Exhaust manifold to turbine connection

Abstract

A turbocharger having a turbine housing including an outer surface and an inner surface defining an exhaust passage; an exhaust inlet port in fluid communication with the exhaust passage; and a folding exhaust inlet flange surrounding the exhaust inlet port, the exhaust inlet flange including a plurality of bolt holes arranged in a trapezoidal bolt pattern.

Description

Technical Field

[0001] The present invention generally relates to an exhaust system for an internal combustion engine, and more specifically to a turbocharger, an exhaust manifold, and the connection therebetween. Background Technology

[0002] The use of turbochargers in internal combustion engines is well-known. Turbochargers improve the quality of air supplied to the engine, thereby increasing the engine's power output. Furthermore, by utilizing the heat energy contained in the engine exhaust gases, turbochargers improve engine efficiency.

[0003] However, the connection between the turbocharger and the engine presents various design challenges. For the engine to operate at optimal efficiency, it must transfer as much energy as possible from the exhaust gases to the turbocharger's turbine, thereby maximizing the boost provided by the turbocharger. However, energy is lost as the exhaust gases flow through the exhaust manifold and from the exhaust manifold into the turbocharger. Therefore, the design of the exhaust passages in the exhaust manifold and the turbocharger's turbine section is crucial for minimizing these energy losses.

[0004] Furthermore, as modern engines and engine systems become more complex and include more components, constraints on the spacing between components on the engine and on the amount of available space for the engine in the engine compartment of the machine also increase. Therefore, design challenges related to spacing and assembly constraints also exist.

[0005] U.S. Patent No. 5,406,795 (“Patent 795”) granted to Raub et al. on April 18, 1995, discloses a conventional prior art exhaust manifold outlet flange design comprising two generally rectangular ports separated by a partition wall. Patent 795 also discloses an alternative exhaust manifold outlet flange having two exhaust ports separated by a partition wall, wherein the paired ports and partition wall are configured in a manner resembling a bow tie. This configuration allows the ports to have the same area as a conventional rectangular port design, and the flange maintains the same bolt pattern as a conventional rectangular port design, while reducing the thermal inertia and stiffness of the surrounding constraint material of the flange, thereby improving transient response and reducing thermal stress. Summary of the Invention

[0006] According to one aspect of the invention, a turbocharger includes a turbine housing having an outer surface and an inner surface defining an exhaust passage; an exhaust inlet port in fluid communication with the exhaust passage; and a folded exhaust inlet flange surrounding the exhaust inlet port, the exhaust inlet flange including a plurality of bolt holes arranged in the form of trapezoidal bolts.

[0007] According to another aspect of the invention, an internal combustion engine includes one or more cylinders; an exhaust manifold in fluid communication with the one or more cylinders; and a turbocharger having a turbine portion in fluid communication with the exhaust manifold. The turbocharger includes a turbine housing having an outer surface and an inner surface defining an exhaust passage; an exhaust inlet port in fluid communication with the exhaust passage; and a folded exhaust inlet flange surrounding the exhaust inlet port, the exhaust inlet flange including a plurality of bolt holes arranged in the form of trapezoidal bolts. Attached Figure Description

[0008] Further features and advantages will become apparent from the following illustrative embodiments, which will now be described by way of example only and without limiting the scope of the claims, with reference to the accompanying drawings, wherein:

[0009] Figure 1 This is a schematic diagram of an engine with an exhaust system including a turbocharger;

[0010] Figure 2 It is attached to Figure 1 A perspective view of an exemplary embodiment of the turbine section of the turbocharger in the exhaust manifold of an engine;

[0011] Figure 3 It is used for Figure 2 A front view of an exemplary embodiment of the exhaust inlet flange of a turbine;

[0012] Figure 4 yes Figure 3 Rear view of the exhaust inlet flange;

[0013] Figure 5 yes Figure 2 A side view of the turbine section;

[0014] Figure 6 It is used for Figure 2 A front view of an exemplary embodiment of the exhaust outlet flange of the exhaust manifold;

[0015] Figure 7 yes Figure 2 A side view of the central portion of the exhaust manifold; and

[0016] Figure 8 yes Figure 2 Top front view of the exhaust manifold. Detailed Implementation

[0017] While this invention describes certain embodiments of turbochargers and exhaust manifolds for internal combustion engines, it should be considered exemplary and not intended to be limited to the disclosed embodiments. Furthermore, certain elements or features of the embodiments disclosed herein are not limited to specific embodiments but are applicable to all embodiments of the invention.

