Caterpillar Inc.

Richard E Annati

Jeffrey W McCormack

Thomas J Williams

Gary W Powers

Eric D Reinhart

Matthew J Frick

Daniel Singer

Craig Miller

Mark E Suchezky

David Ronald Adair

Dean S Musgrave

Robert Charles Griffith, Jr

Walter Sherman Isenberg

Robert C Lancaster

Steve Knight

David Harnadek

Gregg Williams

A compressor for a turbocharger for use with an internal combustion engine includes a compressor wheel having a central hub having a centerline, a root portion, and an end portion. A plurality of blades is formed around the central hub. The plurality of blades includes a group of full-blades extending from the root portion of the central hub up to a maximum distance from the root portion along the centerline, the maximum distance being adjacent the end portion of the central hub. The plurality of blades includes a group of half-blades, the half-blades extending from the root portion of the hub to an area along the centerline that is between 60% and 65% of the maximum distance along the centerline. The plurality of blades is organized in repeating sets of blades arranged around the compressor wheel, each repeating set including at least one full-blade and at least one half-blade.

Turbocharger compressor and method

A compressor wheel for a turbocharger includes first, second and third pluralities of blades formed around a central hub. Each of the second plurality of blades is disposed between adjacent blades from the first plurality of blades and extend a shorter distance than the first plurality of blades along the centerline of the central hub. Each of the third plurality of blades is disposed between adjacent blades from the first and second pluralities of blades, and extends a shorter distance than the second plurality of blades along the centerline of the central hub. Together, the blades are separated in sets, each set including a blade from each of the first, second and third pluralities in order with respect to any radial location around the compressor wheel as the compressor wheel rotates.

A turbocharger for use with an internal combustion engine includes a compressor wheel having a central hub having a centerline, a root portion and an end portion. A plurality of blades is formed around the central hub. The plurality of blades includes a group of full-blades extending from the root portion of the central hub up to a maximum distance from the root portion along the centerline, the maximum distance being adjacent the end portion of the central hub. The plurality of blades further includes a group of partial-blades, the partial-blades extending from the root portion of the hub to an area along the centerline that is between 40% and 55% of the maximum distance along the centerline, and the plurality of blades is organized in repeating sets of blades arranged around the compressor wheel, each repeating set including at least one full-blade and at least one partial-blade.

A compressor in a turbocharger for an internal combustion engine includes a compressor wheel that includes a central hub having a centerline, a root portion and an end portion. A plurality of blades is formed around the central hub. The plurality of blades includes a group of full-blades extending from the root portion of the central hub up to a maximum distance from the root portion along the centerline, a group of partial-blades extending to an area along the centerline that is between 40% and 55% of the maximum distance along the centerline, and a group of half-blades extending to an area along the centerline that is between 55% and 70% of the maximum distance. The plurality of blades is organized in repeating sets of blades arranged around the compressor wheel, each repeating set including at least one full-blade, at least one half-blade and at least one partial-blade.

A compressor assembly is disclosed. The compressor assembly may have a compressor housing. The compressor housing may have an inner wall. The compressor assembly may also have a compressor impeller disposed within the compressor housing. Further, the compressor assembly may have a bearing housing attached to the compressor housing. The bearing housing may have a body portion and a web extending outward from the body portion to a web end. The compressor assembly may also have a diffuser ring disposed between the inner wall and the web. The diffuser ring may have at least one vane. In addition, the compressor assembly may have a vaneless space extending between the compressor impeller and the vane. The vaneless space may be inclined at an angle relative to a plane disposed orthogonal to a rotational axis of the compressor assembly.

Compressor assembly having a vaneless space

A compressor assembly is disclosed. The compressor assembly may have a compressor housing. The compressor assembly may also have a compressor impeller disposed within the compressor housing. Further, the compressor assembly may have a bearing housing attached to the compressor housing. The compressor assembly may also have a diffuser ring disposed between the compressor housing and the bearing housing. In addition, the compressor assembly may have at least one tab. The tab may extend radially outward from the diffuser ring. The tab may be configured to engage with a recess in the compressor housing. The compressor assembly may also have at least one fastener. The fastener may be configured to attach the diffuser ring and the compressor housing.

Compressor assembly having a diffuser ring with tabs

A turbocharger is provided that includes a turbine, a compressor and a bearing housing disposed and connected between the turbine and the compressor. A shaft is rotatably disposed within the bearing housing and extending into the turbine and the compressor. A bearing arrangement is disposed between the shaft and the bearing housing and includes a inner bearing race element and an outer bearing race element. The compressor wheel includes a hub having a collar portion with a bore therein for receiving an end of the shaft. An end portion of the inner bearing race element is arranged to engage an outer circumferential surface of the collar portion.

