Abstract: A turbocharger rotor includes a turbine wheel, a compressor wheel, a shaft extending between the turbine and compressor wheels for rotation together about an axis, and connecting means including two pairs of non-locking cones. In a preferred embodiment, the cones include external cones on the turbine and compressor wheels and internal cones on the ends of the shaft. The non-locking cones are centered on the axis with the external and internal cones drivingly engaging one another to align and connect the wheels with the shaft. A long bolt fastener extends through the compressor wheel and the shaft to engage the turbine wheel and hold the rotor components in assembly. An alternative embodiment includes engaging radial surfaces outward of the cones. The radial surfaces share the transmission of torque through the connecting means and assist in stabilizing the joints between the shaft and the connected wheels. Additional features are disclosed.

Abstract: An improved turbocharger for railway locomotive sized engines includes, in a preferred embodiment, first and second axially spaced ball bearings supporting a rotor with the first bearing being a hybrid ceramic ball bearing mounted to accept both radial and axial loads acting on the shaft at the compressor end. The first bearing is mounted on a reduced diameter portion of the shaft, providing reduced bearing diameter to acceptably limit centrifugal loading of ceramic balls in the bearing against a surrounding bearing race. The first bearing has dual rows of ceramic ball bearings mounted to share all axial thrust loads on the shaft. The second bearing is also a ball bearing. Lubrication of the bearings is preferably by direct impingement on the inner race to minimize oil churning causing heating and power loss. Additional features and advantages are disclosed.

Abstract: An improved turbocharger for railway locomotive sized engines includes, in a preferred embodiment, first and second axially spaced ball bearings supporting a rotor with the first bearing being a hybrid ceramic ball bearing mounted to accept both radial and axial loads acting on the shaft at the compressor end. The first bearing is mounted on a reduced diameter portion of the shaft, providing reduced bearing diameter to acceptably limit centrifugal loading of ceramic balls in the bearing against a surrounding bearing race. The first bearing has dual rows of ceramic ball bearings mounted to share all axial thrust loads on the shaft. The second bearing is also a ball bearing. Lubrication of the bearings is preferably by direct impingement on the inner race to minimize oil churning causing heating and power loss. Additional features and advantages are disclosed.

Abstract: A turbocharger rotor includes a turbine wheel, a compressor wheel, a shaft extending between the turbine and compressor wheels for rotation together about an axis, and connecting means. The connecting means include first and second joints including alignment couplings joining opposite ends of the shaft with adjoining inner ends of the compressor wheel and the turbine wheel. The couplings are configured to coaxially align and drivingly engage the shaft with the compressor and turbine wheels. A fastener rod extends through the shaft and the compressor wheel, engaging the turbine wheel to retain the rotor components together under compressive load. The rod is resiliently stretchable to limit changes in the retaining force changes in axial dimensions during operating and stationary conditions. Additional features and variations are disclosed.