[0018] Reference Figure 1-2 An exemplary embodiment of an internal combustion engine 10 (such as a diesel engine) is shown. Engine 10 can power various types of applications and / or machines. For example, engine 10 can power machines such as off-road trucks, railway locomotives, and earthmoving machinery (such as wheel loaders, excavators, dump trucks, backhoe excavators, motorized graders, material handling machines, etc.). The term "machine" can also refer to stationary equipment, such as a generator driven by engine 10 to generate electricity.

[0019] Engine 10 includes one or more cylinders 12 implemented therein. In the illustrated embodiment, engine 10 includes six cylinders 12. However, in other embodiments, engine 10 may include more or fewer than six cylinders 12. Engine 10 may be inline, V-type, rotary, or other types known in the art as shown. Each of the cylinders 12 may be configured to slidably receive a piston (not shown).

[0020] Each of the cylinders 12 includes one or more intake ports 14 and one or more exhaust ports 16, each intake port 14 having an intake valve (not shown) and each exhaust port 16 having an exhaust valve (not shown). The intake and exhaust valves are configured to regulate fluid communication into and out of the cylinder 12 via one or more intake ports 14 and one or more exhaust ports 16, respectively. The engine 10 includes an intake manifold 18 in fluid communication with one or more cylinders 12 and an intake line 20, and an exhaust manifold 22 in fluid communication with one or more cylinders 12 and an exhaust line 24. Intake air enters from the intake line 20 via the intake manifold 18 into one or more intake ports 14, and exhaust air enters from one or more exhaust ports 16 via the exhaust manifold 22 into the exhaust line 24. The exhaust manifold 22 is configured to be mounted to one or more cylinder heads (not shown) on the engine 10. In the illustrated embodiment, the exhaust manifold 22 and one or more cylinder heads (not shown) are connected by a plurality of bolts 28 (… Figure 2 ( ) connection. However, other connection devices, such as multiple studs and nuts, can also be used.

[0021] Engine 10 includes a turbocharger 30 having an exhaust turbine section 32 and an intake compressor section 34. The compressor section 34 includes an air inlet 36 and an air outlet 38. The air outlet 38 is in fluid communication with the intake line 20. The exhaust turbine section 32 has an exhaust inlet 40. Figure 3 ) and exhaust outlet 42. Exhaust outlet 42 is in fluid communication with exhaust line 24.

[0022] The exhaust inlet 40 of the turbocharger 30 includes an exhaust inlet flange 46 (i.e., turbine foot) surrounding the exhaust inlet port 48. The exhaust inlet flange 46 is configured to connect to an exhaust manifold outlet flange 50 on the exhaust manifold 22. In the illustrated embodiment, the exhaust inlet flange 46 of the turbocharger 30 and the exhaust manifold outlet flange 50 of the exhaust manifold 22 are connected by a plurality of bolts 51 (…). Figure 2 The connection is as follows: However, other connection devices, such as multiple studs and nuts, can also be used. In the illustrated embodiment, gasket 52 is located between exhaust manifold outlet flange 50 and exhaust inlet flange 46. Gasket 52 has bolt holes (not shown) of the same bolt type as exhaust manifold outlet flange 50 and exhaust inlet flange 46, which will be described in more detail below.

