A turbocharger system comprises a first relatively small high-pressure (HP) turbocharger and a second relatively large low pressure (LP) turbocharger. The turbine of the LP turbocharger is connected in series downstream of the turbine of the HP turbocharger. A first exhaust bypass flow passage provi
A turbocharger system comprises a first relatively small high-pressure (HP) turbocharger and a second relatively large low pressure (LP) turbocharger. The turbine of the LP turbocharger is connected in series downstream of the turbine of the HP turbocharger. A first exhaust bypass flow passage provides a bypass flow path around the HP turbine. A second exhaust bypass flow passage provides a bypass flow path around the LP turbine. A rotary valve is located at a junction of the first and second bypass flow passages and a first exhaust gas flow passage. The rotary valve comprises a valve rotor which is rotatable selectively to permit or block flow to the LP turbine and to permit or block flow to the first and second bypass paths.
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1. A turbocharger system comprising: a primary inlet for flow communication with an exhaust gas manifold of an engine and an exhaust outlet;a first relatively small turbocharger having a first turbine with an inlet and an outlet;a second relatively large turbocharger having a second turbine with an
1. A turbocharger system comprising: a primary inlet for flow communication with an exhaust gas manifold of an engine and an exhaust outlet;a first relatively small turbocharger having a first turbine with an inlet and an outlet;a second relatively large turbocharger having a second turbine with an inlet and an outlet;a primary exhaust gas flow path including an inlet portion for delivering exhaust gas to the inlet of the first turbine and an intermediate portion for delivering exhaust gas from the outlet of the first turbine to the inlet of the second turbine;a first bypass flow path in gas flow communication with the primary inlet and the inlet of the second turbine thereby bypassing the first turbine;a second bypass flow path in gas flow communication with the primary inlet and the exhaust outlet thereby bypassing the second turbine; andan exhaust gas flow control valve operable to: i) permit or prevent selectively exhaust gas flow through the primary exhaust flow path;ii) permit or prevent selectively exhaust gas flow through the first bypass path;iii) permit or prevent selectively exhaust gas flow through the second bypass path;wherein the exhaust flow control valve is situated in the inlet portion of the primary exhaust gas flow path so as to permit or allow gas flow through the primary flow path by permitting or allowing gas flow through the inlet portion of the primary flow path; andwherein the exhaust gas flow control valve comprises a primary inlet port communicating with the primary inlet; a primary outlet port communicating with the inlet portion of the primary flow path; a first bypass outlet port communicating with the first bypass path; and a second bypass outlet port communicating with the second bypass path. 2. A turbocharger system according to claim 1, wherein the valve is operable in a first mode to block flow through the first and second bypass outlet ports, a second mode in which flow is permitted through the first bypass outlet port to allow at least a portion of the exhaust gas flow to bypass the first turbine alone, and a third mode in which flow is permitted through said second bypass outlet port to allow at least a portion of the exhaust gas flow to bypass both the first and second turbines. 3. A turbocharger system according to claim 2, wherein in said third mode exhaust gas flow is permitted through both the first and second bypass outlet ports. 4. A turbocharger system according to claim 2, wherein when operating in said second mode the first bypass outlet port is at least partially unobstructed and the second bypass outlet port is fully obstructed. 5. A turbocharger system according to claim 2, wherein in said third mode the first bypass outlet port is fully unobstructed and the second bypass outlet port is at least partially unobstructed. 6. A turbocharger system according to claim 5, wherein in said third mode the second outlet port is fully unobstructed. 7. A turbocharger system according to claim 2, wherein the primary inlet port is at least substantially unobstructed in each said first, second and third modes. 8. A turbocharger system according to claim 1, wherein the exhaust flow control valve is a rotary valve comprising a valve rotor which is rotatable about a valve axis to block or unblock selectively said first and second bypass outlet ports. 9. A turbocharger system according to claim 8, wherein the valve rotor is rotatable between a first position in which both the first and second bypass outlet ports are fully blocked, a second position in which the first bypass outlet port is unblocked and the second outlet port is fully blocked, and a third position in which the first bypass outlet port is unblocked and the second bypass outlet port is at least partially unblocked. 10. A turbocharger system according to claim 9, wherein when the rotor is in said third position the second bypass outlet port is fully unblocked. 11. A turbocharger system according to claim 9, wherein the rotor is selectively positionable at a plurality of positions between said first and second positions. 12. A turbocharger system according to claim 9, wherein the valve rotor is selectively positionable at a plurality of positions between said second and third positions. 13. A turbocharger system according to claim 9, wherein said valve rotor is selectively positionable at any position between said first, second and third positions. 14. A turbocharger system according to claim 8, wherein the valve rotor comprises an arcuate surface for blocking or at least partially blocking the first and second bypass outlet ports, an opening through the rotor for providing gas flow communication between the primary inlet port and one or both of the primary outlet port and the first bypass outlet port, and a recess in communication with the opening for alignment with the second bypass outlet port in the third position in order to provide communication between the primary inlet port and the second bypass outlet port. 15. A turbocharger system according to claim 14, wherein the recess is offset from the opening in the direction along the axis of rotation of the valve rotor. 16. A turbocharger system according to claim 1, wherein the second bypass outlet port has a smaller maximum flow area than either the inlet port or the first bypass outlet port. 17. A turbocharger system according to claim 1, wherein the intermediate portion of the primary exhaust gas flow path communicates with the first bypass outlet path. 18. A turbocharger system according to claim 1, wherein the exhaust gas flow control valve is housed within a housing of the second turbine. 