passage can extend through the bearing housing to permit fluid communication between the chambers and outside of the bearing housing. In this way, a fluid outlet from the chambers is provided. As a result of such an arrangement, the need for a separate heat shield is eliminated, which can facilitate the assembly process and special attachment methods associated with a separate heat shield.

Abstract: A turbocharger bearing system comprising a shaft (211) including at least one shoulder (A2) with a rotor (212) disposed on the shaft (211). First and second bearing sleeves (254) are disposed on the shaft (211) at opposite ends of the rotor (212). Each bearing sleeve (254) includes a collar (213) and a journal portion (225). A journal bearing (249) is disposed on each journal portion (225) and the journal portion (225) of the first bearing sleeve (254) abuts the shoulder (A2) of the shaft (211). In certain aspects of the technology described herein, the bearing sleeves (254) may be oriented in opposite directions. The shaft (211) is the same diameter where the bearing sleeves (254) are positioned. Accordingly, the bearing sleeves (254) may be interchangeable, as well as the journal bearings (249).

Abstract: A turbocharger (1) includes a variable turbine geometry (VTG) device (20) disposed in the turbine housing (11) adjacent to the turbine wheel (4) and configured to selectively control the amount of exhaust gas delivered to the turbine wheel (4). A geared actuating mechanism (40) connects the VTG device (20) to an actuator (30) disposed outside the turbocharger bearing housing (8). The geared actuating mechanism (40) includes an actuation pivot shaft (94) that is rotatably supported in a shaft-receiving bore (25) and connected to the VTG device (20) such that at least a portion of the geared actuating mechanism (40) is disposed externally of the housing (8). A cover (75) surrounds the actuator (30) and the geared actuating mechanism (40), and forms a sealed connection with the housing (8) such that exhaust gas passing into the shaft-receiving bore (25) is prevented from escaping to the atmosphere.

Abstract: A self-adjusting rod end (10) comprising a rod end housing (12) including a connector portion (16), a ball housing portion (14) having an opening (18), and a race insert (26) disposed in the opening (18). A rod end ball (20) is disposed in the race insert (26) and a rod end tensioner (30) is positioned to apply a force (F) against an end of the rod end ball (20). The rod end tensioner (30) includes a clip portion (32) with a spring arm (34) extending therefrom, wherein the clip portion (32) includes a pair of tangs (38) positioned to engage the connector portion (16). The spring arm (34) includes a contact tip (36) confronting the end of the rod end ball (20).

Abstract: A vane pack assembly is provided that can remove the spacers between the upper and lower vane rings to a location outside of the exhaust flow through the vane ring. In particular, the spacers are located within the vanes. Further, the assembly can effectively retain the small blocks used in varying the angle of the vanes on their associated vane pivot posts. A vane pack with such a configuration can use inexpensive parts, eliminate the need for welding of the vane pack and/or simplify the vane pack assembly process. Further, the vane pack can be decoupled from the turbine housing, thereby avoiding problems with differential thermal expansion.

Abstract: The propensity for gas leakage around a shaft, which connects volumes of differing pressures, in, e.g., a turbocharger is minimized in a simple cost-effective manner. The addition of a complementary pair of frusto-spherical, conical, or other profiles to the interface of the shaft and its bearing maintain concentricity of the shaft in its bore and thus improve the efficacy of existing sealing protocols.

Abstract: A turbocharger (10) with a liquid-cooled turbine housing (12) including an intermediate chamber (30) adjacent to the liquid chamber (20) of the turbine housing (12). The intermediate chamber (30) is between the liquid chamber (20) and a turbine housing exducer wall portion (34), partially near the turbine wheel blades. A preferred intermediate chamber (30) is a core that encloses the volute (18) and completely separates and insulates the hot volute (18) from the relatively cool liquid chamber (20). The intermediate chamber (30) may have a passage (40) as an exhaust gas inlet through the turbine housing exducer wall (24) or as an air inlet through the turbine housing (12) for flow into the intermediate chamber (30).

Abstract: A variable-geometry turbocharger (1) with a vane lever (11) that provides a stop function at full open position of the guide vanes (8). The integrated vane-open stop controls the full open position of the VTG mechanism. A vane lever (11) preferably has an integrated protrusion (50) that functions as a vane-open stop that contacts an adjacent vane lever (11), an integrated bolt (56), or the upper vane ring (16) at the full open position to regulate maximum exhaust gas flow to the turbine wheel (5).

