Abstract: A tamperproof and calibration device comprises an adjusting member for adjusting the position of a first element in respect to a second element in a direction which is different from another direction in which a fixing member acts for fixation of the first element with respect to the second element. The tamperproof and calibration device is applicable to a turbocharger comprising a variable nozzle device coupled with an actuated member to be actuated by an actuator, wherein the tamperproof and calibration device connects the actuated member with the actuator for calibration of the relative position of the actuated member of the variable nozzle device with respect to a predetermined position of the actuator.

Abstract: A variable-vane cartridge mechanism for a turbocharger is assembled from a nozzle ring, an insert that engages a turbine housing bore, and a plurality of spacers. Holes larger in diameter than the spacers are formed in the nozzle ring and a nozzle portion of the insert, such that the spacers fit loosely in the holes. A locating fixture is engaged with the nozzle ring and insert for precisely locating these parts radially (and optionally also axially) with respect to each other; the spacers can move within the holes as needed to allow the positions of the parts to be adjusted. Once located relative to each other, the nozzle ring and insert are fixed in the desired relative positions by affixing the spacers to them, such as by welding.

Abstract: A turbocharger turbine containing a separate insert affixed within the housing. The insert is of a stamped metal configuration, and forms at least a portion of inlet passageway outer wall. An axial discontinuity is machined into the inlet passageway outer wall, the axial discontinuity being characterized by a size and location to direct airflow away from the blade-gap zone over at least part of the range of flow conditions. The inlet passageway may be either larger or smaller upstream of the axial discontinuity.

Abstract: A turbocharger with a variable nozzle includes a pin mounted in the center housing and extending axially therefrom and engaged in a hole in the nozzle ring to orient the nozzle ring rotationally relative to the center housing. A portion of a length of the pin has a substantially greater compliance than the remainder of the length such that the pin has a flexible tip that engages the hole in the nozzle ring. The flexible tip reduces constraint of thermal deformation of the nozzle ring. The pin portion of greater compliance can be a section of the tube that is slit and expanded. The turbocharger can also include a one-piece locator and heat shield having a locating portion abutting the center housing and the nozzle ring for radially locating the nozzle ring relative to the center housing, and having a shield portion shielding the center housing from hot exhaust gas.

Abstract: A variable nozzle device including an annular nozzle passage formed by a gap between two opposing wall members and at least one vane rotatably supported in the nozzle passage. The vane is formed by a strip of sheet metal contoured to have an outer aerodynamic profile, and having a hollow interior with surfaces mimicking the outer profile. The vane is affixed to a shaft having a wind-stream portion forming two contact surfaces that conformingly receive opposing portions of the interior surfaces.

Abstract: A tamperproof and calibration device comprises an adjusting member for adjusting the position of a first element in respect to a second element in a direction which is different from another direction in which a fixing member acts for fixation of the first element with respect to the second element. The tamperproof and calibration device is applicable to a turbocharger comprising a variable nozzle device coupled with an actuated member to be actuated by an actuator, wherein the tamperproof and calibration device connects the actuated member with the actuator for calibration of the relative position of the actuated member of the variable nozzle device with respect to a predetermined position of the actuator.

Abstract: A variable-nozzle turbocharger includes a turbine housing and a center housing, and a generally annular nozzle ring and an array of vanes rotatably mounted to the nozzle ring such that the vanes are rotatably adjustable for regulating exhaust gas flow to the turbine wheel. An elastically deformable member is disposed between a radially inwardly facing surface of the nozzle ring and a radially outwardly facing surface of the center housing, the elastically deformable member having a radially inner surface contacting the radially outwardly facing surface of the center housing and having a radially outer surface contacting the radially inwardly facing surface of the nozzle ring so as to radially center the nozzle ring relative to the center housing.

Abstract: A variable-nozzle turbocharger includes a cartridge containing a variable vane mechanism connected between the center housing and the turbine housing. The cartridge comprises an annular nozzle ring supporting an array of rotatable vanes, an insert having a tubular portion sealingly received into the bore of the turbine housing and having a nozzle portion extending radially out from one end of the tubular portion and being axially spaced from the nozzle ring with the vanes therebetween, and a plurality of spacers connected between the nozzle portion of the insert and the nozzle ring. The turbine housing has a surface that directly contacts a surface of the nozzle ring that axially faces the insert for axially locating the nozzle ring relative to the turbine housing. A radial gap is defined between the turbine housing and the nozzle ring to allow radial movement of the nozzle ring relative to the turbine housing.

Abstract: An improved actuating rod end connector is connected with an actuating rod that extends from a turbocharger assembly actuator mechanism. The rod end connector has a body with an opening at one longitudinal end, and the actuator rod is disposed through the opening. An adjustment member is rotatably disposed within the body and has a threaded inside cavity in communication with the opening. The inside cavity is threadably engaged with a threaded outside surface of the actuator rod. The body includes an actuator rod opening disposed therethrough adjacent the adjustment member to receive a section of the actuator rod therein to facilitate contacting the actuator rod disposed within the body from outside of the rod end connector. An attachment opening is disposed through the body to facilitate attachment of the rod end connector with a linkage member, e.g., a linkage member connected with a movable member of the turbocharger.

Abstract: Disclosed are retainers for a turbocharger. In one embodiment, the retainer includes a generally annular body that defines a bore and one or more channels. The bore is generally directed along a central axis of the body and can be configured to mate with a nose of a center housing of a turbocharger. The channels can be configured to accommodate vanes associated with a cartridge assembly of the turbocharger. One or more legs may extend from the retainer body and may be configured to mate with and locate the retainer relative to a cartridge assembly for the turbocharger. The retainer can also include a concave portion disposed around a perimeter of the body. The concave portion and the body may be together configured to act as a spring when the retainer is mechanically loaded in a direction having a component parallel to the central axis. Also disclosed are corresponding turbochargers.

Abstract: A variable nozzle device (1) for a turbocharger comprises an annular nozzle (3) formed between an inner wall (11) and an outer wall (10), and an annular arrangement of adjustable vanes (4) interposed in the nozzle (3) for defining a plurality of nozzle passages, wherein the nozzle (3) is adjustable by controllably adjusting the vanes (4) and by controllably varying an axial clearance between the outer wall (10) and the vanes (4).

Abstract: A variable-vane cartridge mechanism for a turbocharger is assembled from a nozzle ring, an insert that engages a turbine housing bore, and a plurality of spacers. Holes larger in diameter than the spacers are formed in the nozzle ring and a nozzle portion of the insert, such that the spacers fit loosely in the holes. A locating fixture is engaged with the nozzle ring and insert for precisely locating these parts radially (and optionally also axially) with respect to each other; the spacers can move within the holes as needed to allow the positions of the parts to be adjusted. Once located relative to each other, the nozzle ring and insert are fixed in the desired relative positions by affixing the spacers to them, such as by welding.

Abstract: A vane assembly includes vanes each having an axle and an arm immovably connected with the vane prior to assembling the vane assembly. The vane, axle, and arm can be an integral one-piece structure formed by casting, machining, or metal injection molding. The axles engage apertures in a nozzle ring and are rotatable in the apertures about axes of the vanes. An actuator ring is assembled with the nozzle ring and is rotatable relative thereto. The actuator ring defines connecting elements that connect with cooperative connecting elements on the vane arms. Rotation of the actuator ring causes the vanes to rotate for adjusting the angles of the vanes. During assembly, the motion of inserting the axles into the apertures is also effective for placing the arms in position for connection with the actuator ring.