Rotatable valve for a turbocharger system having multiple volute members

Abstract

The present invention relates to a rotatable valve of a turbocharger system having a plurality of volute members. The turbocharger system includes a valve member having at least one valve channel. The valve member is supported to rotate between a first position, a second position, and a third position about an axis of rotation. The axis of rotation is oriented transversely to the flow in the first volute channel and the second volute channel. When the valve member is in the first position, the valve channel provides a cross flow path between the first volute channel and the second volute channel, and provides a bypass flow path from at least one of the first and second volute channels and a bypass channel. In the second position, the valve channel provides a cross flow path, and the valve member substantially prevents flow along the bypass flow path. The valve member in the third position substantially prevents flow along the cross flow path and the bypass flow path.

Description

Technical Field

[0001] The present invention relates generally to a turbocharger system, and more particularly to a rotatable valve for a turbocharger system having multiple volute members. Background Art

[0002] Some engine systems include one or more turbochargers. Typically, a turbocharger includes a turbine wheel and a compressor wheel mounted on a common shaft and carried in separate turbine and compressor housings, respectively. The turbine wheel can be driven to rotate by exhaust gas output from the engine. This in turn causes the compressor wheel to rotate to compress air supplied to the engine's combustion chamber. Thus, a turbocharger can provide performance gains and increased efficiency to the engine.

[0003] The turbocharger system can operate under many conditions. For example, the turbocharger can operate at relatively low engine speeds, relatively high engine speeds, and speeds in between. Thus, the turbocharger system can operate at times when the exhaust mass flow is relatively high, low, and in between.

[0004] Therefore, it is desirable to provide an improved turbocharger system that increases engine performance over a wide range of operating conditions.Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and background discussion. Summary of the invention

[0005] In one embodiment, a turbocharger system is disclosed, which includes a turbine portion having a turbine wheel, a first volute structure having a first volute passage extending along a first axis, and a second volute structure having a second volute passage extending along a second axis. The first volute passage is configured to guide the exhaust gas flow to the turbine wheel. The second volute passage is configured to guide the exhaust gas flow to the turbine wheel. The turbocharger system also includes a downstream exhaust structure having a downstream exhaust passage, and the downstream exhaust passage is configured to receive exhaust gas from the turbine portion. The turbocharger system also includes a bypass structure having a bypass passage, and the bypass passage is configured to provide exhaust gas bypassing the turbine wheel to the downstream exhaust passage. In addition, the turbocharger system includes a valve member having at least one valve passage. The valve member is supported to rotate between a first position, a second position, and a third position around an axis of rotation. The axis of rotation is oriented transversely to the first axis and the second axis. When the valve member is in the first position, the valve passage provides a cross flow path between the first volute passage and the second volute passage, and provides a bypass flow path from at least one of the first volute passage and the second volute passage to the bypass passage. When the valve member is in the second position, the valve passage provides a cross flow path. The valve member in the second position substantially prevents flow along the bypass flow path. The valve member in the third position substantially prevents flow along the cross flow path and the bypass flow path.

[0006] In another embodiment, a turbocharger system is disclosed, which includes a turbine portion having a turbine wheel, a first volute structure having a first volute passage configured to guide exhaust gas flow to the turbine wheel, and a second volute structure having a second volute passage configured to guide exhaust gas flow to the turbine wheel. The turbocharger system also includes a downstream exhaust structure having a downstream exhaust passage, and the downstream exhaust passage is configured to receive exhaust gas from the turbine portion. In addition, the turbocharger system includes a bypass structure having a bypass passage, and the bypass passage is configured to provide exhaust gas bypassing the turbine impeller to the downstream exhaust passage. Moreover, the turbocharger system includes a valve member having a valve passage. The valve member is supported to rotate around an axis between a first position, a second position, and a third position. When the valve member is in the first position, the valve passage provides a cross flow path between the first volute passage and the second volute passage, and provides a bypass flow path from at least one of the first volute passage and the second volute passage to the bypass passage. When the valve member is in the second position, the valve passage provides a cross flow path. The valve member in the second position substantially prevents flow along the bypass flow path. The valve member in the third position substantially prevents flow along the crossover flow path and the bypass flow path.

[0007] In a further embodiment, a method for operating a turbocharger system is disclosed. The method includes operating an engine under variable conditions and detecting a current state of the variable conditions. The method also includes actuating a valve member to rotate about an axis between a first position, a second position, and a third position relative to a first volute structure, a second volute structure, and a bypass structure based at least in part on the current state of the detected variable condition. The first volute structure defines a first volute channel, the second volute structure defines a second volute channel, and the bypass structure defines a bypass channel. The axis is oriented transversely to a first flow axis of the first volute channel and a second flow axis of the second volute channel. The valve member includes at least one valve channel. When the valve member is in the first position, the at least one valve channel provides a cross flow path between the first volute channel and the second volute channel, and provides a bypass flow path from at least one of the first volute channel and the second volute channel to the bypass channel. When the valve member is in the second position, the at least one valve channel provides a cross flow path. The valve member in the second position substantially prevents flow along the bypass flow path. The valve member in the third position substantially prevents flow along the cross flow path and the bypass flow path. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present disclosure will hereinafter be described in conjunction with the following drawings, wherein like reference numerals represent like elements, and wherein:

