Abstract: A bearing assembly installed within a turbocharger housing between a turbine wheel and a compressor impeller mounted for rotation together on a turbocharger shaft may include a journal bearing disposed on a corresponding portion of the turbocharger shaft, a thrust bearing having a thrust bearing surface, and a bearing carrier. The bearing carrier may include a carrier body, a carrier body bore extending axially through the carrier body and receiving the journal bearing therein, and a thrust bearing seat on the exterior of the carrier body facing the turbine wheel. The thrust bearing seat may have a complimentary shape to the thrust bearing surface of the thrust bearing, the thrust bearing disposed between the carrier body and the turbine wheel and engaging the thrust bearing seat. The bearing assembly may further include an anti-thrust bearing surface facing the compressor impeller, and an anti-thrust bearing mounted to the anti-thrust bearing surface.

Abstract: A bearing support for a turbocharger, the bearing support including a body, a bore extending axially through the body and dimensioned to receive a bearing and a portion of a planet carrier, and a plurality of pilots. Each pilot may be formed on an external surface of the body, and each pilot may be machined for an interference fit with a different component of the turbocharger.

Abstract: An impeller attach mechanism for a turbocharger including a stud extending from a central bore of a compressor impeller toward a turbine wheel, the stud having a first threaded region and a second threaded region; a shaft coupled to the turbine wheel and extending toward the compressor impeller, the shaft having a leading portion, the leading portion having a threaded interior configured to engage the second threaded region of the stud; and an insert having an internal portion and an external portion, the internal portion having a threaded external surface to engage the compressor impeller, the internal portion having a threaded internal surface to engage the first threaded region of the stud, the external portion configured to surround the leading portion of the shaft.

Abstract: Disclosed is a compressor housing and method of assembling. The compressor housing may comprise an outer volute, a cavity, an impeller cover, a compressor diffuser and an inner volute. The outer volute includes a back wall and a curved casing. The back wall may include a receptacle and a first plurality of annular steps. The receptacle configured to receive an alignment pin. The cavity is configured to receive the compressor impeller and is at least partially defined by the back wall of the outer volute and the impeller cover. The impeller cover is configured to fragment during impact with the compressor impeller during a failure condition of the compressor impeller. The impeller cover is disposed between the inner volute and the cavity. The compressor diffuser is disposed between the back wall and the impeller cover.

Abstract: A bearing support for a turbocharger, the bearing support including a body, a bore extending axially through the body and dimensioned to receive a bearing and a portion of a planet carrier, and a plurality of pilots. Each pilot may be formed on an external surface of the body, and each pilot may be machined for an interference fit with a different component of the turbocharger.

Abstract: An impeller attach mechanism for a turbocharger including a stud extending from a central bore of a compressor impeller toward a turbine wheel, the stud having a first threaded region and a second threaded region; a shaft coupled to the turbine wheel and extending toward the compressor impeller, the shaft having a leading portion, the leading portion having a threaded interior configured to engage the second threaded region of the stud; and an insert having an internal portion and an external portion, the internal portion having a threaded external surface to engage the compressor impeller, the internal portion having a threaded internal surface to engage the first threaded region of the stud, the external portion configured to surround the leading portion of the shaft.

Abstract: Disclosed is a compressor housing and method of assembling. The compressor housing may comprise an outer volute, a cavity, an impeller cover, a compressor diffuser and an inner volute. The outer volute includes a back wall and a curved casing. The back wall may include a receptacle and a first plurality of annular steps. The receptacle configured to receive an alignment pin. The cavity is configured to receive the compressor impeller and is at least partially defined by the back wall of the outer volute and the impeller cover. The impeller cover is configured to fragment during impact with the compressor impeller during a failure condition of the compressor impeller. The impeller cover is disposed between the inner volute and the cavity. The compressor diffuser is disposed between the back wall and the impeller cover.

