Abstract: Methods, devices, and/or systems for controlling intake to and/or exhaust from an internal combustion engine. An exemplary method for controlling intake charge pressure to an internal combustion engine includes determining one or more control parameters based at least partially on an intake charge target pressure; and outputting the one or more control parameters to control an electric motor operatively coupled to a compressor capable of boosting intake charge pressure and to control a variable geometry actuator capable of adjusting exhaust flow to a turbine.

Abstract: A turbocharger comprises a center housing, and a shaft positioned therein having a first end and a second end. A turbine housing is attached to one side of the center housing and has a turbine wheel disposed therein that is coupled to the first end of the shaft. A first variable geometry member is disposed within the turbine housing between an exhaust gas inlet and the turbine wheel. A compressor housing is attached to another side of the center housing opposite the turbine housing, and includes a compressor impeller disposed therein. The compressor impeller is coupled to the second end of the shaft. A second variable geometry member is disposed within the compressor housing, and is interposed between an air outlet and the compressor impeller. An actuator assembly is disposed within the turbocharger and is connected to both of the variable geometry members to provide simultaneous actuation of the same.

Abstract: Control method for variable geometry turbocharger and related system are disclosed, wherein a boost target for a turbocharger is determined. Next, an error value between target boost and actual boost pressure is calculated and utilized to determine a new vane position. For example, the new vane position can be determined by calculating a needed change in vane position from the equation, &Dgr;&thgr;=kp(err)+kd(err)/dt, where &Dgr;&thgr; is the change in vane position, kp is a proportional gain value, kd is a differential gain value, and err is the error value between the boost target and the actual boost. A new vane position for the turbocharger is then determined by summing &Dgr;&thgr; with the previous vane position, and the turbocharger's set of vanes is positioned according to the new vane position. An open loop diagnostic mechanism and a feed-forward mechanism can also be employed to enhance vane positioning.

Abstract: Methods and systems of this invention for positioning a variable geometry member disposed within a variable geometry turbocharger involve determining a boost pressure target for the turbocharger and comparing the same to an actual boost to calculate an error value, errboost.

Abstract: A shaft seal for use with a unison ring actuator crank is disposed within a center or bearing housing of a variable nozzle turbocharger to reduce leakage of hot exhaust gas from an adjacent turbine housing. A seal ring is disposed within the turbine housing backing plate which has two differently sized diameter sections. The seal ring is positioned within a relatively larger diameter opening section and has an inside diameter sized to permit independent rotation around the shaft and an outside diameter sized to cover a relatively smaller diameter opening section. A relieved back surface directed towards the center housing such as a conical back surface that is tapered axially inwardly moving radially from the outside diameter to the inside diameter of the seal ring provides the desired sealing while not adding to the operating friction of the crank.

Abstract: A throttle loss recovery turbine and supercharger device (10) comprises a housing (12) having a movable intake port (36) and a separately movable exhaust port (38). An outer drum is rotatably placed within the housing. An inner drum (24) is rotatably disposed within the housing, and within an inside diameter of the outer drum (18). The inner drum has an axis of rotation (30) eccentric to an axis of rotation of the outer drum, defining a variable volume annular space (26) therebetween. The inner and outer drum are configured to rotate within the housing at a 1:1 ratio with one another, and the intake and exhaust ports are each in air flow communication with some portion of the annular space. A number of vanes (20) are each interposed radially between the inner and outer drums. Each vane is pivotably attached at one end (22) to the outer drum, and is attached at an opposite end to the inner drum. At least one drum is coupled to an engine crankshaft.

Abstract: Exemplary methods, devices and/or system for reducing noise produced by a turbine, such as, a turbocharger turbine. An exemplary exhaust conduit employs material to absorb exhaust-borne noise and/or structure-borne noise. Another exemplary exhaust conduit employs features that dampen wall vibration.

Abstract: Variable geometry turbochargers comprise a turbine housing having an exhaust gas inlet and outlet, a volute connected to the inlet, and a nozzle wall adjacent the volute. A turbine wheel is carried within the turbine housing and is attached to a shaft. A plurality of movable vanes are disposed within the turbine housing adjacent the nozzle wall, and are positioned between the exhaust gas inlet and turbine wheel. 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 vanes are positioned adjacent respective bypass ports such that the inlet opening for each port is at least partially covered by a respective vane depending on vane placement. The inlet opening is exposed for facilitating bypass exhaust gas flow through the turbocharger when the respective vane is actuated or moved into an open position.

Abstract: Improved vanes of this invention are constructed for use within a variable geometry turbocharger assembly. Each vane comprises an inner airfoil surface oriented adjacent a turbine wheel, and an outer airfoil surface oriented opposite the inner airfoil surface. The inner and outer airfoil surfaces define a vane airfoil thickness. Each vane includes a leading edge positioned along a first inner and outer airfoil surface junction, a trailing edge positioned along a second inner and outer surface junction, a hole disposed within a first axial vane surface substantially parallel to an outer nozzle wall for receiving a respective post therein, and an actuation tab extending from a second axial vane surface opposite from the first vane surface. A key feature of improved vanes of this invention is that they have an airfoil thickness that is greater than 0.16 times a length of the vane as measured between the vane leading and trailing edges.

