Patent ID: 12228069

DETAILED DESCRIPTION

The following description is presented to enable any person skilled in the art to make and use the invention. For the purposes of explanation, specific nomenclature is set forth to provide a plural understanding of the present invention. While this invention is susceptible of embodiment in many different forms, this description describes and the drawings show specific embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.

FIG.1shows diagram view of a turbocharger manifold10deployed with an internal combustion engine12and two turbochargers14,16in an engine system20.

The manifold10comprises a first exhaust conduit22, and a second exhaust conduit24, a bridge conduit26, and a valve28. The first exhaust conduit receives exhaust gas from an engine, such as in internal combustion engine12, at a first end29. In some embodiments, the first exhaust conduit connects to an exhaust manifold (not shown) or headers (not shown) of the engine12. The exhaust manifold or headers of the engine route engine exhaust gas away from one or more engine cylinders360. Opposite of the engine, the first exhaust conduit has a second end30that is for connecting to a first turbocharger14at a first turbocharger outlet43. The second end is for connecting to an exhaust intake opening or port350of the turbocharger14.

The second exhaust conduit24joins to the first exhaust conduit22at a first intersection32, between the engine12and the second end30. In some embodiments the second exhaust conduit24joins to the first exhaust conduit adjacent the engine12as shown inFIG.1.

The valve28controls access to or along the second exhaust conduit. In some embodiments, the valve is located at or adjacent the intersection32.

Opposite of the intersection32, the second exhaust conduit has a second end34that is for connecting to a second turbocharger16via a second turbocharger outlet47. The second end is for connecting to an exhaust intake opening or port108of the turbocharger16.

The third exhaust conduit has a first end36that is for connecting to an exhaust exit opening or port of the first turbocharger14. A second end38of the third exhaust conduit joins with the second exhaust conduit24for connecting to the exhaust intake opening or port108of the turbocharger16.

An exhaust exit opening or port112of the second turbocharger16may be connected to other exhaust system components such as exhaust pipe(s)40, catalytic converter(s) (not shown), and/or muffler(s) (not shown).

FIG.2shows the manifold10ofFIG.1using the same figure labels for the same parts. The first end29of the first exhaust conduit22comprises a first exhaust inlet39and a flange41connectable to a corresponding exit flange (not shown) of an exhaust manifold (not shown) or headers (not shown) of the engine12. The second end30comprises a second a first turbocharger outlet43and a flange44for connecting to the exhaust inlet of first10turbocharger14.

The second exhaust conduit24comprises a second turbocharger outlet47and a first flange46at end34for connecting to the second turbocharger16. The second exhaust conduit comprises a leg48. The bridge conduit26is connectable to the second exhaust conduit at a flange50. In some embodiments, the second exhaust conduit comprises a Y-intersection52at the terminal end of the leg48.

At the end36is a bridge exhaust inlet37and a flange54for connecting to the exhaust exit opening350of the first turbocharger14.

The valve28comprises a door42. The door is shown in a closed position at42and in an open position at42a. The door42is movable between the open and closed positions (directions H and I ofFIG.2) via an arm mechanism55. The arm mechanism55is the same as arm mechanism117explained below. In some embodiments, an actuator51comprises a moveable rod53that is connected to the arm mechanism55to move the arm mechanism and the door between the open and closed positions. The actuator is mounted to a portion of the exterior of the conduit24as shown inFIG.2. In some embodiments, the terminal end of the rod53is pivotally connected to the arm mechanism with a hinge or pivot connection to allow the rod to move with the arm mechanism in an arcing motion about a pivot location31of the arm mechanism55. In some embodiments, the actuator can be pivotally mounted to the conduit24at a rear pivot location35to allow the actuator and the rod53to move with the arm mechanism55between the open and closed positions. In some embodiments, the actuator51is the same as actuators320or322, as described below. In some embodiments, instead of actuator51, the actuator is a motor45, that rotates the arm mechanism55at or about the pivot location between the open position and the closed position. In some embodiments, the motor45is the same as motors325or327explained below.

In some embodiments, the second exhaust conduit comprises the third exhaust conduit and the flange50is not used. The third exhaust conduit may be unitary with the second exhaust conduit.

FIG.3shows a second embodiment turbocharger manifold60deployed with an internal combustion engine12and two turbochargers14,16in an engine system62.

