Turbocharger including a switchable trim compressor and ported shroud

A compressor assembly for a turbocharger for a vehicle, said compressor assembly comprising:

• a rotatable shaft extending longitudinally along an axis;
• a compressor housing defining an interior and defining an air inlet portion spaced from said shaft and disposed about said axis, said air inlet portion defining an inlet diameter perpendicular to said axis;
• a compressor wheel coupled to said shaft and disposed between said air inlet portion and said turbine wheel, with said compressor wheel rotatable by said shaft;
• an inlet adaptor housing coupled to said compressor housing;
• an inlet adaptor housing coupled between said turbine housing and said compressor housing;
• a ported shroud defined by said compressor housing and by said inlet housing adaptor, said ported shroud including a first port defined by said compressor housing that opens to said interior of said compressor housing between said switchable trim compressor and said compressor wheel, and a second port fluidically connected between said first port and said air inlet portion, said second port defined by said inlet adaptor housing;
• and
• a switchable trim compressor disposed within said interior of said compressor housing, said switchable trim compressor comprising:
• an adjusting ring including a plurality of spaced apart axial extensions and one or more flange openings, wherein said adjusting ring is rotatable about said axis between a first position and a second position;
• a guide vane mounted insert comprising:
• an inner ring defining a plurality of openings,
• an outer ring positioned radially outward of said inner ring, with said inner and outer ring defining a channel therebetween that defines a portion of said ported shroud between said first and second ports, and
• a plurality of spokes coupling said inner ring to said outer ring;
• one or more guide vanes, each of said one or more guide vanes comprising a body portion and a projection pin, with said projection pin being inserted within a corresponding one of said plurality of openings in said inner ring, and
• one or more vane levers, each one of said one or more vane levers comprising a body portion, said body portion having a pair of spaced apart prong portions seated against a surface of said adjusting ring in a direction of said compressor wheel and an opposing lever arm, with one of said opposing lever arms extending within a respective one flange opening of said one or more flange openings,
• wherein said guide vanes are positioned with a major planar surface of said body portion of each of said one or more guide vanes normal to said axis and wherein said plurality of spaced apart extensions block said second port when said adjusting ring is in said first position, and
• wherein said guide vanes are positioned with said major planar surface of said body portion of each of said one or more guide vanes transverse to said axis and wherein said plurality of spaced apart extensions are unblocked from said second port when said adjusting ring is in said second position.

A method for controlling mass fluid flow in a turbocharger of a vehicle,

• the turbocharger including a turbine housing defining a turbine housing interior;
• a turbine wheel contained within the turbine housing interior;
• a shaft coupled to and rotatable by the turbine wheel, the shaft extending along an axis longitudinally through the turbine housing interior;
• a compressor assembly including a compressor housing defining an interior and defining an air inlet portion spaced from the shaft and disposed about the axis, the air inlet portion defining an inlet diameter perpendicular to the axis;
• a compressor wheel coupled to the shaft and disposed between the air inlet portion and the turbine wheel, with the compressor wheel rotatable by the shaft;
• an inlet adaptor housing coupled to the compressor housing;
• and a ported shroud defined by the compressor housing and by the inlet housing adaptor for recirculating air back to the air inlet portion, the ported shroud including a first port defined within the compressor housing that opens to the interior of the compressor housing between the switchable trim compressor and the compressor wheel, and a second port fluidically connected between the first port and the air inlet portion, the second port defined by the inlet adaptor housing,
• wherein the turbocharger also a switchable trim compressor mechanism positioned between an air inlet opening of the turbocharger and a compressor wheel of the turbocharger,
• said method comprising said steps of:
• positioning the switchable trim compressor in a first trim position to minimize a diameter of the air inlet opening and to block fluid flow from an interior of the compressor through the first and second port of the ported shroud to a position upstream of the switchable trim compressor at a position near the air inlet opening;
• and
• positioning the switchable trim compressor in a second trim position to increase a diameter of the air inlet opening and to allow recirculation fluid flow from an interior of the compressor assembly through the first and second port of the ported shroud to a position upstream of the switchable trim compressor at a position near the air inlet opening.