[0009] Figure 1 is a schematic diagram of a turbocharger system constructed according to an example embodiment of the present disclosure;

[0010] Figure 2 is an exploded perspective view of a turbocharger system according to an example embodiment of the present disclosure, wherein the valve member is oriented in a first position;

[0011] Figure 3 yes Figure 2 A perspective view of a turbocharger system wherein the valve member is disposed in a second position;

[0012] Figure 4 yes Figure 2 A perspective view of a turbocharger system wherein the valve member is disposed in a third position;

[0013] Figure 5 is a schematic diagram of a turbocharger system of the present disclosure according to another embodiment, wherein the valve member is shown in a fourth position;

[0014] Figure 6 yes Figure 5 An axial view of a turbocharger system wherein the valve member is shown in a fourth position;

[0015] Figure 7 yes Figure 5A schematic diagram of a turbocharger system, wherein the valve member is shown in a first position;

[0016] Figure 8 yes Figure 5 a schematic diagram of a turbocharger system wherein the valve member is shown in a second position; and

[0017] Fig. 9 yes Figure 5 Schematic diagram of a turbocharger system in which the valve member is shown in a third position. DETAILED DESCRIPTION

[0018] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

[0019] In general, the example embodiments disclosed herein include a turbocharger system with improved characteristics. Specifically, the example embodiments include a turbocharger system having at least two volute components (e.g., scrolls). The volute components direct the exhaust flow to the turbine impeller. The system also includes a bypass structure (i.e., a wastegate) that directs the exhaust gas to bypass the turbine impeller. The turbocharger system also includes a valve component that is movable (e.g., rotatable) between different positions to change the flow between the volute component and the bypass structure. The valve component can be precisely controlled to move between these different positions. Accordingly, the turbocharger system can provide engine boost under a variety of operating conditions.

[0020] In addition, the valve member may include other features that provide various advantages. For example, the valve member may be oriented so that its axis of rotation is oriented transverse to the flow axis of the twin vortex structure. The valve member may be partially housed in the first vortex structure and partially housed in the second vortex structure. Therefore, during operation, the force may be substantially evenly distributed on the valve member to facilitate effective and precisely controlled movement of the valve member. This construction may reduce vibration and / or other noise sources during operation of the turbocharger system. In addition, this arrangement may result in a relatively compact turbocharger system. In addition, in some embodiments, the valve member may have a relatively simple shape, such as a cylindrical shape. Accordingly, the valve member may be highly manufacturable. The turbocharger system of the present application may also improve the lightweighting of the catalyst. Other details of the present disclosure will be discussed below.

[0021] Figure 1is a schematic diagram of an example turbocharger system 100 including a turbocharger housing 101 and a rotor 102. The rotor 102 is configured to rotate about an axis 103 (rotor rotation axis) within the turbocharger housing 101. The rotor 102 may be supported by one or more bearings (not shown) to rotate about the axis 103. In some embodiments, the rotor 102 may be rotationally supported by a thrust bearing and a plurality of journal bearings. Alternatively, other bearings may be included.

[0022] As shown in the illustrated embodiment, the turbocharger housing 101 may include a turbine housing 105, a compressor housing 107, and a bearing housing 109. The bearing housing 109 may be disposed between the turbine housing 105 and the compressor housing 107. Also, in some embodiments, the bearing housing 109 may house bearings of the rotor 102.

[0023] In addition, rotor 102 includes a turbine wheel 111, a compressor wheel 113, and a shaft 115. Turbine wheel 111 is substantially located within turbine housing 105. Compressor wheel 113 is substantially located within compressor housing 107. Shaft 115 extends through bearing housing 109 along axis 103 to connect turbine wheel 111 to compressor wheel 113. Therefore, turbine wheel 111 and compressor wheel 113 can rotate together around axis 103.

[0024] The turbine housing 105 and the turbine wheel 111 cooperate to form a turbine (i.e., a turbine portion, a turbine stage) configured to circumferentially receive a high-pressure, high-temperature exhaust flow 121 delivered from an upstream exhaust structure 191 (e.g., one or more upstream exhaust pipes), which extends from an exhaust manifold 123 of an internal combustion engine 125. The high-pressure, high-temperature exhaust flow 121 drives the turbine wheel 111 (and thus the rotor 102) to rotate about the axis 103. The turbine housing 105 may also be connected to a downstream exhaust structure 126 (e.g., one or more downstream exhaust pipes). The turbine housing 105 may release an exhaust flow 127 thereto. The exhaust flow 127 may be of lower pressure and lower temperature than the exhaust flow 121.

[0025] The turbocharger system 100 may also include a bypass structure 194 (i.e., a wastegate). The bypass structure 194 may extend from the downstream exhaust structure 126 and may define a passage therein that is fluidly connected to a passage within the downstream exhaust structure 126. As will be discussed, the bypass structure 194 may allow exhaust flow from the upstream exhaust structure 191 to bypass the turbine wheel 111 and flow into the downstream exhaust structure 126.