The manifold60comprises a first exhaust conduit64, a second exhaust conduit68, a third exhaust conduit66, a fourth exhaust conduit70, a fifth exhaust conduit or bridge conduit72, a first valve74, and a second valve76. The valves74,76,28are the same, but oriented differently as shown and described herein.

The first exhaust conduit64receives exhaust gas from an engine, such as in internal combustion engine12, at a first exhaust inlet75at a first end79. In some embodiments the first exhaust conduit64connects to an exhaust manifold (not shown) or headers (not shown) of the engine12. The first exhaust conduit has a second end80that is for connecting to the first turbocharger14. The second end80is for connecting to an exhaust intake opening or port350of the turbocharger14. The second end80comprises a first turbocharger outlet section83. The first turbocharger outlet section83comprises a first turbocharger outlet85.

The third exhaust conduit66receives exhaust gas from an engine, such as in internal combustion engine12, at an exhaust inlet77at a first end81. In some embodiments the third exhaust conduit66connects to an exhaust manifold (not shown) or headers (not shown) of the engine12. The third exhaust conduit has a second end82that is for connecting to the first turbocharger14at the first turbocharger outlet85. The second end82is for connecting to an exhaust intake opening or port350of the turbocharger14via the first turbocharger outlet85.

The second end80of the first exhaust conduit64and the second end82of the third exhaust conduit66join at a first intersection84and connect therefrom to the turbocharger14at the first turbocharger outlet85.

The second exhaust conduit68joins to the first exhaust conduit64at a second intersection86, between the engine12and the second end80. The valve74controls exhaust gas access to or along the second exhaust conduit68. In some embodiments, the valve74is located at or adjacent the second intersection86.

Opposite of the intersection86, the second exhaust conduit68has a second end88that is for connecting to a second turbocharger16at a second turbocharger outlet95. The second end is for connecting to an exhaust intake opening or port108of the turbocharger16at the second turbocharger outlet95.

The fourth exhaust conduit70joins to the third exhaust conduit66at a third intersection90, between the engine12and the second end92. The valve76controls access to or along the fourth exhaust conduit70. In some embodiments, the valve76is located at or adjacent the intersection90.

Opposite of the intersection90, the fourth exhaust conduit has a second end92that is for connecting to a second turbocharger16at the second turbocharger outlet95. The second end is for connecting to an exhaust intake opening or port108of the turbocharger16at the second turbocharger outlet95.

The second end88of the second exhaust conduit68and the second end92of the fourth exhaust conduit70join at a fourth intersection94for a joint conduit connection at the second turbocharger outlet95to an exhaust intake opening or port108of the turbocharger16.

A bridge port conduit101extends rearward from the fourth intersection94at a first end99. The first end99joins with the second and fourth exhaust conduits68,70at the fourth intersection94.

The conduit101has a bend103, between the first end99and a port outlet107of the conduit101. In some embodiments the bend103is a ninety-degree bend. The terminal end of the port conduit101comprises a flange105and the port inlet107.

A second end98of the fifth exhaust conduit72comprises a flange109and is releasably connected to the flange105of the bridge port conduit101to direct exhaust in the fifth exhaust conduit into the intersection94. The fifth exhaust conduit72can be connected to the bridge port conduit101with a clamp, such as a v-band. A first end96of the fifth exhaust conduit72is connectable to the exhaust exit port354of the first turbocharger.

An exhaust exit opening or port112of the second turbocharger16can be connected to other exhaust system components such as exhaust pipe(s)100, catalytic converter(s) (not shown), and/or muffler(s) (not shown).

FIGS.4through11B, show an embodiment of the manifold60ofFIG.3using the same figure labels for the same parts.FIGS.4to6,10,11Ado not show the fifth exhaust conduit72, which is shown inFIGS.7through9. In some embodiments the first and third exhaust conduits64,66form a w-shape as shown inFIG.4. In some embodiments the second and fourth exhaust conduits68,70form a u-shape as shown inFIG.4.

In some embodiments, a first turbocharger outlet section83extends from the intersection84for connecting with the exhaust intake port350of the first turbocharger.

In some embodiments, the first ends79and81of the first and third exhaust conduits comprise flanges (not shown) for joining the first and second exhaust conduits with an exhaust manifold(s) or header(s) of the engine. In some embodiments, a flange97is mounted to or adjacent the fourth intersection for joining the third, fourth, and fifth exhaust conduits to the exhaust intake port108of the second turbocharger16.

