Borgwarner Inc.

Cummins Inc.

Cummins Turbo Technologies Limited

Holset Engineering Company, Limited

Jeffrey Carter

Lathom Alexander Louco

David Andrew Luck

Tyler R Garrard

Brian Edward Handlon

Christopher Joel Maurus

Nicholas Kenneth Sharp

Henry David Lambton Carr

John Allport

Przemyslaw Swidlinski

Mahir Al-Ani

Keith Nickson

Ryan Thomas Howell

An electric machine includes a rotor extending along an axis and a stator lamination stack radially spaced from the rotor. The stator lamination stack has circumferentially spaced teeth defining gaps therebetween. The electric machine also includes a coil winding disposed in the gaps between the circumferentially spaced teeth and a guard plate disposed at one of the first and second stator ends. The guard plate extends radially away from the axis and includes a plurality of teeth guards extending radially, with each of the teeth guards aligned with one of the teeth of the stator lamination stack to electrically insulate the coil winding from the teeth of the stator lamination stack. The plurality of teeth of the stator lamination stack extend radially inward toward the axis and the teeth guards of the guard plate extend radially inward toward the axis.

Electric machine

An electrically-assisted turbocharger includes a shaft extending along an axis, a compressor wheel, a turbine wheel, a housing, and an electric machine. The electric machine includes a rotor rotatably coupled to the shaft and a stator lamination stack radially spaced from the rotor. The stator lamination stack has circumferentially spaced teeth defining gaps therebetween. The electric machine also includes a coil winding disposed in the gaps between the circumferentially spaced teeth and a guard plate disposed at one of the first and second stator ends. The guard plate extends radially away from the axis and includes a plurality of teeth guards extending radially, with each of the teeth guards aligned with one of the teeth of the stator lamination stack to electrically insulate the coil winding from the teeth of the stator lamination stack.

Electric machine and electrically-assisted turbocharger including the same

An electric power dissipater assembly for an electrically-actuated turbocharger that includes: a power switch configured to be electrically connected to an electric power output of an electrically-actuated turbocharger; at least one resistor that is electrically connected to the power switch such that, when the power switch is in a closed position and connected to the electric power output, the at least one resistor is electrically coupled to the electric power output so that electric power provided by the electrical power output is received at and dissipated by the at least one resistor; a controller that controls whether the power switch is in the closed position or an open position; and a substrate that is physically coupled to the at least one resistor and that includes a coolant path that is used to cool the at least one resistor when coolant is received within the coolant path.

Electric power dissipater for electrically-actuated turbocharger

A power electronics assembly that controls an electrically-actuated turbocharger includes a printed circuit board (PCB) having a non-conductive substrate supporting one or more electrical components that attach to the non-conductive substrate on one or more sides of the PCB; one or more conductive layers that couple with the non-conductive substrate and conduct electrical current within the PCB; a fluid barrier layer applied to an outer surface of the non-conductive substrate or conductor layer; and a PCB housing, configured to couple with the electrically-actuated turbocharger, having a fluid cavity that communicates liquid from an internal combustion engine (ICE) to the fluid barrier layer separating the liquid and the PCB.

Liquid-cooled power electronics assembly for electrically-actuated turbochargers

An electronics assembly drives an electric motor and receives a coolant fluid. The electronics assembly includes a heat sink including a thermally conductive material. The heat sink includes a frame extending between a first surface and a second surface. The first surface defines at least a portion of a cavity for receiving the coolant fluid therein. The heat sink includes a plurality of cooling members coupled to and extending from the first surface of the frame into the cavity such that the plurality of cooling members are disposed within the coolant fluid. The electronics assembly further includes an electrical insulator directly bonded to the second surface of the frame and a semiconductor thermally coupled to the electrical insulator. The electrical insulator is a thermal conductor and facilitates heat transfer between the semiconductor and the heat sink. The electrical insulator electrically insulates the semiconductor from the heat sink.

Electronics assembly having a heat sink and an electrical insulator directly bonded to the heat sink

A product comprising a stator core having a stator base portion and a plurality of stator teeth extending from the stator base portion in a radially inward direction from the stator base portion, wherein adjacent stator teeth define, at least in part, a stator slot therebetween, and a stator slot closer having a portion for closing an associated stator slot.