[0026] Furthermore, in some embodiments, the turbine housing 105 may include one or more structures that define different flow paths for the exhaust gas delivered by the upstream exhaust structure 191. Figure 1 As schematically shown in the embodiment of FIG. 1 , the turbine housing 105 may include a first structure 196 and a second structure 198. As will be discussed, the first and / or second structures 196, 198 may define a volute passage (i.e., a volute flow path) that spirals around the axis 103 and around the turbine wheel 111. Thus, the first and second structures 196, 198 may include a twin scroll arrangement of the turbine housing 105. It should be understood that the turbine housing 105 may include more than two volute structures without departing from the scope of the present disclosure.

[0027] In some embodiments, the first structure 196 may be connected to a first upstream exhaust pipe 193 of the upstream exhaust structure 191, and the second structure 198 may be connected to a second exhaust pipe 195 of the upstream exhaust structure 191. The first exhaust pipe 193 and the second exhaust pipe 195 may be connected to different combustion chambers of the engine 125. Therefore, the rotation of the turbine wheel 111 is less likely to be negatively affected by the different pulse flow conditions of the exhaust gas flowing through the upstream exhaust structure 191.

[0028] The compressor housing 107 and the compressor impeller 113 cooperate to form a compressor (i.e., a compressor portion, a compressor stage). The compressor impeller 113 driven by the exhaust gas to rotate is configured to compress the received input air 131 (e.g., ambient air or already pressurized air from the previous stage in a multi-stage compressor) into a pressurized air flow 133 ejected circumferentially from the compressor housing 107. The compressor housing 107 may have a shape (e.g., a volute shape or other shape) configured to guide and pressurize the air blown out from the compressor impeller 113. Due to the compression process, the pressurized air flow is characterized by an increased temperature that exceeds the temperature of the input air 131.

[0029] The air flow 133 may be directed through an air cooler 135 (i.e., an intercooler), such as a convection-cooled charge air cooler. The air cooler 135 may be configured to dissipate heat from the air flow 133, thereby increasing its density. The resulting cooled, pressurized air flow 137 is directed into an intake manifold 139 of the internal combustion engine 125, or alternatively into a subsequent tandem compressor. The operation of the system may be controlled by an ECU 151 (engine control unit) connected to the rest of the system via a communication connection 153.

[0030] The turbocharger system 100 may also include a valve structure 190. Generally, the valve structure 190 may regulate and change the dynamic flow of exhaust gas between the first structure 196, the second structure 198, and the bypass structure 194. In some embodiments, the valve structure 190 may be moved between various positions to regulate and change the flow between the various structures, which will be discussed in detail below.

[0031] In some embodiments, the valve structure 190 may have at least one position that allows at least some of the airflow 121 to flow through the first and / or second structures 196, 198 of the turbine housing 105 to rotate the turbine wheel 111 and flow to the downstream exhaust structure 126. The valve structure 190 may also have at least one position that allows at least some of the airflow 121 to flow through the bypass structure 194 to the downstream exhaust structure 126, in the process, bypassing the turbine wheel 111. In addition, the valve structure 190 may have at least one position that allows at least some of the airflow 121 to flow between the first structure 196 and the second structure 198 of the turbine housing 105.

[0032] In some embodiments, valve structure 190 can be actuated between its various positions by actuator 192. Actuator 192 can be of any suitable type, such as an electric actuator, a hydraulic actuator, or a pneumatic actuator.

[0033] The actuator 192 may be connected to and controlled by the ECU 151. The ECU 151 may also include a processor 199 connected to one or more sensors 189. The sensor 189 may be configured to detect various conditions associated with the turbocharger system 100. In some embodiments, for example, the sensor 189 may detect various conditions associated with the operation of the engine 125 (e.g., engine speed, exhaust mass flow output, etc.). The sensor 189 may provide a signal corresponding to the detected condition to the processor 199. The processor 199 may in turn generate a control signal for the actuator 192 to move the valve structure 190 according to the condition detected by the sensor 189. Thus, the position of the valve structure 190 (and therefore the flow of the exhaust gas stream 121 relative to the turbocharger system 100) may be controlled. This in turn may allow the speed of the compressor impeller 113, the mass flow of the air stream 133, etc. to be controlled.

[0034] It should be appreciated that the turbocharger system 100 and valve arrangement 190 may vary from Figure 1 Furthermore, it will be understood that Figure 1 The turbocharger system 100, valve structure 190, IC engine 125, and other components are schematically illustrated. Therefore, these components are not necessarily drawn to scale.

[0035] refer to Figure 2-4 , a turbocharger system 200 will be discussed according to an exemplary embodiment. The turbocharger system 200 may include the same Figure 1 Features similar to those discussed above. For the sake of brevity, the description of the above features will not be repeated. Figure 1 The corresponding parts of Figure 2-4The corresponding reference numerals in FIG. 1 are increased by 100.

[0036] The turbocharger system 200 may include a first volute structure 296 and a second volute structure 298. The first volute structure 296 and the second volute structure 298 may be arranged in a twin scroll arrangement.