As shown inFIG.5, the intersection94and/or a portion extending from the intersection, and the opening102of the outlet95, is angled forward from the angle of the first turbocharger outlet section83. Therefore, the second turbocharger16when mounted at the flange97is forward of the outlet section83and the first and third exhaust conduits64,66, as further shown inFIGS.11A and11B.

FIG.8shows an example first turbocharger14mounted to the outlet section83of the turbo charger manifold with a clamp106at an exhaust inlet port350of the turbocharger. In some embodiment the clamp is a v-band clamp. The first end96of the fifth exhaust conduit72is connected to an exhaust outlet352of the turbocharger14. Therefore, the exhaust gas exiting the first turbocharger is directed to the exhaust inlet of the second turbocharger16via the intersection94and the outlet95.

FIGS.11A and11Bshows an example second turbocharger16connected at the second turbocharger outlet95. An extension109is added to raise the second turbocharger outlet95above the intersection94. The extension109can be integrally formed with the intersection94. The exhaust intake port108of the second turbocharger16is connected to the second turbocharger outlet95with a clamp111, such as a v-band. In some applications, a further exhaust pipe100is connected to the exhaust outlet fitting110of the exhaust exit112. In some embodiments, an extension109can be used to position the second turbocharger in the desired position.

FIG.11Bshows the first turbocharger14and the second turbocharger16mounted to the manifold60, with the bridge conduit72connected to the first turbocharger.FIG.11Bshows an exemplary application where the first turbocharger14is smaller than the second turbocharger16.

FIGS.12to15show a section of the manifold60comprising valve74and a portion of exhaust conduits64,68. Valve76at the intersection of exhaust conduits66,70is the same as valve74at the intersection of exhaust conduits64,68, except it valve76rotated 180 degrees about a mid-plane114(FIG.7) bisecting the manifold60. Therefore, only valve74will be described in detail.

The valve comprises a door116and an arm mechanism117. The arm mechanism comprising a first and second door arms118,120, and a first and second mount arms122,124, and a connecting bar125. Distal ends126,128of the respective mount arms122,124are pivotally mounted to respective side mounting plates130,132.

The side mounting plates130,132are attached at and adjacent the intersection of exhaust conduits64and68. The plates create a semi enclosed space134between the intersecting exhaust conduits as shown inFIGS.12,14, and15at a corner of the intersection. In some embodiments, the mounting plates are joined to the respective conduits64,68at or adjacent first edges136,138of the respective plate. Between the first edges of each plate is a second curved edge140,142. The curved edges140,142extend from exhaust conduit64to exhaust conduit68.

The mount arm122is located on the outside side of plate130and mount arm124is located on the outside side of the plate132. The door arms118,120are located between the plates130,132and between arms122,124.

The plates130,132comprise an aperture (not shown) where pins144,146are mounted. The pivot pins extend through apertures (not shown) in the respective arms122,124. The pins have heads or outside washers148,150that are larger than the apertures in the respective arms122,124. The heads or washers are formed with or fixed to the pins to secure the arms122,124to the respective pins144,146and therefore pivotally to the respective plates130,132. In some embodiments, the plates130,132do not have apertures at the pins and the pins are fixed to the outside surface of the respective plates.

In some embodiments, each of the mount arms122,124comprise a first arm portion152,154and a second arm portion156,158. The first arm portions152,154each comprise a mouth160,162. The second arm portion156,158is received into the respective mouth160,162. In some embodiments the mouth160,162covers the second arm portion on at least a portion of two sides. The second arm portion is shaped and sized to be received into the respective mouth. In some embodiments, fasteners, such as bolts or bolt and nut combinations or screws,164,166,168,170join the second arm portion to the respective mouth.

In some embodiments, the second arm portions156,158, the connecting bar125, and the door arms118,120are formed of a unitary piece of material.

The connection bar125extends transverse to the second arm portions156,158, the mount arms122,124, and the door arms118,120. In some embodiments, the connection bar125is perpendicular to the second arm portions156,158, the mount arms122,124, and the door arms118,120. The door arms118,120join to the connection bar125inward of and between the mount arms122,124.

In some embodiments, the connection bar125comprises offset portion172between opposite end portions174,176. The offset portion172is offset from the end portions174,176. The offset portion173provides a back recess178that can accommodate the conduit64and allow a greater range of motion of the connecting bar, the door, and the valve.