Abstract: A vane pack assembly (14) for a variable turbine geometry turbocharger is a stand-alone assembly and can be assembled and transported apart from the turbocharger. The vane pack assembly (14) includes a plurality of guide vanes (16) spaced apart in a circumferential direction and a plurality of pivot centers (38). Each one of the pivot centers (38) corresponds with one of the guide vanes (16). A location of the pivot centers (38) relative to the guide vanes (16) changes as an angular position of the guide vanes (16) is adjusted.

Abstract: Turbochargers typically have separate hydrodynamic journal and thrust bearings. A turbocharger thrust bearing for a turbocharger is provided that merges the function of a journal bearing into a thrust bearing while maintaining the thrust bearing function to produce a turbocharger with a reduced axial space envelope. Such a thrust bearing includes a bore contoured to have a plurality of taper-land pairs distributed circumferentially about the bore. As a result, the axial length of the turbocharger bearing housing and shaft can be reduced.

Abstract: Turbochargers use actuators to control wastegate valve or VTG vane position to control turbine wheel power. Components of such actuators are susceptible to damage when exposed to foreign liquids, solids and debris. To prevent such ingress, boot seals at the actuator shaft can provide a tortuous path for air aspiration and expulsion from the volume inside the actuator boot is provided at one or more interfaces in the actuator system. Such a path can also prevent ingress of undesired liquids, solid and debris, which can affect actuator performance material. In one arrangement, a tortuous pathway is provided between a boot seal holder and another actuator component. In another arrangement, a tortuous pathway is provided between the actuator shaft and an end portion of a boot seal.

Abstract: A journal bearing, such as for a turbocharger, having an axial end face designed for improved balance of lubrication and thrust. The journal bearing axial end face is modified so that it provides thrust, yet does not easily allow oil to escape before allowing lubrication to take place between the bearing and the adjacent face.

Abstract: A self-adjusting rod end (10) comprising a rod end housing (12) including a connector portion (16), a ball housing portion (14) having an opening (18), and a race insert (26) disposed in the opening (18). A rod end ball (20) is disposed in the race insert (26) and a rod end tensioner (30) is positioned to apply a force (F) against an end of the rod end ball (20). The rod end tensioner (30) includes a clip portion (32) with a spring arm (34) extending therefrom, wherein the clip portion (32) includes a pair of tangs (38) positioned to engage the connector portion (16). The spring arm (34) includes a contact tip (36) confronting the end of the rod end ball (20).

Abstract: A turbocharger bearing system comprising a shaft (211) including at least one shoulder (A2) with a rotor (212) disposed on the shaft (211). First and second bearing sleeves (254) are disposed on the shaft (211) at opposite ends of the rotor (212). Each bearing sleeve (254) includes a collar (213) and a journal portion (225). A journal bearing (249) is disposed on each journal portion (225) and the journal portion (225) of the first bearing sleeve (254) abuts the shoulder (A2) of the shaft (211). In certain aspects of the technology described herein, the bearing sleeves (254) may be oriented in opposite directions. The shaft (211) is the same diameter where the bearing sleeves (254) are positioned. Accordingly, the bearing sleeves (254) may be interchangeable, as well as the journal bearings (249).

Abstract: A vane pack assembly is provided that can remove the spacers between the upper and lower vane rings to a location outside of the exhaust flow through the vane ring. In particular, the spacers are located within the vanes. Further, the assembly can effectively retain the small blocks used in varying the angle of the vanes on their associated vane pivot posts. A vane pack with such a configuration can use inexpensive parts, eliminate the need for welding of the vane pack and/or simplify the vane pack assembly process. Further, the vane pack can be decoupled from the turbine housing, thereby avoiding problems with differential thermal expansion.

Abstract: The propensity for gas and soot leakage around a shaft, which extends through a bore which connects volumes of differing pressures (e.g., a turbocharger turbine housing and the ambient air), is minimized by the addition of a complementary pair of narrowing sealing surfaces which provide a seal against the passage of said gases and soot. Such sealing surfaces can be frusto-spherical or frusto-conical. A biasing element is operatively positioned to exert biasing forces on one or more structures to maintain the sealing surfaces in engagement with each other to form a seal.

Abstract: A system and method is provided in which a turbocharger includes a heat shield wall that is formed together with the bearing housing as a unitary structure. The wall can extend from a main body portion of the bearing housing in a generally radially outward direction. The wall can be spaced from the main body and attached by a plurality of ribs such that chambers are defined therebetween. A circumferential passage can extend through the bearing housing to permit fluid communication between the chambers and outside of the bearing housing. In this way, a fluid outlet from the chambers is provided. As a result of such an arrangement, the need for a separate heat shield is eliminated, which can facilitate the assembly process and special attachment methods associated with a separate heat shield.