Borgwarner Inc.

David George Grabowska

Brock Fraser

Paul K Anschel

John P Watson

Jaroslaw Kierat

Rajmohan Chandramohanan

Stephen I Roby

Paul Troxler

Aleksandar Sekularac

Patrick Sweetland

Kurtis Henderson

Stephanie Dextraze

Andrzej Mazurek

Jordan Bucklew Schwarz

Tilman Bernauer

Olgierd Urbanczyk

Laskhmi Srikar Yellapragada

A turbocharger includes a turbine wheel rotatable about an axis and a turbine housing disposed about the turbine wheel. The turbine housing has an inlet portion defining a turbine housing inlet and has a volute portion defining a turbine housing interior. The volute portion has a first volute wall, a second volute wall spaced from the first volute wall, and a tongue separating the turbine housing inlet and the turbine housing interior. The tongue has a first tongue portion extending from the first volute wall substantially toward the second volute wall along the axis, a second tongue portion extending from the first tongue portion substantially circumferentially about the axis, and a third tongue portion extending from the second tongue portion substantially toward the second volute wall along the axis to reduce high cycle fatigue of the turbine wheel.

Turbocharger including a turbine housing to reduce high cycle fatigue

To solve the problems of compressor wheel blade flow separation causing surge type noises when an exhaust gas recirculation (EGR) duct introduces into the compressor exhaust gases to be returned to the engine, the exhaust gas is fed into an annular volume, defined between inner and outer walls or an annular transition cavity shaped as a radially expanded, axially flattened cylindrical space in the compressor inlet, so that the generally unidirectional radial flow from an EGR duct is re-directed and organized as it is turned from generally radial to generally axial, merging with the general inlet flow and presenting the compressor wheel with airflow of 'circumferentially uniform' flow velocity.

Compressor recirculation into annular volume

A turbocharger () has an improved wastegate valve assembly () wherein a port-controlling valve body () includes flow formations which serve to reduce exhaust gas flow in non-optimal directions transverse to an optimal flow direction in the direction of a wastegate passage (). These flow formations serve to optimize or maximize the flow of exhaust gas in the optimal or primary flow direction as the exhaust gas flow turns through a turn angle () from an inlet direction () to the optimal flow direction.

Methods and structure for reducing losses in 90 degree waste gates for turbochargers

A turbine diffuser configured for use in a turbocharger is disclosed. The turbine diffuser may comprise a diffuser wall defining the diffuser and circumscribing a central axis of the diffuser, and a plurality of deswirl ribs each extending axially along the diffuser wall. Each of the deswirl ribs may have a first end attached to the diffuser wall, and an opposing second end exposed in an interior space of the diffuser. The deswirl ribs may be configured to reduce rotation of exhaust gas that flows through the diffuser.

Turbocharger turbine diffuser with deswirl ribs

A turbocharger () including variable turbine geometry has a turbine wheel () with a turbine axis of rotation (R) that extends in an axial direction. The turbocharger () also has a plurality of guide vanes () that is selectively movable between a range of angular positions. Each one of the guide vanes () is supported for pivotal movement about a guide vane axis of rotation (R) and each guide vane axis of rotation (R) is non-parallel to the turbine axis of rotation (R).

Mixed-flow turbocharger with variable turbine geometry

A method for extending thermodynamic turbine mapping of a turbocharger, the turbocharger including a turbine and a compressor, the method including the steps of providing a steady-state turbocharger gas test stand configured to flow continuous gas to the turbocharger, the test stand including a throttle device disposed upstream of an inlet of the compressor of the turbocharger, and varying an area of the inlet with the throttle device to change density of the continuously flowing gas at the inlet of the compressor and establish a choked-flow condition for extending the thermodynamic turbine mapping of the turbocharger.