Abstract: A bearing assembly installed within a turbocharger housing between a turbine wheel and a compressor impeller mounted for rotation together on a turbocharger shaft may include a journal bearing disposed on a corresponding portion of the turbocharger shaft, a thrust bearing having a thrust bearing surface, and a bearing carrier. The bearing carrier may include a carrier body, a carrier body bore extending axially through the carrier body and receiving the journal bearing therein, and a thrust bearing seat on the exterior of the carrier body facing the turbine wheel. The thrust bearing seat may have a complimentary shape to the thrust bearing surface of the thrust bearing, the thrust bearing disposed between the carrier body and the turbine wheel and engaging the thrust bearing seat. The bearing assembly may further include an anti-thrust bearing surface facing the compressor impeller, and an anti-thrust bearing mounted to the anti-thrust bearing surface.

Abstract: A turbine assembly for a turbocharger and method of assembling is disclosed. The turbine assembly may comprise a turbine wheel coupled to a rotatable turbocharger shaft, and a turbine housing that at least partially encloses the turbine wheel. The turbine housing may include an exhaust diffuser configured to direct a flow of exhaust, a support member coupled to the exhaust diffuser by a clamp assembly, the clamp assembly, a diffuser gap and a support gap. The clamp assembly may be disposed on the exhaust diffuser and on the support member. The clamp assembly includes a containment ring and a clamp plate. The containment ring may include a channel. The clamp plate may be disposed in the channel. The diffuser gap may be disposed between the containment ring and the exhaust diffuser. The support gap may be disposed between the containment ring and the support member.

Abstract: A compressor housing for a turbocharger may include an outer volute having an outer volute inner surface with a clamp groove defined therein, and an inner volute having an inner volute outer surface and an axially facing surface. The inner volute is inserted into the outer volute through the outer volute inner surface with the inner volute outer surface facing the outer volute inner surface. The inner volute is positioned with the axially facing surface disposed axially inward of the clamp groove. A clamp plate includes a radially outward portion inserted into the clamp groove and a radially inward portion extending downward past the inner volute outer surface. The clamp groove and the axially facing surface engage the clamp plate to retain the inner volute within the outer volute when an axial load is applied to the inner volute.

Abstract: A turbocharger variable speed control mechanism for a turbocharger for an engine includes a sun gear of a planetary gear set coupled to a turbocharger shaft, a planet carrier operatively connected to an engine output shaft of the engine, a brake disk coupled to and rotatable with a ring gear, and a brake actuator mechanism proximate the brake disk and mounted to a turbocharger housing. The brake actuator mechanism is selectively actuatable between a non-braking state where no braking force is applied to the brake disk so that the ring gear is free to rotate relative to the turbocharger housing, and a full braking state where a full braking force is applied to the brake disk such that the ring gear is held stationary relative to the turbocharger housing and rotation of the planet carrier is transmitted through the planetary gear set to cause rotation of the turbocharger shaft.

Abstract: A turbocharger variable speed control mechanism for a turbocharger for an engine includes a sun gear of a planetary gear set coupled to a turbocharger shaft, a planet carrier operatively connected to an engine output shaft of the engine, a brake disk coupled to and rotatable with a ring gear, and a brake actuator mechanism proximate the brake disk and mounted to a turbocharger housing. The brake actuator mechanism is selectively actuatable between a non-braking state where no braking force is applied to the brake disk so that the ring gear is free to rotate relative to the turbocharger housing, and a full braking state where a full braking force is applied to the brake disk such that the ring gear is held stationary relative to the turbocharger housing and rotation of the planet carrier is transmitted through the planetary gear set to cause rotation of the turbocharger shaft.

Abstract: A compressor inlet recirculation system is disclosed. The compressor inlet recirculation system may have a compressor housing. The compressor inlet recirculation system may also have a compressor impeller disposed within the compressor housing. The compressor inlet recirculation system may further have an inlet flow guide attached to the compressor housing. The inlet flow guide may be configured to direct air to the compressor impeller. The inlet flow guide may have an inlet slot and an outlet slot spaced axially from the inlet slot. The compressor inlet recirculation system may also have an annular air passage extending between the inlet slot and the outlet slot.

