Abstract: A valve assembly for controlling exhaust gas flow to a turbine housing interior of a dual volute turbocharger includes a first valve member, a valve shaft, and a second valve member. The first valve member is disposed about and extends along an axis between a first end and a second end and is movable between a first, a second, and a third position for controlling exhaust gas flow to the turbine housing interior. The first valve member defines a valve interior between the first and second ends. The valve shaft is partially disposed in the valve interior and is coupled to the first end of the first valve member. The second valve member has a base coupled to and disposed about the valve shaft and a projection extending from the base and about the shaft into the valve interior. The second valve member is movable between closed and open positions.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening for receiving the valve shaft. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle such that the spindle is disposed between the valve body and the washer. The spindle head or the washer includes a raised lip extending towards the other of the spindle head or the washer, with the other of the spindle head or the washer defining a notch configured to at least partially receive the raised lip and configured to cooperate with the raised lip to shield the biasing member from exhaust gas and high temperatures.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. A plurality of cup springs is disposed between the spindle and the washer. The plurality of cup springs includes at least a first cup spring and a second cup spring, with the first cup spring supported on the spindle head and the second cup spring orientated substantially identical to the first cup spring and disposed directly on the first cup spring.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening and including a flat surface. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. The washer defines a bottom washer surface facing the flat surface of the spindle head, with the bottom washer surface including a flat region and a beveled region. A biasing member is disposed between the flat surface of the spindle and the flat and beveled regions of the washer. The beveled region extends oblique relative to the flat region for minimizing contact between the washer and the biasing member beyond the flat region.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening for receiving the valve shaft. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle such that the spindle is disposed between the valve body and the washer. The spindle head or the washer includes a raised lip extending towards the other of the spindle head or the washer, with the other of the spindle head or the washer defining a notch configured to at least partially receive the raised lip and configured to cooperate with the raised lip to shield the biasing member from exhaust gas and high temperatures.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle having a head defining an opening and including a flat surface. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. The washer defines a bottom washer surface facing the flat surface of the spindle head, with the bottom washer surface including a flat region and a beveled region. A biasing member is disposed between the flat surface of the spindle and the flat and beveled regions of the washer. The beveled region extends oblique relative to the flat region for minimizing contact between the washer and the biasing member beyond the flat region.

Abstract: A dual volute turbocharger for use with an internal combustion engine includes a valve for controlling exhaust gas flow to a turbine housing interior of the dual volute turbocharger. The dual volute turbocharger also includes a first volute and a second volute each adapted for fluid communication with the internal combustion engine. The dual volute turbocharger further includes a wall separating the first and second volutes and a valve seat. The valve seat and the wall collectively define a valve cavity. The valve is movable between a closed position and an open position. The valve and the wall of the turbine housing collectively define a first cross-sectional flow area. The valve and the valve seat collectively define a second cross-sectional flow area. A method of controlling the valve of the dual volute turbocharger is also disclosed.

Abstract: A system includes a dual volute turbocharger and a controller. The dual volute turbocharger includes a turbine housing. The turbine housing includes a wall, a valve seat, and an interior surface defining a turbine housing interior, a first volute, a second volute, and a turbine housing outlet. The dual volute turbocharger also includes at least one valve member engageable with at least one of the valve seat and the wall of the turbine housing. The at least one valve member and the wall of the turbine housing collectively define a first cross-sectional flow area. The at least one valve member and the valve seat of the turbine housing collectively define a second cross-sectional flow area. The controller is adapted to control the at least one valve member to have an area ratio constant operating range according to a brake-specific fuel consumption of the internal combustion engine.

Abstract: A wastegate assembly for controlling flow of exhaust gas includes a valve element having a valve body and a valve shaft. The wastegate assembly further includes a spindle. The wastegate assembly further includes a washer coupled to the valve shaft and spaced from the spindle for securing the spindle to the valve shaft. A plurality of cup springs is disposed between the spindle and the washer. The plurality of cup springs includes at least a first cup spring and a second cup spring, with the first cup spring supported on the spindle head and the second cup spring orientated substantially identical to the first cup spring and disposed directly on the first cup spring.

Abstract: A valve assembly for controlling exhaust gas flow to a turbine housing interior of a dual volute turbocharger includes a first valve member, a valve shaft, and a second valve member. The first valve member is disposed about and extends along an axis between a first end and a second end and is movable between a first, a second, and a third position for controlling exhaust gas flow to the turbine housing interior. The first valve member defines a valve interior between the first and second ends. The valve shaft is partially disposed in the valve interior and is coupled to the first end of the first valve member. The second valve member has a base coupled to and disposed about the valve shaft and a projection extending from the base and about the shaft into the valve interior. The second valve member is movable between closed and open positions.

Abstract: A dual volute turbocharger for use with an internal combustion engine includes a valve for controlling exhaust gas flow to a turbine housing interior of the dual volute turbocharger. The dual volute turbocharger also includes a first volute and a second volute each adapted for fluid communication with the internal combustion engine. The dual volute turbocharger further includes a wall separating the first and second volutes and a valve seat. The valve seat and the wall collectively define a valve cavity. The valve is movable between a closed position and an open position. The valve and the wall of the turbine housing collectively define a first cross-sectional flow area. The valve and the valve seat collectively define a second cross-sectional flow area. A method of controlling the valve of the dual volute turbocharger is also disclosed.

Abstract: A system includes a dual volute turbocharger and a controller. The dual volute turbocharger includes a turbine housing. The turbine housing includes a wall, a valve seat, and an interior surface defining a turbine housing interior, a first volute, a second volute, and a turbine housing outlet. The dual volute turbocharger also includes at least one valve member engageable with at least one of the valve seat and the wall of the turbine housing. The at least one valve member and the wall of the turbine housing collectively define a first cross-sectional flow area. The at least one valve member and the valve seat of the turbine housing collectively define a second cross-sectional flow area. The controller is adapted to control the at least one valve member to have an area ratio constant operating range according to a brake-specific fuel consumption of the internal combustion engine.