Method of extended thermodynamic turbine mapping via compressor inlet throttling

High pressure loop exhaust gas circulation is achieved in an exhaust system () of an engine () by providing an adjustable valve () in an exhaust passage () of the engine (). The valve () is configured to control fluid flow through the passage () and generate pressure to drive the high pressure exhaust gas recirculation. The valve () includes a valve inner surface () that has a curvilinear profile when viewed in longitudinal cross section. An actuator () is connected to the valve (), and is configured to move the valve () relative to the exhaust passage () so as to control exhaust gas pressure within the exhaust passage (). In some embodiments, a pilot tube () is used in combination with the valve () to generate high pressure exhaust gas recirculation at the engine () intake.

Adjustable, low loss valve for providing high pressure loop exhaust gas recirculation

To solve the problems of compressor wheel blade flow separation causing surge type noises when a compressor return or recirculation valve is opened or closed, recirculation airflow from a compressor recirculation valve is fed into an annular volume, defined between inner and outer walls or shaped as a radially expanded, axially flattened cylindrical space in the compressor inlet, so that the generally unidirectional radial flow from the compressor recirculation valve is re-directed and organized as it is turned from generally radial to generally axial, merging with the general inlet flow and presenting the compressor wheel with airflow of'circumferentially uniform' flow velocity.

A turbocharger () comprising a housing () including a compressor shroud () and a turbine shroud (). A compressor wheel () is disposed in the compressor shroud () and includes a plurality of compressor blades (). Each compressor blade () includes a leading edge () and a compressor shroud contour edge (), wherein each compressor shroud contour edge () is in close confronting relation to the compressor shroud (). A turbine wheel () is disposed in the turbine shroud () and includes a plurality of turbine blades (). Each turbine blade () includes a leading edge () and a turbine shroud contour edge (), wherein each turbine shroud contour edge () is in close confronting relation to the turbine shroud (). At least one of the compressor shroud () and turbine shroud () includes a plurality of grooves () extending cross-wise with respect to the corresponding compressor or turbine shroud contour edges ().

Turbocharger shroud with cross-wise grooves and turbocharger incorporating the same

To solve the problems of compressor wheel blade flow separation causing surge type noises when a compressor return or recirculation valve is opened or closed, bypass airflow from a compressor recirculation valve is fed into an annular volume, defined between inner and outer walls or shaped as a radially expanded, axially flattened cylindrical space in the compressor inlet, so that the generally unidirectional radial flow from the compressor recirculation valve is re-directed and organized as it is turned from generally radial to generally axial, merging with the general inlet flow and presenting the compressor wheel with airflow of 'circumferentially uniform' flow velocity.

A variable geometry turbocharger is simplified yet able to maintain pulse energy. In a first embodiment, a turbine housing is provided with a pivoting wall which pivots about a point near the entry to the turbine housing. By moving the wall about the pivot point, the effective volume of the turbine housing volute is varied, thus effectively reducing the volume of exhaust gas in the volute, allowing control of exhaust gas flowing to the turbine wheel. In the second embodiment of the invention, a rotating wedge segment within the volute is rotated from a first position to a second position, changing the effective volume of the volute and allowing control of exhaust gas flowing to the turbine wheel.

Simplified variable geometry turbocharger with variable flow volumes

A housing () for a turbocharger () is provided. The housing () has an impeller chamber (), diffuser () and scroll () in fluid communication with each other. The diffuser () can have a curved shape and/or a bend () in proximity to a tip () of the impeller (). The curved shape can be defined by one or more radii of curvature (R, R, R). The diffuser () can extend in a radial direction that is non-orthogonal to the center line of the turbocharger (). The housing () can be for a compressor section of the turbocharger ().

Turbocharger diffuser

A wastegate for a turbocharger wherein the valve is provided with a horn to provide a more progressive, optimally near linear, curve of turbocharger boost-to-valve opening than possible with the typical flat wastegate valve. The addition of a three-dimensional horn in the flow path is a far more cost-effective solution to acquire linear flow than an approach involving very finite, accurate control of the valve position.

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Asheville, NC, United States of America

David George Grabowska