Borgwarner Inc.

Daniel N Ward

Allan Douglas Kelly

Richard Dwayne Hall

Michael Bucking

Silvio Koch

Vahidin Alajbegovic

Lauro Takabatake

Edward R Panek

Stan Arnold

Jaroslaw M Kierat

Allen W Gray, Iii

Daniel J Van Saun

Robert S Lerosen

Ed Panek

A variable-geometry turbocharger () with a vane lever () that provides a stop function at full open position of the guide vanes (). The integrated vane-open stop controls the full open position of the VTG mechanism. A vane lever () preferably has an integrated protrusion () that functions as a vane-open stop that contacts an adjacent vane lever (), an integrated bolt (), or the upper vane ring () at the full open position to regulate maximum exhaust gas flow to the turbine wheel ().

Integrated vane stops for variable-geometry turbocharger mechanism

A vane pack assembly () for a variable turbine geometry turbocharger is a stand-alone assembly and can be assembled and transported apart from the turbocharger. The vane pack assembly () includes a plurality of guide vanes () spaced apart in a circumferential direction and a plurality of pivot centers (). Each one of the pivot centers () corresponds with one of the guide vanes (). A location of the pivot centers () relative to the guide vanes () changes as an angular position of the guide vanes () is adjusted.

Variable pivot center VTG vanes and vane pack assembly

A turbocharger unit () incorporating variable turbine geometry. The unit () has a turbine housing () for receiving exhaust gases from an engine, a turbine wheel () located inside a turbine housing (), and a bearing housing () connected to the turbine housing (), having a recessed portion (). A spring member is located in the recessed portion (), and a heat shield () receives apply force from the spring member. There is also a cartridge for providing variable turbine geometry located in the turbine housing (); the cartridge is held in contact with the turbine housing () by the spring member in the form of a contoured sleeve (). The apply force received by the heat shield () from the spring member transfers through the cartridge, and holds the cartridge in place in the turbine housing.

VTG mechanism assembly using wave spring

A system and method is provided in which a turbocharger includes a heat shield wall that is formed together with the bearing housing as a unitary structure. The wall can extend from a main body portion of the bearing housing in a generally radially outward direction. The wall can be spaced from the main body and attached by a plurality of ribs such that chambers are defined therebetween. A circumferential passage can extend through the bearing housing to permit fluid communication between the chambers and outside of the bearing housing. In this way, a fluid outlet from the chambers is provided. As a result of such an arrangement, the need for a separate heat shield is eliminated, which can facilitate the assembly process and special attachment methods associated with a separate heat shield.

Turbocharger bearing housing with integrated heat shield

Turbochargers typically have separate hydrodynamic journal and thrust bearings. A turbocharger thrust bearing for a turbocharger is provided that merges the function of a journal bearing into a thrust bearing while maintaining the thrust bearing function to produce a turbocharger with a reduced axial space envelope. Such a thrust bearing includes a bore contoured to have a plurality of taper-land pairs distributed circumferentially about the bore. As a result, the axial length of the turbocharger bearing housing and shaft can be reduced.

Turbocharger with thrust bearing providing combined journal and thrust bearing functions

A turbocharger bearing system comprising a shaft () including at least one shoulder (A) with a rotor () disposed on the shaft (). First and second bearing sleeves () are disposed on the shaft () at opposite ends of the rotor (). Each bearing sleeve () includes a collar () and a journal portion (). A journal bearing () is disposed on each journal portion () and the journal portion () of the first bearing sleeve () abuts the shoulder (A) of the shaft (). In certain aspects of the technology described herein, the bearing sleeves () may be oriented in opposite directions. The shaft () is the same diameter where the bearing sleeves () are positioned. Accordingly, the bearing sleeves () may be interchangeable, as well as the journal bearings ().