In some embodiments, the door arms118,120each comprise a first portion180,182and a second curved portion184,186. The first portions are non-curved and joined to the respective curved portions. A door mount188is connected to the door arms118,120opposite the connecting bar125. The door mount188is fixed to the door116. In some embodiments the door mount188is fixed to the door116with a fastener190, such as a bolt or screw. The door mount comprises a concave curve and profile between the door arms118,120. The door arms can be fixed to the door mount with fasteners192,194, such as pins.

The door arms118,120extend through or are moveable through, depending on the position of the valve, an arm aperture196in the exhaust conduit68.

FIGS.16and17show a cutout view of the intersection of the exhaust conduits64and68showing an interior of the conduit64and conduit68(FIG.16). An interior bottom portion200of exhaust conduit64comprises a bypass aperture198providing access to exhaust conduit68. InFIG.17, the door116of valve74is in a closed position, covering the bypass aperture198and closing and blocking exhaust gas access to the exhaust conduit68from exhaust conduit64. InFIG.16, the door116of valve74is an open position, where the door is against or adjacent an interior sidewall202of the conduit68, and the aperture198is open allowing exhaust gas access from the exhaust conduit64to the exhaust conduit68.

The valve, arm mechanism, and door are shown in an open position inFIGS.12and14and in a closed position inFIGS.13and15. InFIG.14, the door arms extend through arm aperture196and into conduit68. All or a substantial portion of the curved portion184,186are within the conduit68when the valve is in the closed position. The curved portions184,186cause the door to move to cover the aperture198when the valve is moved to the closed position.

FIGS.18to20show a second embodiment valve204that can be used in place of valve74,76, and/or28. The second embodiment valve204comprises the same door116as valve74. The valve204comprises an arm mechanism206that is similar to the arm mechanism117, except as shown and described.

The arm mechanism206comprises a first and second door arms218,220, and a first and second mount arms222,224, and a connecting bar225. Distal ends226,228of the respective mount arms222,224are pivotally mounted to respective side mounting plates130,132at apertures227,229with pins144,146as described with valve74.

The connection bar225comprises an offset portion225between opposite end portions228,230. The end portions228,230each comprise recesses232,234. The end recess232,234receives terminal ends236,238of the mount arms222,224. The mount arms may be fixed to the connection bar225at the terminal ends236,238with fasteners, such as bolts or screws240.

Ends246,248of the door arms opposite the door mount250are mounted to the connection bar225within the recess244by fasteners (not shown) at apertures252,254. The door mount250comprises recesses256,258for receiving ends260,262of the door arms, which can be fixed thereto with fasteners at apertures265. The door mount is mounted to the back264of the door116at apertures266,268with fasteners. The door116has a concave profile from a first side272to a second side273. The concave curve and profile conforms to the curve and profile of the bottom200of the conduit64.

FIGS.19,20and21show the interior side274of the door116. In some embodiments, the interior side274comprises a perimeter recess276. The perimeter recess276is recessed from the main surface275of the interior side274. The first wall280between the recess276and the main surface comprises a top edge282and a bottom edge277. At the outer edge278of the recess276is an outer sidewall284, which may be angled. In some applications, the perimeter recess contacts the exterior side of conduit64within conduit68about the aperture198, and the main surface275is within the aperture198, when closed.

FIGS.22and23show a cover290. The cover is for coving around the arm aperture196in the conduit68. The cover has arm apertures292,294for the door arms118,120, or218,220respectively to extend through. Therefore, the connecting bar125,225and the mount arms122,124are outside of the cover, while a portion of the door arms118,120,218,220are inside296of the cover when in use.

In some embodiment, the290cover has a rectangular shape. The cover has a front wall298and sidewalls300,302,304,306. The longer first and second sidewalls300,302have a concave cut-outs308,310, and are concave between the third and fourth sidewalls304,306. Therefore, the first and second sidewalls300,302have a concave curved back edge312,314opposite the front wall298. The back edges316,318of the third and fourth sidewalls300,302opposite the front wall298are beveled toward the inside296as shown inFIG.22. The concave back edges312,314allow the cover to conform to the curvature of the outside wall of the conduit68in the general directions A and B ofFIG.15adjacent the arm aperture196along the aperture's196longer length. The beveled back edges316,318allow the cover to conform to the curvature of the outside wall of the conduit68adjacent the arm aperture196along the aperture's196shorter width.

