Borgwarner Inc.

Paul Diemer

Augustine Cavagnaro

Timothy Mark House

Allan Douglas Kelly

Michael Bucking

Joel M Maguire

Ryan Howell

Brian Edward Handlon

Hakan Yilmaz

Mike Harris

A turbocharger is used within a vehicle and includes an electronic actuator assembly. The electronic actuator assembly includes an actuator housing coupled to at least one of the turbine housing, the compressor housing, and the bearing housing, and an accelerometer coupled to the actuator housing. The accelerometer is adapted to detect vibration of at least one of the turbine housing, the compressor housing, the bearing housing, and the actuator housing thereby obtaining acceleration data of at least one of the turbine housing, the compressor housing, the bearing housing, and the actuator housing to determine rotational speed of the turbocharger shaft. Another embodiment includes a vibration detection assembly having an accelerometer coupled to a vehicle component and the vehicle component is one or more of a turbocharger, a valve assembly, an electronically driven compressor, and a turbocharger having an integral electric motor.

Turbocharger, vibration detection assembly, and method of using same

An electric drive module that includes a housing, a pair of drive units and a coupling unit. The drive units are disposed in the housing and each drive unit includes a motor unit and a friction brake. The motor unit has a stator, which is non-rotatably coupled to the housing, and a rotor that is rotatable about a motor axis and configured to drive a wheel of a vehicle. The friction brake has a first portion, which is non-rotatably coupled to the housing, and a second portion that is drivingly coupled to the rotor. The friction brake can be operated to create a rotational drag force that resists rotation of the second portion relative to the first portion. The coupling unit is configured to selectively rotatably couple the second portions of the friction brakes to one another.

Electric drive module with independent drive units having friction brakes that are selectively engageable to one another

To solve both axial and rotational constraint problems in turbochargers with rolling element bearings (REBs), a REB sleeve or outer race is mounted to the bearing housing in a way that is not axially and radially rigid, thus allowing for oil damping films both radially and axially. At the same time, the REB sleeve or outer race is held so that the REB sleeve or outer race does not rotate relative to the bearing housing. This dual purpose is achieved using an anti-rotation ring and a damping ring. The anti-rotation ring includes at least one anti-rotation feature for engaging the bearing housing and at least one anti-rotation feature for engaging the REB cartridge, preventing rotation of the REB cartridge sleeve or outer race. The damping ring axially locates the REB cartridge and dampens axial movement and cushions axial thrust.

Rolling element bearing cartridge with axial thrust damping and anti-rotation assemblies

An electrically assisted turbocharger () comprising a housing () and an electric motor stator () disposed in the housing (). The stator () includes a pair of o-rings, or other circumferential seals (), disposed therearound. The o-rings () are operative to seal against an interior of the housing () to form an annular chamber () around at least a portion of the stator () and a pair of end cavities () at the axial ends of the stator (). The annular chamber () is adapted to allow the circulation of a cooling fluid around the stator (). A pair of bearings () may be disposed in the housing (), one on each side of the stator (). A shaft () is supported in the housing () by the bearings (). The shaft () in turn supports a turbine wheel () and a compressor wheel. An electric motor rotor () is disposed on the shaft () between the bearings () and inside the stator ().

Electrically assisted turbocharger

The propensity for gas and soot leakage around a shaft, which extends through a bore which connects volumes of differing pressures, e.g., a turbocharger turbine housing and the ambient air, is minimized with the addition of a pair of seal rings axially biased by a spring to provide a continuous gas and soot seal. The spring may bias the seal rings apart from each other or towards each other.

Spring biased sealing method for an actuating shaft

To solve both axial and rotational constraint problems in turbochargers with rolling element bearings (REBs), a REB cartridge is mounted to the bearing housing in a way that is not rigid, thus allowing for an oil damping film. At the same time, the REB cartridge is held both axially and rotationally, so that the outer race does not rotate relative to the bearing housing. This dual purpose is achieved using a special dual-mode sliding clip with at least one anti-rotation feature for engaging the bearing housing and at least one anti-rotation feature for engaging the REB cartridge, thereby axially locating the REB cartridge and preventing rotation of the outer race.

Sliding clip method for anti-rotation and thrust constraint of a rolling element bearing cartridge

To solve both axial and rotational constraint problems in turbochargers with rolling element bearings (REBs), a REB cartridge is mounted to the bearing housing in a way that is not rigid, thus allowing for an oil damping film. At the same time, the REB cartridge is held both axially and rotationally, so that the outer race does not rotate relative to the bearing housing. This dual purpose is achieved using a special dual-mode spring clip with at least one anti-rotation feature for engaging the bearing housing and at least one anti-rotation feature for engaging the REB cartridge, thereby axially locating the REB cartridge and preventing rotation of the outer race.

Spring clip method for anti-rotation and thrust constraint of a rolling element bearing cartridge

To solve heat soak and reduced heat rejection capability problems in turbochargers with rolling element bearings (REBs), the REB cartridge is mounted to the bearing housing in a way that is not rigid, thus allows for an oil damping film, but, at the same time, the REB cartridge is held both axially, to transfer thrust loads to the bearing housing, and rotationally, so that the REB cartridge does not rotate relative to the bearing housing, using male or female features in the REB and corresponding female or male features associated with the bearing bore or the turbine face of the bearing housing closure.

Anti-rotation method for a rolling element bearing cartridge

A turbocharger using a high speed rolling element bearing system is improved in desired speed and life by providing an insulating spacer, with a thermal conductivity lower than that of the material in the inner race of the REB, between the turbine-end of the inner race of the bearing system and the compressor-end face of the piston ring boss to impede the flow of heat from the turbine wheel to the inner race of the rolling element bearing.

Insulating spacer for ball bearing cartridge

A turbocharger uses a high speed rolling element bearing system. An exemplary rolling element bearing system includes a polymer sleeve to impede the flow of heat from the bearing housing into the outer race of the rolling element bearing system. In a second embodiment of the invention, the sleeve is supported by an oil film. In a third embodiment of the invention, the bearing cartridge is damped by a damping medium which also connects the bearing cartridge to the bearing housing.

Growing community of inventors

Arden, NC, United States of America

Paul Diemer