[0023] Reference Figure 3-5 The turbine portion 32 of the turbocharger 30 has a turbine housing 54 having one or more outer surfaces 56 and one or more inner surfaces 58. The inner surface 58 defines an exhaust inlet port 48 and a helical exhaust passage 59 (i.e., a volute) that is in fluid communication with the exhaust inlet port 48 and extends from the exhaust inlet port 48 to an exhaust outlet 42. Figure 5 As shown, the exhaust passage 59 is spiraled around the central axis Y, and the turbine housing 54 has a radius R that decreases as the exhaust passage 59 spirals inward.

[0024] In the illustrated embodiment, the inner surface 58 defining the exhaust passage 59 is integral with and smoothly transitions into the exhaust inlet flange 46, such that the exhaust passage 59 smoothly transitions into the exhaust inlet port 48. The exhaust inlet flange 46 includes a flat end face 60, an outer surface 62 opposite to the end face 60, and an outer peripheral edge 64 connecting the end face 60 to the outer surface 62. Figure 5 As shown, the plane P defined by the flat end face 60 is at a distance B1 from the central axis Y. Distance B1 represents the shortest distance between plane P and the central axis Y. In some exemplary embodiments, the exhaust inlet flange 46 is in a folded configuration. As used in this invention, the exhaust inlet flange 46 is "folded" when the distance B1 is less than or equal to the radius R along the same radial line. An "extended" configuration is the configuration when the distance B1 is greater than the radius R along the same radial line (i.e., the exhaust inlet flange 46 extends beyond the turbine housing 54).

[0025] In some exemplary embodiments, the distance B1 is less than 80% of the radius R along the same radial line, or less than 70% of the radius R along the same radial line, or less than 60% of the radius R along the same radial line. In one exemplary embodiment, the distance B1 of the exhaust inlet flange 46 is in the range of 50% to 60% of the radius R along the same radial line.

[0026] In the illustrated embodiment, the outer peripheral edge 64 includes a first outer edge 66, a second outer edge 68 parallel to and opposite to the first outer edge 66, a third outer edge 70 extending between the first outer edge 66 and the second outer edge 68, and a fourth outer edge 72 parallel to and opposite to the third outer edge 70 and extending between the first outer edge 66 and the second outer edge 68. The first outer edge 66 is located at the inner side 73 of the turbine housing 54 relative to the helical direction of the exhaust passage 59, and the second outer edge 68 is located at the outer side 75 of the turbine housing 54.

[0027] The second outer edge 68 transitions to the third outer edge 70 via the first rounded corner 74, and to the fourth outer edge 72 via the second rounded corner 76. The first outer edge 66 transitions to the third outer edge 70 via the third rounded corner 78, and to the fourth outer edge 72 via the fourth rounded corner 80. The third rounded corner 78 and the fourth rounded corner 80 extend laterally outward from the third outer edge 70 and the fourth outer edge 72, respectively.

[0028] The exhaust inlet flange 46 includes a plurality of bolt holes for mounting the turbocharger 30 to the exhaust manifold 22. In the illustrated embodiment, a first hole 82 is located near a first fillet 74, a second hole 84 is located near a second fillet 76, a third hole 86 is located near a third fillet 78, and a fourth hole 88 is located near a fourth fillet 80. The first hole 82 is centered on a first axis 90 extending perpendicular to the end face 60, the second hole 84 is centered on a second axis 92 extending perpendicular to the end face 60, the third hole 86 is centered on a third axis 94 extending perpendicular to the end face 60, and the fourth hole 88 is centered on a fourth axis 96 extending perpendicular to the end face 60.

[0029] In the illustrated embodiment, the third axis 94 is at a first distance D1 from the fourth axis 96, the first axis 90 is at a second distance D2 from the second axis 92, the first axis 90 is at a third distance D3 from the third axis 94, and the second axis 92 is at a fourth distance D4 from the fourth axis 96. In an exemplary embodiment, the first distance D1 is greater than the second distance D2, and the third distance D3 is equal to the fourth distance D4. In an exemplary embodiment, the first line intersecting the first axis 90 and the second axis 92 is parallel to the second line intersecting the third axis 94 and the fourth axis 96. Therefore, the bolts for the exhaust inlet flange 46 are trapezoidal in shape.

