Abstract: A method for constructing a nozzle ring for a turbocharger turbine nozzle includes the steps of: providing a nozzle ring in the form of an annular flat disk, the nozzle ring having a first face and an opposite second face; forming a plurality of circumferentially spaced circular bores extending through the nozzle ring from the first face to the second face; providing a plurality of vanes, each vane having a circular vane shaft extending from one end of the vane; inserting the vane shafts respectively into the bores in the nozzle ring from said first face thereof and orienting each vane to achieve a desired setting angle for the vane; and rigidly affixing the vane shafts to the nozzle ring to fix the vanes at the desired setting angles.

Abstract: A waste gate assembly for a turbocharger includes a valve member formed by a valve shaft and an arm attached to an end of the shaft, the arm defining a through bore, an inner surface of the through bore defining an arm groove therein. A poppet for the valve has a pin whose outer surface defines a pin groove. A generally polygonal retaining ring of elastically deformable wire is installed partially in the arm groove and partially in the pin groove to retain the poppet on the pin, thereby attaching the poppet to the arm of the valve member. An anti-rotation feature prevents relative rotation of the poppet about the pin axis. Vertices of the retaining ring are in the arm groove, while sides of the retaining ring are in the pin groove. Once the retaining ring is pre-installed in the arm groove of the arm, the arm can be assembled to the poppet by a push-to-connect process.

Abstract: A crank and linkage assembly for a component of a turbocharger includes a linkage having an end defining a through bore, an inner surface of the through bore defining a linkage groove therein. The crank has a pin whose outer surface defines a pin groove. A generally polygonal retaining ring of elastically deformable wire is installed partially in the linkage groove and partially in the pin groove to retain the linkage on the pin while allowing the linkage to rotate about the pin axis. Vertices of the retaining ring are in the linkage groove, while sides of the retaining ring are in the pin groove. Once the retaining ring is pre-installed in the linkage groove, the assembly can be assembled by a push-to-connect process.

Abstract: Turbocharger systems and related methods and devices are provided for determining rotational speed of a turbocharger. A speed sensing device is mounted to a turbocharger and includes an acceleration sensing arrangement and an acoustic sensing arrangement. The speed sensing device outputs an acceleration-based speed value as the current turbo speed when the acceleration-based speed is stable, and otherwise outputs an acoustic-based speed value to as the current turbo speed if the acoustic-based speed value stable or outputs an estimated value as the current turbo speed when both of the acceleration-based and acoustic-based speeds are unstable. In exemplary embodiments, the acceleration sensing arrangement and the acoustic sensing arrangement are provided on a common substrate.

Abstract: Turbocharger systems and related methods and devices are provided for determining rotational speed of a turbocharger. A speed sensing device is mounted to a turbocharger and includes an acceleration sensing arrangement and an acoustic sensing arrangement. The speed sensing device outputs an acceleration-based speed value as the current turbo speed when the acceleration-based speed is stable, and otherwise outputs an acoustic-based speed value to as the current turbo speed if the acoustic-based speed value stable or outputs an estimated value as the current turbo speed when both of the acceleration-based and acoustic-based speeds are unstable. In exemplary embodiments, the acceleration sensing arrangement and the acoustic sensing arrangement are provided on a common substrate.

Abstract: A compressor recirculation valve having a noise-suppressing muffler. The muffler has a double-walled construction, including a perforated outer wall and a non-perforated inner wall. The muffler is arranged surrounding the RCV such that when the RCV valve member is in an open position, compressed recirculation air is constrained to flow along the non-perforated inner wall and past an upper end thereof before reaching and flowing radially outwardly through the perforated outer wall to a transverse flow passage for delivery back into an inlet of the compressor.

Abstract: A compressor recirculation valve having a noise-suppressing muffler. The muffler has a double-walled construction, including a perforated outer wall and a non-perforated inner wall. The muffler is arranged surrounding the RCV such that when the RCV valve member is in an open position, compressed recirculation air is constrained to flow along the non-perforated inner wall and past an upper end thereof before reaching and flowing radially outwardly through the perforated outer wall to a transverse flow passage for delivery back into an inlet of the compressor.