Bearing system for a turbocharger with an internal electric motor

A self-adjusting rod end () comprising a rod end housing () including a connector portion (), a ball housing portion () having an opening (), and a race insert () disposed in the opening (). A rod end ball () is disposed in the race insert () and a rod end tensioner () is positioned to apply a force (F) against an end of the rod end ball (). The rod end tensioner () includes a clip portion () with a spring arm () extending therefrom, wherein the clip portion () includes a pair of tangs () positioned to engage the connector portion (). The spring arm () includes a contact tip () confronting the end of the rod end ball ().

Rod end tensioner and self adjusting rod end

A vane pack assembly is provided that can remove the spacers between the upper and lower vane rings to a location outside of the exhaust flow through the vane ring. In particular, the spacers are located within the vanes. Further, the assembly can effectively retain the small blocks used in varying the angle of the vanes on their associated vane pivot posts. A vane pack with such a configuration can use inexpensive parts, eliminate the need for welding of the vane pack and/or simplify the vane pack assembly process. Further, the vane pack can be decoupled from the turbine housing, thereby avoiding problems with differential thermal expansion.

Vane pack assembly for VTG turbochargers

The propensity for gas leakage around a shaft, which connects volumes of differing pressures, in, e.g., a turbocharger is minimized in a simple cost-effective manner. The addition of a complementary pair of frusto-spherical, conical, or other profiles to the interface of the shaft and its bearing maintain concentricity of the shaft in its bore and thus improve the efficacy of existing sealing protocols.

Control shaft seal

A turbocharger oil discharge assembly () can have a thrust collar () with a first radially outwardly extending wall and a second radially outwardly extending wall to define a first annular channel. The first radially outwardly extending wall can have an annular flange that at least in part defines a second annular channel. The assembly can also have a thrust bearing () having a radially inner end received in the first annular channel, and an insert (). An oil collection chamber () can be defined at least in part by a drainage channel of the insert (), the annular flange of the thrust collar () and the thrust bearing (). Pressurized oil discharged from an oil release interface can be directed towards a radially outer region of the oil collection chamber () and can be collected in the oil collection chamber () for subsequent exhaust.

Sealing system between bearing and compressor housing

A turbocharger thrust bearing assembly, which maintains a constant relationship between the thrust faces, for example by use of gimbal or spherical segment geometry. Spherical geometry, while more difficult to manufacture than that of a flat thrust bearing, provides a more constant relationship between the thrust pads and thrust washers than is possible with a typical flat thrust bearing. As a consequence of this more constant relationship the thrust bearing operates with less oil flow, which ultimately may reduce vehicle emissions.

Spherical thrust bearing system for turbochargers

The present invention is directed toward a hybrid bearing which will have the advantages of ball bearings as well as hydrodynamic oil films. The present invention is a hybrid bearing assembly for a turbocharger unit, having an inner race track with a series of grooves, and one or more roller balls located in the grooves of the inner race track. There is also an outer race track having a series of grooves for receiving the one or more roller balls, where the outer race track circumscribes the inner race track. The hybrid bearing also includes a sleeve made from an established tribological material located inside the inner race track, with a shaft located inside the sleeve. A hydrodynamic oil film is located between the sleeve and the shaft, wherein the hydrodynamic oil film allows the shaft to spin at greater speeds than the inner race track.

Combination hydrodynamic and rolling bearing system

A bearing system for a turbocharger, simple in design and easy to manufacture, having desired rotational dynamics of a three piece bearing design, yet having the superior vibration damping characteristics of a one piece bearing design. The inboard end of each journal bearing includes an axial recess for receiving an outboard end of a cylindrical bearing spacer, thereby axially locating the journal bearings as well as axially and radially locating the bearing spacer.

Bearing system for a turbocharger

A greatly simplified turbocharger assembly comprised of a minimum number of parts allows accurate and efficient control of oil flow over the bearings ( ), thereby permitting excellent lubrication of the bearings with a reduced amount of oil flow through the bearing housing ( ), resulting in significantly lower hydrocarbon leakage from the turbocharger into the engine or engine exhaust, and ultimately lower hydrocarbon emissions by the engine.

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Asheville, NC, United States of America

Daniel N Ward