Stator core and stator slot closer

A printed circuit board (PCB) includes a first aluminum layer, having a first thickness, electrically insulated with a coating of alumina applied to a surface of the first aluminum layer; a second aluminum layer, having a second thickness that is different than the first thickness, insulated with a coating of alumina applied to a surface of the second aluminum layer; and a conductive layer bonded to the coating of alumina on the first aluminum layer, the coating of alumina on the second aluminum layer, or both.

Insulated metal printed circuit board

A printed circuit board (PCB), including electrical components for controlling electrically-actuated turbochargers, having a switching device configured to be electrically connected to an electrical power source and electrically connected to an electric motor of an electrically-actuated turbocharger, wherein the switching device is physically attached to a side of the PCB within a cavity formed in the side of the PCB such that at least a portion of the switching device is below the side of the PCB.

PCB design for electrically-actuated turbochargers

A compressor wheel that can be employed in devices such as turbochargers. The compressor wheel includes an axially extending hub having an inlet end, a shaft bore extending from the inlet end and an arcuate outer surface opposed to the shaft bore. The axially extending hub is composed of a metal and has a porous region located proximate to the arcuate outer surface of the axially extending hub. The compressor wheel also includes a blade array disposed on the arcuate outer surface of the axially extending hub. The blade array has an outer surface and an inner region. The blade array comprises a plurality of circumferentially-spaced, radially and axially extending blades disposed thereon and is composed, at least in part of a polymeric material. Polymeric material located in the inner region of the blade array extends into the porous region defined in the axially extending hub.

Polymeric compressor wheel with metal sleeve

An engine system () includes an engine (), and a turbocharger () that receives exhaust gas from the engine () and delivers charged air to the engine (). The engine system () also includes an electrically-driven compressor-expander () disposed in the engine air intake passage () between a compressor section () of the turbocharger () and the engine (). The compressor-expander () is configured to modify the pressure and temperature characteristics of the charged air flow exiting the turbocharger compressor section (). A valve () controls the flow path and/or direction of the charged air flow as it enters the compressor-expander ().

Electrically driven compressor-expander for a turbocharged engine system and associated flow control valves

A variable geometry turbine comprises a turbine wheel and a primary inlet passage of variable axial width. The turbine has a secondary inlet passage provides a flow path for a working fluid which circumnavigates at least part of the primary inlet passage. A seal element and one or more apertures are cooperable to selectively allow or prevent fluid flow through the secondary inlet passage. The ratio of the minimum cross-sectional area of the flow path through the primary inlet passage to that of the secondary inlet passage is between 1.3 and 1.7.

Variable geometry turbine

A system for controlling movement of an actuator includes an input power source that provides an input pulse width (PWM) signal; a motor driver that receives the PWM signal and provides a synthesized three-phase drive signal; a brushless direct current (BLDC) motor that receives the drive signal and operates in response to the received drive signal to reposition the actuator; and a controller that receives the PWM signal. The controller includes an amplitude detection module that detects the amplitude of the PWM signal, and a direction detection module that detects the polarity of the PWM signal.

Brushless DC motor control and method

A variable geometry turbine comprises a turbine wheel and a primary inlet passage of variable axial width. The turbine has a secondary inlet passage provides a flow path for a working fluid which circumnavigates at least part of the primary inlet passage. A seal element and one or more apertures are cooperable to selectively allow or prevent fluid flow through the secondary inlet passage. The turbine wheel is of the radial-inflow axial-outflow type and secondary inlet passage has an outlet configured to direct working fluid to exit the secondary inlet passage in a direction which has an axial component in the opposite direction to the direction of axial outflow of the turbine wheel.

According to an aspect of the present invention, there is provided a turbocharger assembly, comprising: a turbocharger; one or more actuators for controlling a flow of fluid in, around, or associated with the operation of the turbocharger; control electronics for use in controlling actuation of the one or more actuators; and boost electronics configured to receive an input voltage, and to provide a boosted output voltage to the control electronics.

Turbocharger assembly

A compressor comprises a housing defining an inlet, a volute, an outlet, and a compressor chamber between the inlet and the outlet within which a compressor wheel is rotatably mounted. The housing has discrete attached first and second housing portions, the first housing portion defining at least part of the inlet and the second housing portion defining at least part of a volute of the outlet. The first housing portion has a conductive element for conducting an electric signal and a second sensor arrangement in sensing communication with the inlet. The compressor further comprises a first sensor arrangement, the first sensor arrangement being configured such that it is in sensing communication with the volute or outlet and such that it is electrically connected to the conductive element.

Growing community of inventors

Mirfield, United Kingdom

Jeffrey Carter