US 2003/0196435 A1 · Adjustable turbocharger wastegate controller suitable for after-market installation

Abstract

The invention disclosed is an adjustable turbocharger wastegate controller suitable for after-market installation. In the after-market installation, the invention makes use of the existing factory wastegate mechanism to form a fully adjustable turbine-inlet pressure relief. The factory wastegate valve assembly and the wastegate lever-arm connected to the wastegate shaft are utilized. The invention extends the lever-arm, and applies seating pressure to the valve with a spring assembly using a substantially lower spring-rate than the factory assembly. The spring loading is adjustable over a very wide range, and improved pressure regulation is achieved. The adjustment allows for operation of the vehicle's turbocharger to be adapted for conditions. There are many conditions for which it may be desirable to adjust the turbine inlet pressure limit, including: the load the vehicle must carry or tow, the terrain, flat or with a lot of climbing and descents, the altitude and ambient air pressure, and the ambient air temperature. As an example, an engine required to tow a trailer at high altitude may require higher boost pressure than an unencumbered truck operating at sea-level. The factory wastegate controller must be a one size fits all answer to these variable conditions. The present invention allows for the maximum turbine inlet pressure to be adjusted to meet these variable conditions with the turn of a wrench.

Claims17

Dependent claims

A turbocharger wastegate controller suitable for after-market installation and making use of the existing wastegate valve, wastegate shaft, and wastegate lever arm comprising;

a lever-arm extension attached to the wastegate lever-arm such that it rotates with the wastegate lever-arm in response to movement of the wastegate valve,
a control arm having a first end rotatably attached to the lever-arm extension and a second end which is threaded, a bracket with a through-hole for the control arm to pass through and a means for attachment to the turbocharger housing,
an inner spring cap mounted over the second end of the control arm,
a spring comprising a first and second end wherein the spring is mounted over the second end of the control arm such that the first end of the spring is seated against the inner spring cap,
an outer spring cap mounted over the second end of the control arm and seated against the second end of the spring, and
an adjusting nut fitting the threads on the second end of the control arm and seated against the outer spring cap,
wherein the compression in the spring is adjusted by turning the adjusting nut.

4 more elements

A turbocharger wastegate controller suitable for after-market installation and making use of the existing wastegate valve, wastegate shaft, and wastegate lever arm comprising;

a lever-arm extension attached to the wastegate lever-arm such that it rotates with the wastegate lever-arm in response to movement of the wastegate valve,
a control arm having a first end rotatably attached to the lever-arm extension and a second end which is threaded,
a bracket with a through-hole for the control arm and a means for attachment to the turbocharger housing, wherein the bracket has a means for capturing the end of a spring such that it is held substantially coaxially with the control arm,
a spring comprising a first and second end,
wherein the spring is mounted over the second end of the control arm such that the first end of the spring is seated against the bracket,
an outer spring cap mounted over the second end of the control arm and seated against the second end of the spring, and
an adjusting nut fitting the threads on the second end of the control arm and seated against the outer spring cap,
wherein the compression in the spring is adjusted by turning the adjusting nut.

5 more elements

Dependencies are inferred from the claim text.

Adjustable turbocharger wastegate controller suitable for after-market installation

Life of this patent

Adjustable turbocharger wastegate controller suitable for after-market installation

Life of this patent

Abstract

Claims17