Abstract: A variable-vane assembly has a nozzle ring supporting an array of pivotable vanes, and a unison ring for pivoting the vanes in unison. A crank mechanism rotatably drives the unison ring, and includes an external crank assembly positioned radially outward of the unison ring, a non-round drive block disposed in a non-round recess in an outer periphery of the unison ring, and a crank arm having a forked end connected to the drive block and an opposite end connected to the external crank assembly. The forked end defines two legs and the drive block is disposed between the legs and is pivotally connected to the legs such that the drive block is pivotable relative to the crank arm about a pivot axis. The crank mechanism is arranged such that the crank arm is caused to swing through an arc of movement, thereby rotating the unison ring.

Abstract: A variable-vane assembly has a nozzle ring supporting an array of pivotable vanes, and a unison ring for pivoting the vanes in unison. A crank mechanism rotatably drives the unison ring, and includes an external crank assembly positioned radially outward of the unison ring, a non-round drive block disposed in a non-round recess in an outer periphery of the unison ring, and a crank arm having a forked end connected to the drive block and an opposite end connected to the external crank assembly. The forked end defines two legs and the drive block is disposed between the legs and is pivotally connected to the legs such that the drive block is pivotable relative to the crank arm about a pivot axis. The crank mechanism is arranged such that the crank arm is caused to swing through an arc of movement, thereby rotating the unison ring.

Abstract: A method of assembling a crank arm (100, 200, 300) and vane assembly for a variable nozzle without requiring metallurgical bonding. In accordance with one aspect of the invention, the method comprises the steps of providing a vane assembly comprising a vane (120, 220, 320) joined to a vane shaft (110, 210, 310) that extends from the vane and terminates in a distal end (112, 212, 312), providing a recess (114, 214, 314) in an outer surface of the vane shaft at a location between the vane and the distal end, providing a crank arm (100, 200, 300) having an aperture (102, 202, 302) therein, inserting the distal end (112, 212, 312) of the vane shaft into the aperture (102, 202, 302) until the recess (114, 214, 314) in the vane shaft is inside the aperture, and causing a retaining member (104, 204, 304) associated with the crank arm (100, 200, 300) to engage the recess (114, 214, 314) in such a manner as to fasten the crank arm to the vane shaft in a substantially immovable manner.

Abstract: The present invention relates to a turbocharger assembly lock comprising a retaining ring partially disposed in a circumferential groove of a first turbocharger stage component and partially in a circumferential groove of a second turbocharger stage component so that the turbocharger stages are securely attached to each other.

Abstract: A method of assembling a crank arm (100, 200, 300) and vane assembly for a variable nozzle without requiring metallurgical bonding. In accordance with one aspect of the invention, the method comprises the steps of providing a vane assembly comprising a vane (120, 220, 320) joined to a vane shaft (110, 210, 310) that extends from the vane and terminates in a distal end (112, 212, 312), providing a recess (114, 214, 314) in an outer surface of the vane shaft at a location between the vane and the distal end, providing a crank arm (100, 200, 300) having an aperture (102, 202, 302) therein, inserting the distal end (112, 212, 312) of the vane shaft into the aperture (102, 202, 302) until the recess (114, 214, 314) in the vane shaft is inside the aperture, and causing a retaining member (104, 204, 304) associated with the crank arm (100, 200, 300) to engage the recess (114, 214, 314) in such a manner as to fasten the crank arm to the vane shaft in a substantially immovable manner.