[0030] In one exemplary embodiment, the first distance D1 is in the range of 108mm to 118mm or 113mm, and the second distance D2 is in the range of 90mm to 100mm or 95mm. Therefore, the ratio of the first distance D1 to the second distance D2 is in the range of 1.08 to 1.31 or 1.19. The third distance D3 and the fourth distance D4 are in the range of 65mm to 75mm or 70mm.

[0031] In an exemplary embodiment, the exhaust inlet port 48 is a single open port symmetrical about the central axis A. Therefore, the exhaust inlet port 48 is not divided into two ports by a partition wall, but is the only exhaust inlet port of the turbocharger 30. However, in other embodiments, the exhaust inlet port 48 may not be symmetrical about the central axis A. The exhaust inlet port 48 includes a first linear portion 100, a second linear portion 102 spaced apart from and parallel to the first linear portion 100, a third linear portion 104 perpendicular to the first linear portion 100 and the second linear portion 102 and extending between the first linear portion 100 and the second linear portion 102, and a fourth linear portion 106 parallel to the third linear portion 104 and perpendicular to the first linear portion 100 and the second linear portion 102 and extending between the first linear portion 100 and the second linear portion 102.

[0032] The first linear portion 100 transitions to the third linear portion 104 via a first inner fillet 108, and to the fourth linear portion 106 via a second inner fillet 110. The second linear portion 102 transitions to the third linear portion 104 via a first inclined portion 112 located between pairs of first shallow curved portions 114, and to the fourth linear portion 106 via a second inclined portion 116 located between pairs of second shallow curved portions 118. In some exemplary embodiments, the first inclined portion 112 is formed at an angle of 40 to 60 degrees or 45 to 55 degrees relative to the second linear portion 102, or at 55 degrees.

[0033] The first linear portion 100 has a first length L1, the second linear portion 102 has a second length L2, the third linear portion 104 has a third length L3, and the fourth linear portion 106 has a fourth length L4. In an exemplary embodiment, the third length L3 is equal to the fourth length L4. Furthermore, due to the first inclined portion 112 and the second inclined portion 116, the second length L2 is less than the first length L1. Therefore, relative to the spiral direction of the exhaust passage 59, the linear portion of the exhaust inlet port 48 adjacent to the inner side is longer than the linear portion of the exhaust inlet port 48 adjacent to the outer side. In an exemplary embodiment, the ratio of the first length L1 to the second length L2 is in the range of 1.25 to 1.5 or 1.33.

[0034] One or more outer surfaces 56 of the turbine housing 54 can be configured to prevent interference between the turbine housing 54 and installation tools (e.g., sockets for mounting bolts 51), and to provide sufficient clearance to allow the installer to more easily attach the turbocharger 30 to the exhaust manifold 22. (See reference...) Figure 4 In one exemplary embodiment, one or more outer surfaces 56 of the turbine housing 54 may include one or more recessed, recessed, or concave surface regions adjacent to one or more of the first axis 90, second axis 92, third axis 94, and fourth axis 96. For example, the turbine housing 54 may have recessed portions of its outer surface 56, such as one or more grooves. The recessed portions may extend along a portion of the outer surface 56 parallel to one or more of the first axis 90, second axis 92, third axis 94, and fourth axis 96.

[0035] In an exemplary embodiment, the turbine housing 54 includes a first recessed portion 120 adjacent to a first hole 82, a second recessed portion 122 adjacent to a second hole 84, a third recessed portion 124 adjacent to a third hole 86, and a fourth recessed portion 126 adjacent to a fourth hole 88. Each hole 82, 84, 86, 88 has an assembly clearance defined as the closest radial distance between the central axis of the hole and a surface of the turbine housing at a location along the central axis outside the hole. In other words, the assembly clearance is associated with the clearance between the turbine housing and an installation tool (such as a socket or socket extension) for driving bolts 51 to attach the turbocharger 30 to the exhaust manifold 22.