19. A turbocharger system according to claim 1, wherein the valve is operable to move to an exhaust gas heating mode wherein the second bypass outlet port is blocked by the valve, the first bypass outlet port is at least partially blocked by the valve and the primary outlet port is at least partially blocked. 20. A turbocharger system according to claim 1, wherein the valve is operable to move to an engine braking mode wherein the primary inlet port is at least partially blocked. 21. A method of operating a turbocharger system wherein the system has a first relatively small turbocharger with a first turbine, a second relatively large turbocharger having a second turbine, a primary exhaust gas flow path for delivering exhaust gas to an inlet of the first turbine and an intermediate portion for delivering exhaust gas from an outlet of the first turbine to an inlet of the second turbine, a first bypass flow path in gas flow communication for bypassing the first turbine, a second bypass flow path for bypassing the second turbine; and an exhaust gas flow control valve having a primary inlet port for communication with an exhaust gas manifold of an engine, the method comprising operating the valve to occupy a position where the primary inlet port is at least partially blocked; wherein the second bypass flow path delivers exhaust gas from the exhaust gas manifold of the engine to an exhaust gas outlet path of the second turbine. 22. A method of operating a turbocharger system, the system having a first relatively small turbocharger with a first turbine, a second relatively large turbocharger having a second turbine, a primary exhaust gas flow path for delivering exhaust gas to an inlet of the first turbine and an intermediate portion for delivering exhaust gas from an outlet of the first turbine to an inlet of the second turbine, a first bypass flow path in gas flow communication for bypassing the first turbine, a second bypass flow path for bypassing the second turbine; and an exhaust gas flow control valve having a primary outlet port in communication with an exhaust gas manifold of an engine, a first bypass outlet port in communication with the first bypass path and a second bypass outlet port in communication with the second bypass path; the method comprising operating the valve to occupy a position in which the second bypass outlet port is blocked, the first bypass outlet port is at least partially blocked by the valve and the primary outlet port is at least partially blocked; wherein the second bypass flow path delivers exhaust gas from the exhaust gas manifold of the engine to an exhaust gas outlet path of the second turbine. 23. A turbocharger system comprising: a primary inlet for flow communication with an exhaust gas manifold of an engine and an exhaust outlet;a first relatively small turbocharger having a first turbine with an inlet and an outlet;a second relatively large turbocharger having a second turbine with an inlet and an outlet;a primary exhaust gas flow path including an inlet portion for delivering exhaust gas to the inlet of the first turbine and an intermediate portion for delivering exhaust gas from the outlet of the first turbine to the inlet of the second turbine;a first bypass flow path in gas flow communication with the primary inlet and the inlet of the second turbine thereby bypassing the first turbine;a second bypass flow path in gas flow communication with the primary inlet and the exhaust outlet thereby bypassing the second turbine; andan exhaust gas flow control valve situated in the inlet portion of the primary exhaust gas flow path and having:a primary inlet port communicating with the primary inlet; a primary outlet port communicating with the inlet portion of the primary flow path; a first bypass outlet port communicating with the first bypass path; and a second bypass outlet port communicating with the second bypass path; andan exhaust gas flow control valve,wherein the exhaust gas flow control valve is selectively operable in each of the following states: (i) a first state to permit flow through the primary outlet port but block flow through the first and second bypass outlet ports;(ii) a second state to permit flow through the primary outlet port and the first bypass outlet port but block flow through the second bypass outlet port, to allow at least a portion of exhaust gas flow to bypass the first turbine alone;(iii) a third state to permit flow through said first bypass outlet port and said second bypass outlet port to allow at least a portion of the exhaust gas flow to bypass both the first and second turbines;(iv) a fourth state to block flow through each of the primary outlet port, first bypass port and second bypass port; and(v) a fifth state to block flow through the first and second bypass outlet ports and to partially block flow through the primary outlet port. 24. A method of operating a turbocharger system which comprises: a primary inlet for flow communication with an exhaust gas manifold of an engine and an exhaust outlet;a first relatively small turbocharger having a first turbine with an inlet and an outlet;a second relatively large turbocharger having a second turbine with an inlet and an outlet;a primary exhaust gas flow path including an inlet portion for delivering exhaust gas to the inlet of the first turbine and an intermediate portion for delivering exhaust gas from the outlet of the first turbine to the inlet of the second turbine;a first bypass flow path in gas flow communication with the primary inlet and the inlet of the second turbine thereby bypassing the first turbine;a second bypass flow path in gas flow communication with the primary inlet and the exhaust outlet thereby bypassing the second turbine; andan exhaust gas flow control valve situated in the inlet portion of the primary exhaust gas flow path and having:a primary inlet port communicating with the primary inlet; a primary outlet port communicating with the inlet portion of the primary flow path; a first bypass outlet port communicating with the first bypass path; and a second bypass outlet port communicating with the second bypass path; andan exhaust gas flow control valve, wherein the method comprises selectively operating the exhaust gas flow control valve in each of the following states: (i) a first state to permit flow through the primary outlet port but block flow through the first and second bypass outlet ports;(ii) a second state to permit flow through the primary outlet port and the first bypass outlet port but block flow through the second bypass outlet port, to allow at least a portion of exhaust gas flow to bypass the first turbine alone;(iii) a third state to permit flow through said first bypass outlet port and said second bypass outlet port to allow at least a portion of the exhaust gas flow to bypass both the first and second turbines;(iv) a fourth state to block flow through each of the primary outlet port, first bypass port and second bypass port; and(v) a fifth state to block flow through the first and second bypass outlet ports and to partially block flow through the primary outlet port.
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