[0037] The first volute structure 296 may be a volute structure having a first volute passage 240 defined therein. The first volute passage 240 may extend along a first axis 241 about the rotation axis 203 of the turbine wheel. Figure 2-4 is hidden in the , but can be configured similar to Figure 1 The first volute passage 240 may include an inlet segment 242, and the first volute passage 240 may extend in a downstream direction along a first axis 241. The first axis 241 may be substantially straight along the inlet segment 242; however, the first axis 241 may spiral about the axis 203 further downstream in the first volute passage 240. In addition, the cross-sectional area of ​​the first volute passage 240 (perpendicular to the axis 241) may be greater than the cross-sectional area further downstream.

[0038] In addition, the first volute structure 296 may include a first branch hole 243. The first branch hole 243 may be an opening, hole, or other opening extending through the wall of the first volute structure 296 in the inlet segment 242. The first branch hole 243 may have various shapes and may be disposed at various locations on the first volute structure 296 without departing from the scope of the present disclosure.

[0039] Similarly, the second volute structure 298 may be a volute structure having a second volute passage 244 defined therein. The second volute passage 244 may extend along a second axis 245 about the rotational axis 203 of the turbine wheel. The second volute passage 244 may include an inlet segment 246 that is substantially similar to the inlet segment 242 of the first volute passage 240.

[0040] In addition, the second volute structure 298 may include a second branch hole 247. The second branch hole 247 may be an opening, hole, or other opening on the wall of the second volute structure 298 extending through the inlet segment 246. The second branch hole 247 may have various shapes and may be disposed at various locations on the second volute structure 298 without departing from the scope of the present disclosure.

[0041] As shown, the first and second volute structures 296, 298 can be compactly arranged in a twin-scroll arrangement. It should be appreciated that in some embodiments, a single turbine housing (such as Figure 1The turbine housing 105 of the embodiment of the present invention may define first and second volute structures 296, 298 (and thus first and second volute passages 240, 244). Furthermore, it should be understood that the first volute structure 296 may be connected to an upstream exhaust pipe (such as Figure 1 The upstream exhaust pipe 193 of the first volute passage 240 is fluidly connected to receive exhaust gas therefrom. Similarly, the second volute structure 298 can be connected to another upstream exhaust pipe (such as Figure 1 Upstream of the exhaust pipe 195 ), the inlet segment 246 is fluidly connected to receive exhaust gas therefrom.

[0042] like Figure 2 As shown, the downstream exhaust structure 226 may extend generally parallel to the axis 203. The exhaust structure 226 may be a hollow elongated tube defining a downstream exhaust passage 248 therein.

[0043] The bypass structure 294 may be a thin-walled hollow structure defining a bypass channel 249 therein. In some embodiments, the bypass structure 294 may have a truncated cone or a truncated pyramid-like shape. The bottom 250 may be connected to the outer surface 252 of the downstream exhaust structure 226, and the bypass structure 294 may protrude radially from the outer surface 252. The bypass structure 294 may also taper so that the cross-sectional area gradually decreases as the bypass structure 294 extends further away from the surface 252. The hollow internal bypass channel 249 may be in fluid communication with the downstream exhaust channel 248 near the bottom 250. In other words, the bypass channel 249 may lead to the downstream exhaust channel 248 near the bottom 250. In addition, the bypass structure 294 may include a bypass opening 254 (i.e., a bypass channel inlet). The bypass opening 254 may be an opening, a hole, a slot or other opening. The bypass opening 254 may be arranged along one side of the bypass structure 294. As will be discussed, at least a portion of the bypass flow path may be defined from the bypass opening 254 , through the bypass passage 249 toward the base 250 and into the downstream exhaust passage 248 .

[0044] The valve structure 290 may generally include a valve member 260 and a support structure 261. In some embodiments, the support structure 261 may be hollow and generally cylindrical. Moreover, the support structure 261 may be fixedly connected to the bypass structure 294, the first volute structure 296, and / or the second volute structure 298. The valve member 260 may be supported to move relative to the support structure 261, and therefore, supported to move relative to the bypass structure 294, the first volute structure 296, and the second volute structure 298. In some embodiments, the valve member 260 may be supported to rotate around a longitudinal axis 262. The valve member 260 may be oriented so that the axis 262 extends transversely to the fluid entering the volute passage 240 and the second volute passage 244. In some embodiments, for example, the axis 262 may be substantially perpendicular to the axis 241 of the first volute passage 240 and the axis 245 of the second volute passage 244.

[0045] For clarity, in Figure 2 , the valve member 260 is shown as being exploded from the support structure 261. In some embodiments, the valve member 260 can be generally cylindrical and hollow. In other words, the valve member 260 can include an outer wall 266 that defines the outer surface and the inner surface of the valve member 260. In some embodiments, the outer wall 266 can be an integral one-piece member. In other embodiments, the outer wall 266 can be assembled from multiple parts.

[0046] In some embodiments, the outer wall 266 may include a first end member 263, a second end member 264, and a side member 265 extending between the first end member 263 and the second end member 264 along the axis 262. The first end member 263 may be disposed near the first end 267 of the valve member 260, and the second end member 264 may be disposed near the second end 268 of the valve member 260. Thus, the first and second end members 263, 264 may be separated along the axis 262, and the axis 262 extends through both. The side member 265 may annularly surround the axis 262 in a circumferential direction. In some embodiments, the first and / or second end members 263, 264 (and the cross-section of the side member 265) may be substantially circular. Moreover, in some embodiments, the first and second end members 263, 264 and the side member 265 may be centered relative to the axis 262. Thus, the outer wall 266 of the valve member 260 may have a shape corresponding to a right circular cylinder.