[0036] like Figure 4 As shown, the first hole 82 has a first assembly gap C1, the second hole 84 has a second assembly gap C2, the third hole 86 has a third assembly gap C3, and the fourth hole 88 has a fourth assembly gap C4. In the illustrated embodiment, the assembly gaps C1-C4 (i.e., the closest radial distance between the central axis of each hole and the surface of the turbine housing) are located at the recesses 120, 122, 124, and 126 of each hole 82, 84, 86, and 88. However, in other embodiments, one or more assembly gaps may be located at other portions of the turbine housing 54. In some exemplary embodiments, each assembly gap C1-C4 is greater than 11.5 mm, or greater than 12 mm, or greater than 12.5 mm.

[0037] Reference Figure 2 In the illustrated embodiment, the exhaust manifold 22 has a central manifold portion 140 in fluid communication with the first pair of cylinders 12, a first transverse manifold portion 142 in fluid communication with the second pair of cylinders 12, and a second transverse manifold portion 144 opposite to the first transverse manifold portion 142 and in fluid communication with the third pair of cylinders 12.

[0038] Reference Figure 6-8 The central manifold portion 140 of the exhaust manifold 22 has a generally cylindrical tubular body 146, which has an outer surface 148 and an inner surface 150 defining an exhaust outlet port 152 and an exhaust passage 154 in fluid communication with the exhaust outlet port 152.

[0039] In the illustrated embodiment, the inner surface 150 defining the exhaust passage 154 is integral with and smoothly transitions into the exhaust manifold outlet flange 50, such that the exhaust passage 154 smoothly transitions into the exhaust outlet port 152. The exhaust manifold outlet flange 50 includes a flat end face 160, an outer surface 162 opposite to the end face 160, and an outer peripheral edge 164 connecting the end face 160 to the outer surface 162. In the illustrated embodiment, the outer peripheral edge 164 includes a first outer edge 166, a second outer edge 168 parallel to and opposite to the first outer edge 166, a third outer edge 170 extending between the first outer edge 166 and the second outer edge 168, and a fourth outer edge 172 opposite to the third outer edge 170 and extending between the first outer edge 166 and the second outer edge 168.

[0040] The second outer edge 168 transitions to the third outer edge 170 via the first rounded corner 174, and to the fourth outer edge 172 via the second rounded corner 176. The first outer edge 166 transitions to the third outer edge 170 via the third rounded corner 178, and to the fourth outer edge 172 via the fourth rounded corner 180.

[0041] The exhaust manifold outlet flange 50 includes a plurality of bolt holes for mounting the turbocharger 30 to the exhaust manifold 22. In the illustrated embodiment, a first hole 182 is located near a first fillet 174, a second hole 184 is located near a second fillet 176, a third hole 186 is located near a third fillet 178, and a fourth hole 188 is located near a fourth fillet 180. The first hole 182 is centered on a first axis 190 extending perpendicular to the end face 160, the second hole 184 is centered on a second axis 192 extending perpendicular to the end face 160, the third hole 186 is centered on a third axis 194 extending perpendicular to the end face 160, and the fourth hole 188 is centered on a fourth axis 196 extending perpendicular to the end face 160.

[0042] In the illustrated embodiment, the first axis 190 is a first distance E1 from the second axis 192, the third axis 194 is a second distance E2 from the fourth axis 196, the first axis 190 is a third distance E3 from the third axis 194, and the second axis 192 is a fourth distance E4 from the fourth axis 196. In an exemplary embodiment, the first distance E1 is less than the second distance E2, and the third distance E3 is equal to the fourth distance E4. In an exemplary embodiment, the first line intersecting the first axis 190 and the second axis 192 is parallel to the second line intersecting the third axis 194 and the fourth axis 196. Therefore, the bolts for the exhaust manifold outlet flange 50 are trapezoidal in shape. Similarly, the third outer edge 170 and the fourth outer edge 172 taper inward from the first outer edge 166 to the second outer edge 168; therefore, the outer edges of the exhaust manifold outlet flange 50 are also trapezoidal in shape.