In some embodiments, the arm apertures292,294are sized to closely fit around the door arms, either by surface-to-surface contact about the door arm at the points of intersection or by being closely adjacent thereto. The close fit can seal against gas escape from the cover and the exhaust conduit68if gas passes through the arm aperture196into the inside of the cover. Further, the cover can be mechanically held against conduit68about the arm aperture196with a fastener, such as a clamp, or adhesive. Therefore, the edges312,314,316,318can contact and seal to the outside surface of the conduit68about the arm aperture196.

As shown inFIG.8, in some embodiments, the manifold60comprises or has attached actuators320,322for moving the arm mechanism117of valves74and76between, to, and from the closed position and the open position. In some embodiments, the actuators are linear actuators. The actuators comprise a moveable rod324,326. The terminal end of the rod324,326are connected328,330attached to the connecting bar125,225of valves74,76. In some embodiments, the connection328,330is a hinged or pivot connection which allows the terminal end of the rod324,326to pivot relative to the connecting bar125,225as the valve moves between closed and open positions in the directions F and E for valve74and H and G for valve76. The valves74,76are shown in or close to the closed position inFIG.8. Therefore, when the rods of the actuators are in a retracted position, the valves are in a closed position. When the rods of the actuators are extended to an extended position, the valves are in the open position, with the door116of the valves76,74adjacent or against the inside wall of conduits68,70, and the respective apertures between conduit64and68and conduits66and70open. In some embodiments, the rods can move in an arc motion to follow the arc motion of the connecting bar125,225moving along the path defined by its connection via the mount arms122,124,222,224to the pins144,146and the plates130,132. In some embodiments, the rods comprise a curved portion332,334and a straight portion as shown inFIG.8. The straight portion is adjacent the actuator housing336,338. The curved portions332,334assist or allow in following the curved path of the connecting bar125,225from and to the open and closed positions.

In some embodiments, the actuators are pressure or vacuum operated. In some embodiments, pressure operated actuators comprise a chamber comprising a diaphragm and a spring biasing the diaphragm to a first position corresponding to a retracted position of the rod324,326. The diaphragm operatively moves the rod from the retracted position to an extended position when a predefined open pressure is applied to the diaphragm to overcome the spring bias of the spring. When pressure drops below the predefined open pressure, the spring overcomes the pressure to move the diaphragm back toward and to the first position and therefore retracts the rod to the retracted position. In some embodiments, pressure supplied to the actuators is pressure from the manifold10,60ahead of the first turbocharger. This pressure may be known as exhaust back pressure. Therefore, a pressure control conduit (not shown) can extend from conduit64,64or24to the actuator. The actuation of the actuators and therefore the positions of the valves can be controlled by based on the pressure in the manifold10,60upstream of the first turbocharger.

When the actuator is vacuum operated, vacuum is applied and/or released from one side of the diaphragm causing the diaphragm to move, which causes the operatively connected rod to move.

In some embodiments, the actuators are electro-mechanical linear actuators. In some embodiments, the electro-mechanical linear actuators comprise a motor and a gear mechanism, such as a leader screw and a nut. The leader screw comprises threads. A nut is operably fixed to the movable rod and engaged to the threads of the leader screw. The rotation of the lead screw by the motor is a first rotation direction causes the nut to move in a first linear direction along the screw, thus moving the rod with it in the first linear direction. The rotation of the screw by the motor in a second rotation direction opposite the first rotation direction causes the nut to move in a second linear direction opposite the first linear direction along the screw, thus moving the rod with the nut in the second linear direction opposite the first linear direction. Therefore, powering the motor to rotate in one direction causes the rod to extend and powering the motor to rotate in the opposite direction causes the rod to retract.

In some embodiments, the actuator that controls each valve74,76is a motor325,327(shown diagrammatically inFIG.9), such as a servomotor. Each motor is connected to the respective pins144,146or to the respective arms122,124,222,224at or about the pins to rotate the arms from and to the open and closed positions for each respective valve74,76.

FIG.24shows an exemplary block diagram of turbocharger14, which, in some embodiments, is the same as turbocharger16. The turbocharger14comprises a turbine340and a compressor342. The turbine340is connected to the compressor such as by a shaft344. The turbine drives the compressor. The turbine is rotated by the force of exhaust gas from the engine12passing through the turbine housing346from an exhaust inlet350to an exhaust outlet352. The exhaust gas turns the turbine which is connected to the shaft344which turns the compressor342. The compressor342receives ambient air from an inlet354and forces the air out the forced air outlet356of the compressor housing348. The compressor compresses the air forced out of the air outlet356at a pressure higher than atmospheric pressure.