[0047] In some embodiments, the outer wall 266 may also define one or more valve passages 269 within the valve member 260. Figure 2As shown in the embodiment of the present invention, for example, the valve member can include a single valve channel 269, which includes a hollow interior of the valve member 260 defined by the inner surface of the outer wall 266. Moreover, as shown, the outer wall 266 can have a substantially constant wall thickness; therefore, the valve channel 269 can define a cylindrical volume space. However, it will be appreciated that the valve member 260 can include inner surface features, undulating surfaces, channels, etc., so that the valve channel 269 can have a variety of shapes, as long as it does not depart from the scope of the present disclosure. Moreover, as will be discussed in detail below, without departing from the scope of the present disclosure, the valve member 260 can include more than one different valve channel 269.

[0048] The valve member 260 may further include one or more first openings, namely an upper opening 270 and a lower opening 272, which extend radially through the side member 265 of the outer wall 266 to provide an entrance to the valve passage 269. The upper opening 270 may be disposed near the first end 267 of the valve member 260, and the lower opening 272 may be disposed near the second end 268 of the valve member 260. In some embodiments, the shape of the upper opening 270 and the lower opening 272 may be generally rectangular. Moreover, the upper opening 270 and the lower opening 272 may have substantially similar sizes. However, it should be understood that the shapes and sizes of the upper and lower openings 270, 272 may be different from those shown and described without departing from the scope of the present disclosure.

[0049] Additionally, the valve member 260 can include a second opening 274. The second opening 274 can extend radially through the side member 265 of the outer wall 266 to provide an outlet from the valve passage 269. The second opening 274 can extend between the first end 267 and the second end 268 of the valve member 260. In some embodiments, the shape of the second opening 274 can be generally rectangular; however, it should be understood that the shape of the second opening 274 can have any suitable shape and size without departing from the scope of the present disclosure.

[0050] In some embodiments, the upper opening 270 and the lower opening 272 can be arranged in the first section 276 of the valve member 260 relative to the axis 262. The second opening 274 can be arranged in the second section 277 of the valve member 260 relative to the axis 262. Figure 2As shown, the first segment 276 can be defined between the first radial plane 275 and the second radial plane 278. At the same time, the second segment 277 can be defined between the third radial plane 273 and the fourth radial plane 279. In some embodiments, the first segment 276 can be larger than the second segment 277 (as measured in a circumferential direction about the axis 262). As will be discussed, the valve member 260 can be supported for rotation relative to the first and second volute structures 296, 298 and the bypass structure 294. Rotation of the valve member 260 causes the first and second segments 276, 277 to rotate relative to these structures 296, 298, 294 (and therefore rotate the openings 270, 272, 274), thereby changing the flow through the turbocharger system 100 in a controlled manner.

[0051] The valve member 260 may be accommodated within the support structure 261. Moreover, at least a portion of the first end 267 of the valve member 260 may be accommodated within the inlet segment 242 of the first volute passage 240. In this way, a portion of the first end 267 of the valve member 260 may be exposed within the inlet segment 242. Likewise, at least a portion of the second end 268 of the valve member 260 may be accommodated within the inlet segment 246 of the second volute passage 244. In this way, a portion of the second end 268 of the valve member 260 may be exposed within the inlet segment 246. In addition, a portion of the valve member 260 may be accommodated and exposed within the bypass passage 249.

[0052] The support structure 261 may support the valve member 260 to rotate about the axis 262. For example, when the valve member 260 rotates about the axis 262, the outer surface of the outer wall 266 may slide on the inner surface of the support structure 261. When the valve member 260 rotates, different sections of the valve member 260 may be exposed in the inlet segment 242 of the first volute passage 240, the inlet segment 246 of the second volute passage 244, and the bypass passage 249.

[0053] Now refer to Figure 2 , 3 4 discuss the operation of the turbocharger system 100. As described above, the valve member 260 can rotate about the axis 262 to change the flow through the turbocharger system 100. In some embodiments, the valve member 260 can rotate between at least three positions: Figure 2 The first position represented by Figure 3 The second position represented by Figure 4 In some embodiments, the valve member 260 can also rotate to one or more additional intermediate positions to gradually change the amount of the opening area of ​​the upper opening 270, the lower opening 272, and the second opening 274 relative to the first branch hole 243, the second branch hole 247, and the bypass hole 254. The valve member 260 can be moved by an actuator (such as Figure 1 Furthermore, the rotation of the valve member 260 may be controlled by an ECU such as Figure 1 ECU 151) is based at least in part on sensors such as Figure 1 The control is performed based on the condition detected by the sensor 189).