[0043] In one exemplary embodiment, the first distance E1 is in the range of 90mm to 100mm or 95mm, and the second distance E2 is in the range of 108mm to 118mm or 113mm. Therefore, the ratio of the first distance E1 to the second distance E2 is in the range of 1.08 to 1.31 or 1.19. The third distance E3 and the fourth distance E4 are in the range of 65mm to 75mm or 70mm.

[0044] In an exemplary embodiment, the exhaust outlet port 152 is a single open port symmetrical about the central axis B. Therefore, the exhaust outlet port 152 is not divided into two ports by a partition wall, but is the only exhaust outlet port of the exhaust manifold 22. However, in other embodiments, the exhaust outlet port 152 may not be symmetrical about the central axis B. The exhaust outlet port 152 includes a first linear portion 200 and a second linear portion 202, the second linear portion 202 being collinear with the first linear portion 200 and separated from the first linear portion 200 by a first inward bend 204. The exhaust outlet port 152 also includes a third linear portion 206 opposite to and parallel to the first linear portion 200, and a fourth linear portion 208 opposite to and parallel to the second linear portion 202. The third linear portion 206 is collinear with the fourth linear portion 208 and separated from the fourth linear portion 208 by a second inward bend 210.

[0045] The exhaust outlet 152 also includes a fifth linear portion 212 that is perpendicular to the first linear portion 200 and the third linear portion 206 and extends between the first linear portion 200 and the third linear portion 206, and a sixth linear portion 214 that is parallel to the fifth linear portion 212 and perpendicular to the second linear portion 202 and the fourth linear portion 208 and extends between the second linear portion 202 and the fourth linear portion 208.

[0046] The first linear portion 200 transitions to the fifth linear portion 212 via a first inner fillet 218, and the second linear portion 202 transitions to the sixth linear portion 214 via a second inner fillet 220. The third linear portion 206 transitions to the fifth linear portion 212 via a first inclined portion 222, and the fourth linear portion 208 transitions to the sixth linear portion 214 via a second inclined portion 224.

[0047] The center manifold portion 140 includes one or more cylinder head mounting flanges for mounting the center manifold portion 140 to one or more cylinder heads (not shown) of the engine 10. In the illustrated embodiment, the center manifold portion 140 includes a first cylinder head mounting flange 230 and a second cylinder head mounting flange 232. The first cylinder head mounting flange 230 includes a flat end face 234, an outer surface 236 opposite to the end face 234, and an outer peripheral edge 238 connecting the end face 234 to the outer surface 236. The first cylinder head mounting flange 230 also includes a first end 240 and a second end 242 opposite to the first end 240.

[0048] The first cylinder head mounting flange 230 includes a pair of bolt holes for mounting the center manifold portion 140 to the cylinder head (not shown). In the illustrated embodiment, a first hole 244 is located near a first end 240, and a second hole 246 is located near a second end 242. The first hole 244 is centered on a first axis 248 extending perpendicularly to the end face 234, and the second hole 246 is centered on a second axis 250 extending perpendicularly to the end face 234.

[0049] The second cylinder head mounting flange 232 is substantially similar to the first cylinder head mounting flange 230. The second cylinder head mounting flange 232 includes a flat end face 254, an outer surface 256 opposite to the end face 254, and an outer peripheral edge 258 connecting the end face 254 to the outer surface 256. The second cylinder head mounting flange 232 also includes a first end 260 and a second end 262 opposite to the first end 260.

[0050] The second cylinder head mounting flange 232 includes a pair of bolt holes for mounting the center manifold portion 140 to the cylinder head (not shown). In the illustrated embodiment, a first hole 264 is located near a first end 260, and a second hole 266 is located near a second end 262. The first hole 264 is centered on a first axis 268 extending perpendicularly to the end face 254, and the second hole 266 is centered on a second axis 270 extending perpendicularly to the end face 254.

[0051] like Figure 6As shown, the flat end face 160 of the exhaust manifold outlet flange 50 extends at an angle α relative to the flat end face 254 of the second cylinder head mounting flange 232. In the illustrated embodiment, this angle is in the range of 50 to 60 degrees or 55 degrees. However, in other embodiments, this angle may be greater than 60 degrees or less than 50 degrees.