In some embodiments, the turbine comprises turbine fan blades (not shown) for capturing the momentum of the exhaust air flowing through the turbine housing and causing the turbine to rotate. The turbine housing directs the exhaust gas to follow through and spin the turbine.

In some embodiments, the compressor is a centrifugal compressor comprising an impeller and a diffuser. The impeller raises the energy of the intake air. The diffuser is downstream of the impeller and coverts the kinetic energy of the air/gas into pressure by slowing the gas velocity. A collector is downstream of the diffuser to gather the flow of air/gas from the diffuser and deliver this flow to a downstream conduit, which may be joined to the outlet356. The outlet356of the compressor is connected to the intake manifold at390of the engine12.

FIG.25shows a block diagram of a portion360of the engine12including a cylinder362, and a portion of a crankshaft370. The engine may have any number of cylinders, such as 2, 3, 4, 5, 6, 8, 10, or 12 cylinders. The cylinder362comprises a piston364connected to a connecting rod366. The connecting rod366is rotatably connected at a terminal end368to a crankpin374of a crankshaft370(partially shown inFIG.25). The crankshaft370is journaled to rotate in the engine block of the engine at block journal location372on the crankshaft where the engine main bearings are located between the crankshaft and the engine block.

The cylinder has four cycles: an intake, compression, combustion, and exhaust cycles. During the intake cycle, the intake valve or valves (not shown) are opened to allow air and fuel to enter the cylinder362through an intake opening376and the piston is drawn down in direction D by the crankshaft to draw air and fuel into the cylinder. The forced air from the turbocharger increases the density of the intake gas/air entering cylinder during the intake cycle. The increase in density of the intake gas/air allows more power per engine cycle.

FIG.29is a block diagram showing that the compressed/forced air of the compressor of the turbochargers14,16is routed to the engine, usually through an engine intake manifold at390. The output of the compressors of the turbochargers14,16are routed to intake opening of the cylinders of the engine.

At the end of the intake cycle the intake valve or valves are closed and the crankshaft drives the piston upward in the direction C to compress the air and fuel within the cylinder above the piston. When the piston is at or about the top of its up and down travel allowed by the rotation of the crankshaft, a spark is provided at the spark plug380, which extends into the top of the cylinder. The spark ignites the air fuel mixture compressed in the cylinder above the piston, causing fuel to burn and release energy driving the piston downward in the direction D, and driving the crankshaft to rotate. When the piston reaches the bottom of its up and down travel, one or more exhaust valves (not shown) will open to allow exhaust gas to exit the cylinder through an exhaust opening378. The exhaust gas will be received in an engine exhaust manifold or headers. The engine exhaust manifold or headers are connected to the turbocharger manifold at exhaust inlets75,77or39. Therefore, the turbocharger manifold receives the exhaust gas from the engine.

In some applications, an engine will have two exhaust manifolds, a first exhaust manifold for receiving exhaust from a first set of cylinders of the engine and the second exhaust manifold for receiving exhaust from a second set of cylinders of the engine. Therefore, the two inlets75and77allow the turbo manifold60to receive exhaust exiting from two exhaust manifolds.

In some applications, one engine exhaust manifold may have two exit openings. Therefore, each of the openings can be connected to one of the inlets75,77so that the turbocharger manifold60can collect all of the exhaust gas from the engine.

In some embodiments, a controller382controls the operation of the actuators320,322or325,327, or51,45to control the position of the valves74,76, or28. The controller382is connected by wire or wireless connection to a pressure sensor and/or a turbo speed sensor as shown inFIG.26. The controller is connected by wire or wireless connection to the actuators320,322or325,327in the case of manifold60or actuator51or45in the case of manifold10. The controller is configured to send control signals and/or power to direct the movement of the actuators. In some embodiments, the control signals and/or power are sent based on the data received from the one or both of the sensors384,386.

In operation, the controller is configured to and will instruct and/or power the actuators to move or position the valves28,74,76to the closed position at lower engine operating speeds up to a predefined open threshold. In the case where the actuators320,322,51are pressure or vacuum operated, the actuators are configured to maintain the valves in a closed position at pressure or vacuum corresponding to lower engine operating speeds up to the predefined open threshold.