[0054] exist Figure 2 In the first position shown, the upper opening 270 of the valve member 260 can be at least partially aligned with the first branch hole 243 of the first volute passage 240 (i.e., fluidly connected). Similarly, the lower opening 272 can be at least partially aligned with the second branch hole 247 of the second volute passage 244. In addition, the second opening 274 of the valve member 260 can be at least partially aligned with the bypass hole 254 of the bypass structure 294. In this position, a first volute flow path can be established, allowing exhaust gas to flow through the first volute passage 240 along the axis 241 toward the turbine impeller. Moreover, a second volute flow path can be established, allowing exhaust gas to flow through the second volute passage 244 along the axis 245 toward the turbine impeller. In addition, the valve passage 269 can provide a cross flow path in this position, wherein the exhaust gas can flow between the first volute passage 240 and the second volute passage 244 via the upper opening 270 and the lower opening 272. Furthermore, in the first position, the valve passage 269 may provide a bypass flow path wherein exhaust gas may flow from the first volute passage 240 and / or the second volute passage 244 to the bypass passage 249 via the upper opening 270 , the lower opening 272 , and the second opening 274 .

[0055] exist Figure 3 In the second position shown, the upper opening 270 of the valve member 260 may be at least partially aligned with (i.e., fluidly connected to) the first branch hole 243 of the first volute passage 240. Similarly, the lower opening 272 may be at least partially aligned with the second branch hole 247 of the second volute passage 244. However, the second opening 274 of the valve member 260 may not be aligned with the bypass hole 254, but rather, the outer wall 266 of the valve member 260 may cover the bypass hole 254. Therefore, the valve passage 269 of the valve member 260 can provide a cross flow path, thereby allowing exhaust gas to flow between the first and second volute passages 240, 244, as described above with respect to Figure 2 However, the outer wall 266 of the valve member 260 can prevent flow to the bypass passage 249 and substantially prevent flow along the bypass flow path.

[0056] exist Figure 4In the third position shown, the upper opening 270 may not be aligned with the first branch hole 243, and the lower opening 272 may not be aligned with the second branch hole 247. In this way, the outer wall 266 may block the first and second branch holes 243, 247. In addition, the second opening 274 may not be aligned with the bypass hole 254, and on the contrary, the outer wall 266 may block the bypass hole 254. Therefore, in Figure 4 In the illustrated position, the outer wall 266 of the valve member 260 can prevent flow along the cross flow path (i.e., flow between the first and second volute passages 240, 244). Similarly, the outer wall 266 of the valve member 260 can prevent flow along the bypass flow path (i.e., flow from the first and / or second volute passages 240, 244 to the bypass passage 249).

[0057] It should be understood that the shape, size, dimension, orientation and / or position of the upper opening 270, the lower opening 272 and the second opening 274 can be configured to provide desired flow characteristics at one or more angular positions of the valve member 260. For example, Figure 3 As shown, a portion of the upper opening 270 may be aligned with the first branch hole 243, and a portion of the lower opening 272 may be aligned with the second branch hole 247. Other portions of the upper opening 270 and the lower opening 272 may not be aligned with the first and second branch holes 243, 247, respectively. Figure 2 , wherein most of the upper opening 270 is aligned with the first branch hole 243, and most of the lower opening 272 is aligned with the second branch hole 247. Due to this contrast, Figure 2 The mass flow between the first and second volute passages 240, 244 can be greater than Figure 3 Thus, by rotating valve member 260 , mass flow can be varied and controlled for one or more of the various flow paths of turbocharger system 100 .

[0058] Therefore, according to the current operating conditions, the valve member 260 can be controlled to move between these different positions (and the positions between them). When the valve member 260 rotates to change the flow along various flow paths, the amount of the open exposed area of ​​the upper opening 270, the lower opening 272 and the second opening 274 can change. The flow through the turbocharger system 100 can be accurately controlled. Therefore, engine boost can be provided under a variety of operating conditions. In addition, during operation, the force on the valve member 160 can be fairly evenly distributed on the valve member 160, so as to effectively and accurately control the movement. Vibration and / or other noise sources can also be reduced. In addition, the turbocharger system 100 can be relatively compact. In addition, in some embodiments, the valve member 160 can have a relatively simple cylindrical shape that is highly manufacturable.

[0059] Now refer to Figure 5-9 , a turbocharger system 300 is shown according to another embodiment. The turbocharger system 300 may be substantially similar to Figure 2-4 Except as discussed below, Figure 2-4 The corresponding reference numerals of those corresponding parts are increased by 100.

[0060] First refer to Figure 5 and Figure 6 , the valve member 360 can be substantially cylindrical, similar to the embodiments discussed above. The valve member 360 can include a plurality of valve channels therein, which are schematically shown. The valve channels can include a first valve channel 380, a second valve channel 381, and a third valve channel 382. These valve channels 380, 381, 382 can extend longitudinally along the axis 362 and can be separated from each other (i.e., fluidly disconnected) by at least one partition wall 384.

[0061] The first valve passage 380 may include a first bypass opening 385. The second valve passage 381 may include a second bypass opening 386. The third valve passage 382 may include two or more cross-flow openings 387, wherein one cross-flow opening 387 is in fluid communication with the first volute passage 340 and another cross-flow opening is in fluid communication with the second volute passage 344. The first, second, and third openings 385, 386, 387 may be spaced apart in different sections of the valve member 360 relative to the axis 362.

[0062] In addition, if Figure 6 As shown, the valve member 360 may include one or more second openings 374. As shown, the second openings 374 may be disposed on the first end 367 of the valve member 360. In some embodiments, one second opening 374 may be fluidly connected to the first valve channel 380, and another second opening 374 may be fluidly connected to the second valve channel 381. The second openings 374 may be fluidly connected to the bypass channel 349.