[0052] The outer surface 148 of the center manifold portion 140 can be configured to avoid interference between the center manifold portion 140 and installation tools (e.g., sockets for mounting bolts 28), and to provide sufficient clearance to allow the installer to more easily attach the center manifold portion 140 to one or more cylinder heads (not shown). See reference... Figure 6 and 8 In one exemplary embodiment, the outer surface 148 of the central manifold portion 140 may include one or more recessed, recessed, or concave surface regions adjacent to one or more of the first axes 248, 268 and / or one or more of the second axes 250, 270. In one exemplary embodiment, the outer surface 148 of the cylindrical tubular body 146 of the central portion includes one or more recessed, recessed, or concave surface portions.

[0053] In an exemplary embodiment, the center manifold portion 140 includes a first recessed portion 272 adjacent to a first hole 244 of the first cylinder head mounting flange 230, a second recessed portion 274 adjacent to a second hole 246 of the first cylinder head mounting flange 230, a third recessed portion 276 adjacent to a first hole 264 of the second cylinder head mounting flange 232, and a fourth recessed portion 278 adjacent to a second hole 266 of the second cylinder head mounting flange 232. Each hole 244, 246, 264, 266 has an assembly clearance defined as the closest radial distance between the central axis of the hole and the outer surface of the center manifold portion 140 or the outer surface of the turbine housing 54 at a location along the central axis outside the hole when assembled to the center manifold portion 140. In other words, the assembly clearance is associated with the clearance between the center manifold portion 140 or the turbine housing 54 and an installation tool (such as a socket or socket extension) for driving bolts 28 to attach the center manifold portion 140 to one or more cylinder heads (not shown).

[0054] like Figure 8As shown, the first hole 244 of the first cylinder head mounting flange 230 has a first assembly gap D1, the second hole 246 of the first cylinder head mounting flange 230 has a second assembly gap D2, the first hole 264 of the second cylinder head mounting flange 232 has a third assembly gap D3, and the second hole 266 of the second cylinder head mounting flange 232 has a fourth assembly gap D4. In the illustrated embodiment, the assembly gaps D1-D4 (i.e., the nearest radial distance between the central axis of each hole and the surface of the central manifold portion) are located at the recesses 272, 274, 276, and 278 of each hole 244, 246, 264, and 266. However, in other embodiments, one or more assembly gaps may be located at other portions of the central manifold portion 140. In some exemplary embodiments, each assembly gap D1-D4 is greater than 14.5 mm, or greater than 15 mm, or greater than 15.5 mm.

[0055] Industrial applicability

[0056] Engines utilizing the turbocharger and exhaust manifold of this invention can be used in a variety of applications, such as powering off-road trucks, railway locomotives, earthmoving machinery, engine-driven generators or pumping systems, or other engine-driven applications. The disclosed turbocharger and exhaust manifold are particularly suitable for applications where the spacing between the turbocharger and exhaust manifold is constrained. For example, the turbocharger may include a folded exhaust inlet flange that provides a more compact spacing between the turbocharger and the exhaust manifold.

[0057] However, a more compact turbocharger and exhaust manifold arrangement presents assembly challenges. For example, conventional rectangular exhaust inlet flanges can cause interference between installation tools (such as spigots and spigot extensions) and the outer surfaces of the turbine housing and / or exhaust manifold.

[0058] The turbocharger and exhaust manifold of the present invention may include one or more features to prevent interference between the installation tool and the outer surface of the turbine housing and / or the exhaust manifold. For example, the turbine exhaust inlet flange may have a novel configuration including a four-hole, non-square bolt configuration with a narrower spacing between the bolts on the outer side of the exhaust inlet flange relative to the direction of the exhaust passage helix. When the turbocharger is bolted to the exhaust manifold, the narrower spacing of the outer edge bolt holes provides additional clearance for entry.