Therefore, all of the exhaust gas will be directed via conduits64and66, in the case of manifold60or conduit22in the case of manifold10, to the first turbocharger14. When the predefined open threshold is reached, the valves28,74,76are opened, to allow some of the exhaust gas to travel in conduits68,70in the case of manifold60and conduit24in the case of manifold10, to the second turbocharger16. In the case where the actuators320,322,51are pressure or vacuum operated, the actuators are configured to move the valves28,74,76to the open position when the pressure or vacuum corresponding to the predefined open threshold is reached. In the case of the use of a controller283to control the actuators, the controller is configured to and will instruct and/or power the actuators to move or position the valves2874,76to the open position when the predefined open threshold is reached or exceeded.

The turbocharger manifolds10,60direct the exhaust gas exiting the first turbocharger14to the second turbocharger16via conduits26and72to the second turbocharger16even when the valves2874,76are closed.

In some embodiments, the predefined open threshold is set at the peak efficiency threshold of the first turbocharger14. The peak efficiency can be correlated to a speed of rotation of the turbocharger and/or a manifold pressure leading up to the first turbocharger in the turbocharger manifold60.

In some embodiments, the turbocharger14comprises a speed sensor384that measures and reports the rotational speed of the compressor and/or the turbine of the turbocharger14to the controller382. In some embodiments, the turbocharger16comprises a speed sensor383that measures and reports the rotational speed of the compressor and/or the turbine of the turbocharger16to the controller382.

In some embodiments, conduits22,64, and/or66comprise a pressure sensor386that measures and reports the pressure within the respective conduit. Therefore, the pressure sensor386can measure the pressure in the turbocharger manifold upstream of the first turbocharger14. The pressure sensor can be mounted to extend into the conduit to measure the pressure. The connection between the sensor and the conduit will be air-tight.

Therefore, when a predefined open rotation speed of the first turbocharger14is reached or exceeded as reported by the speed sensor384and/or a predefined open manifold pressure is reached or exceeded in the manifold exhaust conduit(s) upstream of the first turbocharger as reported by sensor(s)386, the valves2874,76will open. Before and below such predefined open speed and/or such predefined open manifold pressure is reached valves are and remain closed.

In this manner all or substantially all of the exhaust gas from the engine is directed into the first turbo until the predefined open threshold(s) are reached. After a one or more of the open threshold(s) are reached the valves28,74,76are opened to divert some of the exhaust gas from reaching the first turbo charger and directing it through conduits24,68,70to the second turbocharger16.

In some applications, the actuators open or the controller is configured to direct the actuators to open the valves when the first turbo charger reaches peak efficiency so that diverting exhaust gas to the second turbo charger will provide better performance gains from the engine than continuing to deliver all exhaust gas to the first turbocharger.

While peak efficiency of the first turbocharger is one threshold at which the controller or the actuators could be configured to open the valve, other user selected or programed thresholds may be used depending on the selected components, such as type and size of the turbos, engine size, and/or other components, and the performance goals of the users. Therefore, the condition(s) upon which the valves are caused to be open or can be selected by the user to achieve the desired performance.

In some embodiments, the controller382is an engine control unit (ECU) that controls the operation of the engine12, and components of thereof, as well as the valves28,74,76. The ECU may also receive data from one or more other sensors for controlling engine operation. In some embodiments, the controller382is in communication with and/or directed by the ECU.

In some embodiments, the references to conduit herein includes pipe as a conduit. The conduit(s) of the turbocharger manifolds disclosed herein have one or more enclosing walls that are gas impermeable so as to contain the exhaust gas within the conduit and allow it to travel in the open space within the conduit bounded by the enclosing wall or walls. In some embodiments, a turbocharger wastegate is added at location113(FIG.9).

In some embodiments, the controller382comprises processing circuitry. The processing circuitry may comprise one or more of microprocessor(s), microcontroller(s), a hardware circuit(s), application-specific integrated circuit(s) (ASIC), digital signal processor(s) (DSP), field-programmable gate array(s) (FPGA), discrete logic circuit(s), or combinations thereof for performing the operations of the controller382or the ECU.

From the foregoing, it will be observed that numerous variations and modifications may be affected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. For example, one or more component embodiments may be combined, modified, removed, or supplemented to form further embodiments within the scope of the invention. Further, steps could be added or removed from the processes described. Therefore, other embodiments and implementations are within the scope of the invention.