[0063] The valve member 360 can be arranged relative to the volute structures 396, 398 so that the axis 362 extends transversely (e.g., perpendicularly) to the fluid entering the volute passage 340 and the second volute passage 344. The first end 367 can be received and exposed within the first volute passage 340, and the second end 368 can be received and exposed within the second volute passage 344 ( Figure 6 ). Moreover, the rotation of the valve member 360 may change the exposed area of ​​the valve member 360 within the volute passages 340 , 344 .

[0064] The valve member 360 can be rotated to provide the Figure 2-4Furthermore, valve member 360 may provide additional flow characteristics.

[0065] When in Figure 5 and Figure 6 , for example, the first opening 385 (and therefore the first valve passage 380) can be fluidly connected to the first volute passage 340, and the second opening 386 (and therefore the second valve passage 381) can be fluidly connected to the second volute passage 344. The first valve passage 380 can provide a first bypass flow path from the first volute passage 340 to the bypass passage 349. Moreover, the second valve passage 381 can provide a second bypass flow path from the second volute passage 344 to the bypass passage 349. It should be understood that the valve member 360 can keep the first and second bypass flow paths fluidly distinct (i.e., fluidly disconnected from each other).

[0066] The valve member 360 can also be rotated to Figure 7 In this position, the third opening 387 leading to the third valve passage 382 can be exposed to the volute passage 340, allowing cross flow between the first and second volute passages 340, 344. Moreover, at least one of the openings 385, 386 leading to the first and second volute passages 340, 344 can be exposed in the first and second volute passages 340, 344, respectively. Therefore, a bypass flow path can be set. Therefore, Figure 7 The configuration can correspond to Figure 2 Configuration.

[0067] In addition, Figure 8 , the third opening 387 may be exposed, allowing cross flow between the first and second volute passages 340, 344. However, the first and second openings 385, 386 may remain unexposed, preventing bypass flow from the volute passages 340, 344. Figure 8 The configuration can correspond to Figure 3 Configuration.

[0068] In addition, Fig. 9 When the position is set to 1, the openings 385, 386, 387 may not be exposed to the flow in the volute passages 340, 344. Therefore, the cross flow between the volute passages 340, 344 and the bypass flow from the volute passages 340, 344 to the bypass passage 349 are substantially prevented.

[0069] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that the exemplary embodiments or exemplary embodiments are only examples and are not intended to limit the scope, applicability or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing the exemplary embodiments of the present disclosure to those skilled in the art. It should be understood that various changes can be made in the functions and arrangements of the elements described in the exemplary embodiments without departing from the scope of the present disclosure as set forth in the appended claims.

Claims

1. A turbocharger system, comprising: a turbine portion having a turbine wheel, a first volute structure having a first volute passage extending along a first axis and configured to direct exhaust flow toward the turbine wheel, and a second volute structure having a second volute passage extending along a second axis, the first volute passage configured to direct exhaust flow toward the turbine wheel, the second volute passage configured to direct exhaust flow toward the turbine wheel; a downstream exhaust structure having a downstream exhaust passage configured to receive exhaust gas from the turbine section; a bypass structure having a bypass passage configured to provide exhaust gas bypassing the turbine wheel to the downstream exhaust passage; and a valve member having at least one valve passage, the valve member having a generally cylindrical shape, the valve member supported for rotation about a rotation axis between a first position, a second position, and a third position; wherein the rotation axis is oriented transversely to the first axis and the second axis; wherein the at least one valve passage provides a cross flow path between the first volute passage and the second volute passage and provides a bypass flow path from at least one of the first volute passage and the second volute passage to the bypass passage when the valve member is in the first position; wherein said at least one valve passage provides said cross flow path when said valve member is in a second position; wherein the valve member substantially prevents flow along the bypass flow path when in the second position; and wherein the valve member substantially prevents flow along the crossover flow path and the bypass flow path when in the third position, wherein the valve member includes an outer wall defining the valve passage; wherein the valve member includes at least one first opening through the outer wall; wherein the valve member includes at least one second opening through the outer wall; wherein the at least one first opening fluidly connects the valve passage to the first volute passage and the second volute passage when the valve member is in the first position; wherein the at least one second opening fluidly connects the valve passage to the bypass passage when the valve member is in the first position; wherein the at least one first opening fluidly connects the valve passage to the first volute passage and the second volute passage when the valve member is in the second position; wherein the at least one second opening is fluidly disconnected from the bypass passage when the valve member is in the second position; wherein the at least one first opening is fluidly disconnected from the first volute passage and the second volute passage when the valve member is in the third position; and Wherein, the at least one second opening is fluidly disconnected from the bypass passage when the valve member is in the third position.

2. The turbocharger system according to claim 1, wherein: The at least one valve passage includes a single valve passage that provides the crossover flow path and the bypass flow path when the valve member is in the first position.

3. The turbocharger system according to claim 1, wherein: The at least one valve channel comprises a plurality of valve channels separated by at least one divider, the plurality of valve channels comprising: a first valve passage providing said cross flow path when said valve member is in a first position; and A second valve passage provides the bypass flow path when the valve member is in the first position.

