Abstract: A method of assembling and retaining a noise attenuation device (30) within an air inlet (16) of a compressor cover (12) includes inserting the noise attenuation device (30) into the air inlet (16) and applying a rolling compressive force to the air inlet (16) using a forming tool (40). As a result, the air inlet terminal end (17) is deformed radially inward so as to form a radially-inwardly protruding lip (17b) about the air inlet terminal end (17). The radially-inwardly protruding lip (17b) is configured to retain the noise attenuation device (30) within the air inlet (16). The forming tool (40) used to form the radially-inwardly protruding lip (17b) is also described.

Abstract: A turbine (32) section of a turbocharger (30) includes a turbine wheel (37) disposed in a turbine housing (33), the turbine housing (33) defining a gas inlet (34), a volute configured to direct gas from the inlet (34) to the turbine (32) wheel, and a gas outlet. A rotary diverter valve (100, 200) is disposed in the gas inlet (34) upstream of the volute, and provides three modes of controlling exhaust gas flow about the turbocharger (30).

Abstract: A turbine (32) section of a turbocharger (30) includes a turbine wheel (37) disposed in a turbine housing (33), the turbine housing (33) defining a gas inlet (34), a volute configured to direct gas from the inlet (34) to the turbine (32) wheel, and a gas outlet. A rotary diverter valve (100, 200) is disposed in the gas inlet (34) upstream of the volute, and provides three modes of controlling exhaust gas flow about the turbocharger (30).

Abstract: A turbocharger (1) includes a compressor wheel (50) disposed in a compressor housing (12), a turbine wheel (40) disposed in a turbine housing (11), and a shaft (60) that connects the compressor wheel (50) to the turbine wheel (40). The shaft (60) includes a journal portion (63) that adjoins one end and supports journal bearings (7a, 7b), a thrust portion (64) that adjoins the journal portion (63) that supports a thrust bearing (20), a connection portion (66) that adjoins the thrust portion (64) that has surface features (72) formed on an outer surface thereof, and a guide portion (69) that adjoins the connection portion (66). The guide portion (69) and the connection portion (66) are received within a blind bore (58) of the compressor wheel (50) and are configured to connect the shaft (60) to the compressor wheel (50).

Abstract: A vane pack for a VTG turbocharger is provided. The vane pack includes a plurality of vanes pivotably positioned between an inner surface of an upper vane ring and an inner surface of a lower vane ring. Clearances are defined between opposing cheek surfaces of the vanes and the inner surfaces of the vane rings. The vane pack is configured to minimize these clearances by applying an abradable coating is to the inner surface of the upper vane ring, the inner surface of the lower vane ring and/or cheek surface(s) of one or more of the vanes. In this way, an essentially zero clearance can be established without interfering with the proper function of the vanes. As a result, there can be gains in efficiency. Further wearing of the abradable coating may occur during turbocharger operation.

Abstract: A turbocharger compressor noise attenuation device (60, 160) is formed separately from the air inlet (16) of the compressor housing (12). The device (60) includes a tapered inner surface (66) having a minimum diameter portion (62) that is axially spaced apart from a first end face (50), a maximum diameter portion (64) that is between the minimum diameter portion (62) an opposed second end (48), and an annular groove (72) formed in a working face (74) of the minimum diameter portion that is parallel to the first end face (50).

Abstract: An axial compressor (30) is disposed upstream from a compressor wheel (16), and may be mounted in the inlet pipe (32) of a compressor housing (26) of a turbocharger (10). The axial compressor (30) can increase the pressure ratio approximately 1.3. The axial compressor (30) can be driven by a motor (40), such as a magnetic stepper, servo and squirrel cage motor. The axial compressor may have a fan (34) where boost can be controlled by speed of the fan (34), which can be accelerated or decelerated depending on use conditions. A magnetic stepper motor (40) can drive the fan (34) with a fan wheel (36) having magnets (44) associated with energizeable coils (42) that make a rotating magnetic field that the magnets (44) can follow.

Abstract: A method of assembling and retaining a noise attenuation device (30) within an air inlet (16) of a compressor cover (12) includes inserting the noise attenuation device (30) into the air inlet (16) and applying a rolling compressive force to the air inlet (16) using a forming tool (40). As a result, the air inlet terminal end (17) is deformed radially inward so as to form a radially-inwardly protruding lip (17b) about the air inlet terminal end (17). The radially-inwardly protruding lip (17b) is configured to retain the noise attenuation device (30) within the air inlet (16). The forming tool (40) used to form the radially-inwardly protruding lip (17b) is also described.

Abstract: A vane pack for a VTG turbocharger is provided. The vane pack includes a plurality of vanes pivotably positioned between an inner surface of an upper vane ring and an inner surface of a lower vane ring. Clearances are defined between opposing cheek surfaces of the vanes and the inner surfaces of the vane rings. The vane pack is configured to minimize these clearances by applying an abradable coating is to the inner surface of the upper vane ring, the inner surface of the lower vane ring and/or cheek surface(s) of one or more of the vanes. In this way, an essentially zero clearance can be established without interfering with the proper function of the vanes. As a result, there can be gains in efficiency. Further wearing of the abradable coating may occur during turbocharger operation.