[0059] The exhaust inlet ports are configured to accommodate a narrower spacing of the outer edge bolt holes, while still having sufficient size and design to allow adequate exhaust flow to the turbine. For example, the linear portion of the exhaust inlet port near the inner side can be longer than the linear portion of the exhaust inlet port near the outer side. Therefore, the exhaust inlet ports are wider near the inner side than near the outer side.

[0060] In addition, recessed portions on the outer surfaces of the turbine housing and the exhaust manifold provide additional space for the inlet or inlet extension to engage and drive the bolts that attach the exhaust manifold to the cylinder head and the turbocharger to the exhaust manifold.

[0061] While the invention has been described by way of examples, and while the examples have been described in considerable detail, the applicant does not intend to limit the scope of the appended claims or restrict them in any way to such details. Additional advantages and modifications will be apparent to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, representative components or concepts, and illustrative examples shown and described. Thus, deviations from such details may be made without departing from the spirit or scope of the applicant's general disclosure herein.

Claims

1. A turbocharger (30), comprising: Turbine housing (54) having an outer surface (56) and an inner surface (58) defining an exhaust passage (59); An exhaust inlet port (48) is in fluid communication with the exhaust passage (59); and A folded exhaust inlet flange (46) surrounds the exhaust inlet port (48), the exhaust inlet flange (46) including a plurality of bolt holes (82) arranged in the form of trapezoidal bolts. The exhaust inlet flange (46) has a flat end face (60) defining a first plane (P), and the turbine housing (54) is about a central axis (Y). The shortest distance from the first plane (P) defined by the flat end face (60) to the central axis (Y) is B1. When the distance B1 is less than or equal to the radius (R) along the same radial line, the exhaust inlet flange (46) is in a folded configuration. The exhaust inlet flange (46) includes an inner side (73) and an outer side (75), and the exhaust inlet port (48) includes a first linear portion (100) adjacent to the inner side (73) and a second linear portion (102) parallel to the first linear portion (100) and adjacent to the outer side (75), wherein the first linear portion (100) has a first length (L1) and the second linear portion (102) has a second length (L2) less than the first length (L1). The outer side has a first bolt hole (82) centered on a first axis (90) and a second bolt hole (84) centered on a second axis (92), the inner side has a third bolt hole (86) centered on a third axis (94) and a fourth bolt hole (88) centered on a fourth axis (96), and the third axis (94) is a first distance (D1) from the fourth axis (96), the first axis (90) is a second distance (D2) from the second axis (92), and the first distance (D1) is greater than the second distance (D2).

2. The turbocharger (30) according to claim 1, wherein the ratio of the first distance (D1) to the second distance (D2) is in the range of 1.08 to 1.

31.

3. The turbocharger (30) according to claim 1, wherein the ratio of the first length (L1) to the second length (L2) is in the range of 1.25 to 1.5 or 1.

33.

4. The turbocharger (30) according to any one of claims 1-3, wherein the exhaust inlet port (48) is undivided and is the only exhaust inlet port (48) of the turbocharger (30).

5. The turbocharger (30) according to any one of claims 1-3, wherein the shortest distance (B1) of the first plane (P) from the central axis (Y) is in the range of 50% to 80% of the radius (R) of the turbine housing (54) along the same radial line.

6. The turbocharger (30) according to any one of claims 1-3, wherein the turbine housing (54) has a minimum assembly clearance of more than 11.5 mm, the assembly clearance being defined as the closest radial distance between the central axis of the bolt hole and the surface of the turbine housing at a location along the central axis outside the bolt hole.

7. The turbocharger (30) of claim 6, wherein one or more outer surfaces (56) of the turbine housing (54) include one or more recessed portions adjacent to one or more of the first axis (90), the second axis (92), the third axis (94) and the fourth axis (96), and the minimum assembly clearance is associated with the recessed portion adjacent to the bolt hole in the exhaust inlet flange (46).

8. An internal combustion engine (10), comprising: One or more cylinders (12); An exhaust manifold (22) is in fluid communication with one or more cylinders (12); as well as The turbocharger (30) according to claim 1.

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