Abstract: A turbocharger includes a compressor housing and a turbine housing wherein at least one of the compressor housing and the turbine housing includes an anti-ballistic material such as, for example, aramid fibers, S glass fibers and/or carbon fibers. A turbocharger system optionally includes a temperature controller that controls temperature in instances where operational temperatures may be detrimental to the performance characteristics of anti-ballistic material. Various other exemplary devices, methods, systems, etc., are also disclosed.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: Turbochargers comprise a compressor housing having an air inlet passage for receiving inlet airflow, an air outlet passage for passing pressurized air to an engine combustion system, and a compressor impeller rotatably disposed within the housing for receiving air from the air inlet passage, pressurizing the inlet air, and passing the pressurized air to the air outlet passage. An air flow conditioner is placed into air flow communication with the compressor housing air inlet passage, and can be disposed within an air inlet section of the compressor itself, or can be placed within a vehicle air ducting positioned upstream from the turbocharger.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: A charge air condensation separation system for a turbocharged engine, especially suited for engines employing EGR, includes a turbocharger having a compressor providing charge air with a charge air cooler connected to the compressor to cool the charge air. A charge air delivery duct is connected to an outlet of the charge air cooler and a torroidal trap having an annular inlet is disposed in the charge air delivery duct with a sump for collecting condensation integral to the torroidal trap. A drain line for removing condensation from the sump for expulsion to the atmosphere is connected to the trap and a pump or other device for overcoming pressure differential in the drain line is employed in certain embodiments. For EGR systems employing a mixer, the condensation separator can be incorporated adjacent to or integral with the mixer to minimize additional volume requirements in the engine compartment.

Abstract: A charge air condensation separation system for a turbocharged engine, especially suited for engines employing EGR, includes a turbocharger having a compressor providing charge air with a charge air cooler connected to the compressor to cool the charge air. A charge air delivery duct is connected to an outlet of the charge air cooler and a torroidal trap having an annular inlet is disposed in the charge air delivery duct with a sump for collecting condensation integral to the torroidal trap. A drain line for removing condensation from the sump for expulsion to the atmosphere is connected to the trap and a pump or other device for overcoming pressure differential in the drain line is employed in certain embodiments. For EGR systems employing a mixer, the condensation separator can be incorporated adjacent to or integral with the mixer to minimize additional volume requirements in the engine compartment.

Abstract: A turbomachinery apparatus. A turbine is provided with a retainer having a bore step element for turbine wheel retention, and with an aperture manifesting a tailored diameter less than the trim diameter of the turbine, thereby to permit customization of the turbine efficiency characteristic. Various configurations of turbine retainers, with tailored diameter apertures, are disclosed.

Abstract: A double sided 360° thrust bearing having oppositely oriented interlocking elements each with an open segment and an elevated segment is assembled over a thrust collar on the shaft interconnecting the turbine wheel and compressor wheel of a turbocharger. Bearing pads on the front surface and rear surface of the mated interlocking elements and on the oppositely oriented elevated segments engage reaction surfaces in a channel on the thrust collar. Lubrication channels in the mating faces of the interlocking elements provide oil to the bearing pads on the front and rear surfaces of the bearing while interconnecting lubrication conduits provide oil to the bearing pads on the elevated segments.

Abstract: An Exhaust Gas Recirulation (EGR) valve is integrated onto a turbocharger by providing an EGR outlet in a flange in the volute of the turbine housing and a mating valve assembly extending from a mating flange with an elbow. The outlet direction of the elbow is adjustable to a plurality of directions by positioning the mating flange relative to the EGR outlet flange.

Abstract: An Exhaust Gas Recirulation (EGR) valve is integrated onto a turbocharger by providing an EGR outlet in a flange in the volute of the turbine housing and a mating valve assembly extending from a mating flange with an elbow. The outlet direction of the elbow is adjustable to a plurality of directions by positioning the mating flange relative to the EGR outlet flange.

Abstract: A variable geometry turbocharger employs multiple vanes in the turbine inlet with a unison ring and integral cast wall in the turbine housing forming the nozzle walls. The unison ring incorporates actuation slots receiving tabs on the vanes for opening the closing the nozzle area upon rotation of the unison ring. An integral electrohydraulic actuator rotates the unison ring through a rack and pinion driven crank shaft with direct position feedback to the spring biased variable current solenoid via a cam on the crank shaft.

Abstract: A axial to rotational motion actuator employs two sets of engaged helical splines on rotational collars provides a large degree of rotary actuation from a relatively short axial stroke to provides efficient non-binding and reduced effort actuator operation. This improved actuation movement makes the actuator assembly both more responsive to a hydraulic activating means, i.e., oil pressure, and enables packaging the actuator assembly in a compact size to optimize available space around a turbocharger and inside of an engine compartment.