Abstract: A shaft seal for use with a unison ring actuator crank is disposed within a center or bearing housing of a variable nozzle turbocharger to reduce leakage of hot exhaust gas from an adjacent turbine housing. A seal ring is disposed within the turbine housing backing plate which has two differently sized diameter sections. The seal ring is positioned within a relatively larger diameter opening section and has an inside diameter sized to permit independent rotation around the shaft and an outside diameter sized to cover a relatively smaller diameter opening section. A relieved back surface directed towards the center housing such as a conical back surface that is tapered axially inwardly moving radially from the outside diameter to the inside diameter of the seal ring provides the desired sealing while not adding to the operating friction of the crank.

Abstract: A vane and post arrangement for a variable geometry turbocharger employs vanes having a hole in a first end surface receiving a post extending from a surface of the nozzle in the turbine housing. A second end surface on each vane incorporates an extending tab which is received in a respective slot in a unison ring for rotation of the vanes on the posts upon movement of the unison ring.

Abstract: A vane and post arrangement for a variable geometry turbocharger employs vanes having a hole in a first end surface receiving a post extending from a surface of the nozzle in the turbine housing. A second end surface on each vane incorporates an extending tab which is received in a respective slot in a unison ring for rotation of the vanes on the posts upon movement of the unison ring.

Abstract: An enhanced bearing system for turbochargers incorporates a thrust collar centrally mounted on the rotating shaft interconnecting the turbine and compressor and a thrust bearing centrally located within the center housing to constrain the thrust collar. Central placement of the thrust collar allows journal bearings and journal seals to be placed immediately adjacent the turbine and compressor wheel attachment points on the shaft enhancing the shaft motion characteristics and sealing capability.

Abstract: A throttle loss recovery turbine and supercharger device (10) comprises a housing (12) having a movable intake port (36) and a separately movable exhaust port (38). An outer drum is rotatably placed within the housing. An inner drum (24) is rotatably disposed within the housing, and within an inside diameter of the outer drum (18). The inner drum has an axis of rotation (30) eccentric to an axis of rotation of the outer drum, defining a variable volume annular space (26) therebetween. The inner and outer drum are configured to rotate within the housing at a 1:1 ratio with one another, and the intake and exhaust ports are each in air flow communication with some portion of the annular space. A number of vanes (20) are each interposed radially between the inner and outer drums. Each vane is pivotably attached at one end (22) to the outer drum, and is attached at an opposite end to the inner drum. At least one drum is coupled to an engine crankshaft.

Abstract: A variable geometry turbocharger employs multiple vanes in the turbine inlet with a unison ring and integral cast wall in the turbine housing forming the nozzle walls. The unison ring incorporates actuation slots receiving tabs on the vanes for opening the closing the nozzle area upon rotation of the unison ring. An integral electrohydraulic actuator rotates the unison ring through a rack and pinion driven crank shaft with direct position feedback to the spring biased variable current solenoid via a cam on the crank shaft.

Abstract: A variable geometry system for a turbocharger includes a sliding piston disposed within a turbine housing between a primary exhaust gas volute and turbine blades. The sliding piston is axially displaceable within the turbine housing to increase or decrease the volumetric flowrate of exhaust gas to the turbine. The sliding piston is positioned by an actuator having reciprocating movement translated through a rotating sleeve with a first pin engaging a helical slot for axial motion of the piston and a second pin engaging an alignment slot for maintaining axial alignment of the piston.

Abstract: A turbocharger with an integral Exhaust Gas Recirculation system for an internal combustion engine having a compressor rotor with two sets of vanes on opposite sides of the rotor disk for compression of charge air and recirculated exhaust gas. The charge air and recirculated exhaust gas streams are segregated in the turbocharger and an inlet and an outlet volute for the recirculated exhaust gas is integral with the turbocharger center housing. A variable geometry turbine inlet is provided for exhaust backpressure and fuel air mixture control and an integral exhaust gas bypass for recirculating EGR is controlled by an integral valve mounted with the turbine housing.

Abstract: A low speed high pressure ration turbocharger incorporates a compressor impeller having impeller blades for a first stage of compression mounted on a first side of the wheel and impeller blades for a second stage of compression mounted on a second side of the wheel. Driving the dual sided compressor impeller on a common shaft from the turbine wheel allows reduction in rotational speeds while increasing compression ratio of the turbine. The scroll inlet and outlet volute for the second stage inducer are integrated with the compressor housing or other portions of the turbocharger case for compact packaging.

Abstract: A control valve for an EGR system employs a variable pressure actuator connected to a valve for metering EGR flow and a differential pressure valve connected to supply actuation pressure to the actuator. The differential pressure valve incorporates a proportional solenoid connected to a pressure balancing piston which receives EGR pressure on one side and exhaust flow pressure on the other. The piston is connected to a shaft having an orifice positionable adjacent a pressure source in a first position and a pressure vent in a second position, an outlet of the orifice communicating with the pressure actuator. EGR control is accomplished by providing a signal to the proportional solenoid which shifts the pressure balance point for the piston.

Abstract: An Exhaust Gas Recirculation system for an internal combustion engine incorporates a turbocharger having a compressor rotor with two sets of vanes on opposite sides of the rotor disk for compression of charge air and recirculated exhaust gas. The charge air and recirculated exhaust gas streams are segregated in the turbocharger and an inlet and an outlet volute for the recirculated exhaust gas is integral with the turbocharger center housing. A mixer receives the charge air downstream of the charge air cooler and mixes the recirculated exhaust gas for input into the intake manifold. A variable valve intermediate the exhaust manifold of the engine and the inlet of the turbocharger EGR inlet volute controls the amount of recirculation.