Turbocharger with bearing piloted compressor wheel

A turbocharger is provided that includes a turbine, a compressor and a bearing housing disposed and connected between the turbine and the compressor. A shaft rotatably disposed within the bearing housing and extending into the turbine and the compressor. A bearing arrangement is disposed between the shaft and the bearing housing. The bearing arrangement including first and second bearings, each of the first and second bearings formed by a respective first and second plurality of roller elements engaged between a respective first and second inner race and a respective first and second outer race. The shaft is made of a steel alloy with a carbon content of less than 0.40% by weight.

Turbocharger with low carbon steel shaft

A turbocharger includes a turbine, a compressor, and a bearing housing forming a bearing bore. A bearing arrangement is disposed between a shaft interconnecting the turbine and compressor wheels, and the bearing housing. The bearing arrangement includes an outer bearing race element that frictionally engages the bearing bore at both ends. At a first end, a bearing retainer that is connected to the bearing housing includes a cylindrical element that extends into the bearing bore and abuts and frictionally engages a first end of the outer bearing race element. The second end of the outer bearing race element abuts and frictionally engages a stop formed at an end of the bearing bore such that no pins or other structures are required for preventing rotation of the outer bearing race element in the bearing bore.

Turbocharger and method

A turbocharger is provided including a turbine housing having a gas inlet passage. A turbine wheel having a plurality of blades is arranged within the turbine housing. A nozzle ring is disposed around the turbine wheel and includes a plurality of vanes with flow channels being defined between the vanes that are in fluid communication the gas inlet passage and with the turbine wheel. A shroud is arranged in surrounding relation to at least a portion of the turbine wheel and in spaced relation from the turbine housing. The shroud is integrally formed with the nozzle ring such that the plurality of vanes extend away from the shroud.

Turbocharger turbine nozzle and containment structure

A turbocharger is provided including a turbine, a compressor and a bearing housing. A shaft is rotatably disposed within the bearing housing and extends into the turbine and the compressor. A bearing arrangement is disposed between the shaft and the bearing. The bearing arrangement includes a roller bearing formed between an outer bearing race element disposed in the bearing bore, and an inner bearing race element disposed in the outer bearing race element. A bearing retainer connected between the bearing housing and the compressor. An end portion of the bearing inner race element includes an integral oil slinger comprising a radially outward extending portion that slopes away from the shaft.

Turbocharger with oil containment arrangement

A turbine assembly includes a turbine housing and a turbine wheel disposed within the turbine housing. The turbine wheel includes a rotational axis and a plurality of blades. The turbine assembly includes a turbine shroud disposed between the turbine housing and the turbine wheel along a radial direction. The turbine shroud is separate from the turbine housing. The turbine shroud includes an annular portion extending generally in an axial direction with respect to the rotational axis and a plate portion intersecting the annular portion to form a convex curved surface. At least a portion of the blades is disposed in at least a portion of the annular portion. Each blade includes a leading edge and a tip portion. Each leading edge is angled with respect to the rotational axis, and each tip portion forms a concave portion that curves around the curved surface of the turbine shroud.

Turbocharger with turbine shroud

A housing for a turbocharger includes a first outer surface, a second outer surface opposite the first outer surface, and a mounting hole extending between the first outer surface and the second outer surface. The mounting hole includes a first end opposite a second end and a counterbore formed at the first end. The counterbore includes threads that are configured to engage with threads on a shank of a lifting device. The mounting hole also includes a throughbore extending from the counterbore to the second end and configured to receive a fastener for mounting the turbocharger housing. The counterbore forms a first opening through the first outer surface of the turbocharger housing, and the throughbore forms a second opening through the second outer surface of the turbocharger housing. The mounting hole is configured to receive only one fastener or shank at a time.

Turbocharger with dual-use mounting holes

A turbocharger includes a turbine, a compressor, and a bearing housing forming a bearing bore. A bearing arrangement is disposed between a shaft interconnecting the turbine and compressor wheels, and the bearing housing. The bearing arrangement includes an outer bearing race element and an inner bearing race element rotatably disposed within the outer bearing race element. The inner bearing race element forms a hollow extension extending up to the compressor wheel, the extension having a hollow cylindrical shape that surrounds a portion of the shaft that is connected on one end to the compressor wheel and at another end is disposed adjacent to a seat formed on the extension portion around the shaft, and a nut engaged on the shaft and disposed within the extension at an offset distance from the seat.

A turbocharger includes a turbine, a compressor, and a bearing housing forming a bearing bore. A bearing arrangement is disposed between a shaft interconnecting the turbine and compressor wheels, and the bearing housing. The bearing arrangement includes first and second bearings formed between an outer bearing race element disposed within the bearing bore an inner bearing race element disposed within the outer bearing race element and between the outer bearing race element and the shaft. The inner bearing race element includes a flared portion extending radially outwardly to provide torsional and bending rigidity to the shaft.

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Lafayette, IN, United States of America

Richard E Annati