4. The turbocharger system according to claim 3, wherein one of the first volute passage and the second volute passage comprises a segment; Wherein a first opening leading to the first valve passage is included in a first section of the valve member about the axis of rotation; Wherein a second opening leading to the second valve passage is included in a second section of the valve member; wherein the valve member comprises an exposed area exposed to the segment and an unexposed area not exposed to the segment; Wherein when the valve member is in the first position, the first opening and the second opening are included in the exposed area; wherein when the valve member is in the second position, the first opening is contained in the exposed region and the second opening is contained in the unexposed region; and Wherein when the valve member is in the third position, the first opening and the second opening are included in the unexposed area.

5. The turbocharger system according to claim 3, wherein the at least one valve passage comprises a first valve passage and a second valve passage; Wherein the first valve channel is separated from the second valve channel by a separator; Wherein the valve member is supported to rotate about the rotation axis between the first position, the second position, the third position and the fourth position; wherein the valve member substantially prevents flow along the cross-flow path when the valve member is in the fourth position; and wherein the first valve passage provides a first bypass flow path from the first volute passage to the bypass passage; and The second valve passage provides a second bypass flow path from the second volute passage to the bypass passage.

6. The turbocharger according to claim 1, further comprising: an actuator configured to actuate the valve member between the first position, the second position, and the third position; a sensor configured to detect a condition associated with the operation of the turbocharger system; and A controller is configured to control the actuator based at least in part on the condition detected by the sensor. 7 . The turbocharger system of claim 6 , wherein the sensor is configured to detect a condition of an engine configured to provide exhaust gas to the first and second volute passages.

8. The turbocharger system of claim 1 , wherein the valve member includes a first portion and a second portion separated along the rotational axis; and Wherein the first portion is at least partially accommodated in the first volute passage, and the second portion is at least partially accommodated in the second volute passage.

9. The turbocharger system of claim 1, wherein: The rotational axis is oriented substantially perpendicular to the first axis and the second axis.

10. A turbocharger system comprising: a turbine portion having a turbine wheel, a first volute structure having a first volute passage configured to direct exhaust flow toward the turbine wheel, and a second volute structure having a second volute passage configured to direct exhaust flow toward the turbine wheel; a downstream exhaust structure having a downstream exhaust passage configured to receive exhaust gas from the turbine section; a bypass structure having a bypass passage configured to provide exhaust gas bypassing the turbine wheel to a downstream exhaust passage; a valve member having a valve passage, the valve member supported for rotation about an axis between a first position, a second position, and a third position; the valve passage providing a cross flow path between the first volute passage and the second volute passage and providing a bypass flow path from at least one of the first volute passage and the second volute passage to the bypass passage when the valve member is in the first position; wherein the valve passage provides the cross flow path when the valve member is in the second position; wherein the valve member substantially prevents flow along the bypass flow path when in the second position; and wherein the valve member substantially prevents flow along the crossover flow path and the bypass flow path when in the third position, wherein the valve member includes an outer wall defining the valve passage; Wherein said valve member comprises at least one first opening through said outer wall; Wherein said valve member comprises at least one second opening through said outer wall; wherein the at least one first opening fluidly connects the valve passage to the first volute passage and the second volute passage when the valve member is in the first position; wherein said at least one second opening fluidly connects said valve passage to said bypass passage when said valve member is in said first position; wherein the at least one first opening fluidly connects the valve passage to the first volute passage and the second volute passage when the valve member is in the second position; wherein said at least one second opening is fluidly disconnected from said bypass passage when said valve member is in said second position; wherein the at least one first opening is fluidly disconnected from the first volute passage and the second volute passage when the valve member is in the third position; and Wherein, the at least one second opening is fluidly disconnected from the bypass passage when the valve member is in the third position.

11. The turbocharger system of claim 10, wherein: The at least one first opening is disposed in a first section of the outer wall relative to the axis; wherein the at least one second opening is disposed in a second section of the outer wall relative to the axis; and The first section is larger than the second section.

12. The turbocharger system according to claim 10, wherein said valve member comprises a plurality of first openings through said outer wall; Wherein said plurality of first openings are spaced apart along said axis; in, The plurality of first openings collectively fluidly connect the valve passage to the first volute passage and the second volute passage when the valve member is in the first position; wherein the plurality of first openings collectively fluidly connect the valve passage to the first volute passage and the second volute passage when the valve member is in the second position; and Wherein, the plurality of first openings are fluidly disconnected from the first volute passage and the second volute passage when the valve member is in the third position.

13. The turbocharger system according to claim 10, wherein said outer wall comprises sides and ends; Wherein the side extends along said axis; wherein said axis intersects said end; and The second opening is arranged through the side of the outer wall.

14. The turbocharger system of claim 10, wherein the outer wall has a generally cylindrical shape.

15. The turbocharger according to claim 10, further comprising: an actuator configured to actuate the valve member between the first position, the second position, and the third position; a sensor configured to detect a condition of the turbocharger system; and A controller is configured to control the actuator based at least in part on the condition detected by the sensor.

16. The turbocharger system of claim 15, wherein: The sensor is configured to detect a condition of an engine configured to provide exhaust gas to the first and second volute passages.

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