BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention generally relates to an electronic actuator assembly for use with a turbocharger of a vehicle and also to a vibration detection assembly for use in a vehicle having an internal combustion engine.

2. Description of the Related Art

Turbochargers receive exhaust gas from an internal combustion engine and deliver compressed air to the internal combustion engine. Turbochargers are used to increase power output of the internal combustion engine, lower fuel consumption of the internal combustion engine, and reduce emissions produced by the internal combustion engine. Delivery of compressed air to the internal combustion engine by the turbocharger allows the internal combustion engine to be smaller, yet be able to develop the same or similar amount of horsepower as larger, naturally aspirated internal combustion engines. Having a smaller internal combustion engine for use with a vehicle reduces the mass and aerodynamic frontal area of the vehicle, which helps reduce fuel consumption of the internal combustion engine and improve fuel economy of the vehicle.

Typical turbochargers include a turbine housing defining a turbine housing interior, a turbine wheel disposed within the turbine housing interior for receiving the exhaust gas from the internal combustion engine, and a turbocharger shaft coupled to and rotatable by the turbine wheel. Typical turbochargers also include a compressor housing defining a compressor housing interior, and a compressor wheel disposed within the compressor housing interior and coupled to the turbocharger shaft, with the compressor wheel being rotatable by the turbocharger shaft for delivering compressed air to the internal combustion engine. Specifically, energy from exhaust gas from the internal combustion engine, which would normally be wasted energy, is used to drive the turbine wheel, which is used to drive the turbocharger shaft and, in turn, the compressor wheel to the deliver the compressed air to the internal combustion engine.

Typical turbochargers also include various electronic actuator assemblies, which are used to control various components of a turbocharger, such as a wastegate valve, a bypass valve, or a variable turbine geometry (VTG) valve. Typical turbochargers further include various electronics, which are commonly used to perform diagnostics on the turbocharger or to control various functions of the turbocharger. However, the electronics and the electronic actuator assemblies of typical turbochargers are usually separate components. This results in more components for the turbocharger, which ultimately results in a more expensive and larger turbocharger.

Additionally, typical turbochargers may have a method of determining rotational speed of the turbocharger shaft, and a method for analyzing acceleration data for performing diagnostics on the turbocharger. However, the electronics and the electronic actuator assemblies of typical turbochargers are expensive and result in a larger turbocharger.

As such, there remains a need to provide for a turbocharger having an improved electronic actuator assembly and improved methods of using the turbocharger.

SUMMARY OF THE INVENTION AND ADVANTAGES

A turbocharger is used with a vehicle for receiving exhaust gas from an internal combustion engine and for delivering compressed air to the internal combustion engine. The turbocharger includes a turbine housing defining a turbine housing interior, a turbine wheel disposed within the turbine housing interior for receiving the exhaust gas from the internal combustion engine, and a turbocharger shaft coupled to and rotatable by the turbine wheel. The turbocharger also includes a compressor housing defining a compressor housing interior, and a compressor wheel disposed within the compressor housing interior and coupled to the turbocharger shaft, with the compressor wheel being rotatable by the turbocharger shaft for delivering compressed air to the internal combustion engine. The turbocharger additionally includes a bearing housing coupled to and disposed between the turbine housing and the compressor housing, with the bearing housing defining a bearing housing interior, and with the turbocharger shaft disposed within the bearing housing interior. The turbocharger further includes an electronic actuator assembly. The electronic actuator assembly includes an actuator housing coupled to at least one of the turbine housing, the compressor housing, and the bearing housing. The electronic actuator assembly also includes an accelerometer coupled to the actuator housing. The accelerometer is adapted to detect vibration of at least one of the turbine housing, the compressor housing, the bearing housing, and the actuator housing thereby obtaining acceleration data of at least one of the turbine housing, the compressor housing, the bearing housing, and the actuator housing to determine rotational speed of the turbocharger shaft.

According to another embodiment of the present invention, a vibration detection assembly for use in a vehicle having an internal combustion engine includes a vehicle component. The vehicle component may be selected from the group consisting of a turbocharger, a valve assembly, an electronically driven compressor, a turbocharger having an integral electric motor, or combinations thereof. The vibration detection assembly also includes an electronic control assembly which has an assembly housing coupled to the vehicle component. Moreover, an accelerometer is coupled to the assembly housing. The accelerometer is adapted to detect vibration of the vehicle component thereby obtaining acceleration data of the vehicle component to perform diagnostics of at least one of the vehicle component, the internal combustion engine, or the vehicle.

Additionally, the present invention further provides for a method of determining rotational speed of a turbocharger shaft of a turbocharger, and a method of analyzing acceleration data of a turbocharger of an internal combustion engine of a vehicle to perform diagnostics of one of the turbocharger, the internal combustion engine, and the vehicle. Accordingly, the electronic actuator assembly of the turbocharger adds the accelerometer to the electronic actuator assembly, which results in a less expensive and smaller turbocharger. Additionally, the method of determining rotational speed of the turbocharger shaft utilizing the electronic actuator assembly using fewer components is more cost effective than how typical turbochargers determine the rotational speed of the turbocharger shaft. Furthermore, the method for analyzing acceleration data for performing diagnostics on the turbocharger using the electronic actuator assembly is more cost effective than typical turbochargers analyzing acceleration data, as typical turbochargers use additional components.