Abstract: A compressor assembly is disclosed. The compressor assembly may have a compressor housing and a compressor impeller disposed within the compressor housing. The compressor impeller may have a hub extending from a hub front end to a hub rear end and an exducer blade disposed on the hub adjacent the hub rear end. The compressor impeller may further include a hub extension extending outward from the hub rear end. The compressor assembly may also have an impeller cap disposed on the hub extension. Further, the compressor assembly may have a windage seal disposed on the impeller cap. The windage seal may be separated from a blade rear surface by an axial gap. In addition, the compressor assembly may have a compressor diffuser disposed within the compressor housing. The compressor diffuser may have a diffuser inner surface separated from an outer rim of the exducer blade by a radial gap.

Abstract: An engine system is disclosed. The engine system may have an engine having an accessory end and a drive end opposite the accessory end. The engine system may also have a turbocharger arrangement located adjacent the accessory end. The turbocharger arrangement may be configured to receive exhaust from the engine and to deliver compressed air to the air cooling arrangement. Further, the engine system may have an air cooling arrangement located adjacent the accessory end and configured to deliver fresh air to the engine. In addition, the engine system may have a mixing duct extending from the accessory end to the drive end and configured to receive the exhaust from the turbocharger arrangement. The engine system may also have an after-treatment system located adjacent the drive end. The after-treatment system may be configured to receive the exhaust from the mixing duct and to discharge the exhaust to an ambient.

Abstract: A compressor impeller assembly is disclosed. The compressor impeller assembly may have a compressor impeller having an impeller bore. The compressor impeller assembly may further have an insert screwed into the impeller bore, the insert having a threaded insert bore. The compressor impeller assembly may also have a shaft having a threaded shaft bore. In addition, the compressor impeller assembly may have a stud. The stud may have a first threaded portion engaged with the threaded insert bore. The stud may also have a second threaded portion engaged with the threaded shaft bore.

Abstract: A turbine bearing and seal assembly is disclosed. The turbine bearing and seal assembly may have a turbine cartridge. The turbine cartridge may have a compressor end and a turbine end opposite the compressor end. The turbine bearing and seal assembly may also have a bearing attached to the turbine cartridge. The bearing may be disposed between the compressor end and the turbine end. The turbine bearing and seal assembly may further have a seal collar attachable to a shaft. The seal collar may be disposed within the turbine cartridge adjacent the turbine end.

Abstract: A turbine housing support is disclosed. The turbine housing support may have a flange. The flange may be configured to connect at least a pair of turbocharger components. The turbine housing support may also have a first column extending outward from a first location on a side surface of the flange. The first column may be disposed on a first side of the flange. The turbine housing support may also have a second column extending outward from a second location on the side surface of the flange. The second column may be disposed on a second side of the flange opposite the first side.

Abstract: A turbine housing assembly is disclosed. The turbine housing assembly may have a turbine housing. The turbine housing may have a turbine housing flange. The turbine housing assembly may also have a bearing housing having a boss extending from a compressor end to a turbine end opposite the compressor end. The bearing housing may also have a bearing housing flange abutting on the turbine housing flange. The bearing housing flange may be disposed between the compressor end and the turbine end. The turbine housing assembly may also have a clamping plate abutting on the turbine housing flange and the boss. Further the turbine housing assembly may have a backing plate abutting on the clamping plate. In addition, the turbine housing assembly may have a fastener disposed within the boss and attached to the backing plate.

Abstract: A bypass mechanism is disclosed for use with a turbocharger. The bypass mechanism may have an exhaust passage formed by at least a first wall, and a bypass manifold formed by at least a second wall surrounding the exhaust passage and including a space between the first wall and the second wall. The bypass mechanism may further have at least one opening in the first wall fluidly connecting the exhaust passage with the space. At least one valve is configured to open and close the opening to selectively allow exhaust gas to pass from the exhaust passage to the space through the at least one opening. The space may be fluidly connected to at least one entry passage of an exhaust stack. In addition, the at least one opening and the at least one entry passage may be positioned on opposite sides of the exhaust passage.