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GM patent reveals new two-stage turbocharger

Modern turbochargers may be some of the best ever made, but performance is something that engineers are always trying to improve. According to GM Inside News, General Motors (GM) is hoping to alleviate some of the negative aspects of a two-stage turbocharger setup with a newly-patented design. The patent, that was filed on May 19, 2016, reveals a clever bypass system that allows the engine, a four-cylinder unit, to optimize both the low-pressure and high-pressure inlets for its respective functions. According to the filing, a conventional two-stage turbocharger setup is engineered to allow both turbines to operate simultaneously at low and mid engine speeds. At high engine speeds, only the low-pressure turbine works. The setup can't isolate either the low or high pressure side, which can impair low-end performance. GM's new two-stage turbocharger setup looks to eliminate this by linking the high-pressure turbo to the exhaust manifold through the high-pressure inlet duct. The low-pressure turbo is attached to the high-pressure turbo by a low-pressure inlet duct, which is linked to a connecting channel. A single actuator that is housed in the exhaust manifold creates a bypass that can opens the high-pressure inlet or close the connecting channel. Depending on what the engine load and speed is, the ECU guides the actuator—a single rotating spindle with discs corresponding to flanges on the high and low pressure sides—to isolate one of the two turbos. Isolating the turbos allow the respective inlets to be engineered for the best possible fluid dynamic performance. The setup should increase performance and decrease lag. There's no word on what car this setup will make an appearance on, but it will most likely be used in premium vehicles before trickling down to the rest of GM's vehicles. Related Video: News Source: GM Inside News, AutoGuide via GM Authority Cadillac Chevrolet GM Technology Sedan turbo patent engine turbocharging

GM Recalling Another 2.7 Million Vehicles In Five Separate Campaigns

The recalls keep rolling in from General Motors, evidently keen to avoid repeating the mistakes of the ignition-switch debacle and clean house. This time they're all coming at once, with five separate recalls announced together covering approximately 2.7 million vehicles. The largest of the five actions involves over 2.4 million units of the previous-generation Chevrolet Malibu and Malibu Maxx, Pontiac G6 and Saturn Aura in order to fix brake light wiring harness, which have been found to be susceptible to corrosion. The recall is separate from the 56k Aura sedans which GM recently recalled over faulty shift cables, not to mention the previous massive recall of 1.3 million vehicles – some of them the same models – but appears to have resulted from the National Highway Traffic Safety Administration investigation that started with the G6 almost a year ago. The second-largest campaign involves the 2014 Chevy Malibu, specifically those fitted with GM's 2.5-liter engine and stop/start system, approximately 140,000 examples of which has been found to have problematic brakes. The issue does not appear to be connected to the recall of 8k Malibu and Buick LaCrosse sedans (also involving brake woes) which we reported upon last week. Four crashes have been reported in such models, but GM admits it's not yet clear if the problem was a contributing factor in the accidents. A further 112k Corvette models from the 2005-2007 model years are being called in for problems with their low-beam headlamps resulting from a flexing relay control circuit wire that's not meant to bend. GM says it is "aware of several hundred complaints" about this issue, but notes that there have been no reports of related accidents. In addition, over 19k examples of Cadillac CTS from the 2013 and 2014 model years are being recalled over windshield wipers that might not work after a jump start. Finally, GM is also bringing in 477 examples of its 2014 Chevy Silverado, Tahoe and GMC Sierra (though not the Yukon) to fix a problem with a tie rod in its steering rack. As ever, all recall repairs will be performed free of charge, and GM is now estimating that recall-related actions this quarter will result in an estimated $200-million charge against its second-quarter earnings. Read the full announcement from GM below for further details.

This is how GM is hiding new Chevy Volt in public

General Motors is letting the public know that, well, it's not about to let the public know anything else about the next-generation Chevrolet Volt. But the automaker is willing to talk about its camouflaging process for upcoming versions of the extended-range plug-in. So it's a half-hearted secret, at best. GM actually has a "camouflage engineer" charged with creating ways to disguise the styling of new vehicles. In the Volt's case, the company is applying black and white swirly color patterns on top of the materials, such as plastics, vinyl and foam, that are used liberally across the body. It's all part of a teaser campaign that started last month with pictures of part the 2016 Volt. Earlier this month, GM said it was keeping track of Volt drivers' habits as it works on the next-gen model. The company noted that more than four out of five trips are being made in all-electric driving mode, and that 60 percent of Volt owners use a plain-old 100-volt outlet to recharge their cars. The car is slated to make its global debut at Detroit's North American International Auto Show next January, and the early word is that performance and all-electric range will be improved (we should hope so). The car will also be sleeker. By how much, we can't tell yet, because of those darn swirly patterns. GM's got more non-details in its press release below. Engineers charged with hiding styling while vehicle testing proceeds in public DETROIT – The styling of the next-generation Chevrolet Volt is one of the automotive world's best-kept secrets. Keeping customers and media eager to see the successor to the groundbreaking original at bay until the new Volt debuts at the North American International Auto Show in Detroit in January is tricky business. First, it is engineers, not designers, who are charged with creating camouflage that balances styling secrecy with the need to validate the Volt and its systems in public. "If it were up to me it would be a shoebox driving down the road," said Lionel Perkins, GM camouflage engineer. "The design team wants us to cover more of the vehicle and the engineering team needs to have enough of the vehicle's weight and aero exposed so that the tests in the development process are consistent with the product that will come to market." The engineers responsible for the "cool" designs covering the car might deserve style points but their efforts are intended strictly to hide the metal beneath.