A New Development Method for the Design of a New Wastegate Control System for EU6 Gasoline Engines 2016-01-1040

A new generation of gasoline engine turbochargers has been developed with a focus on high performance and excellent NVH characteristics, especially with regards to the wastegate control system. With the recent introduction of EU6 emission standards, there is a clear demand to precisely control the flow of exhaust gas through the turbine wastegate. Engine operational duty cycles measured on EU6 compatible vehicles have shown increased stresses on wastegate parts due to a higher amount of regulation strokes during operation. Recent developments in the compact design of exhaust systems together with high pressure pulsation forces acting on wastegate flaps constitute the main challenges facing turbo engineers in the effort to achieve customer durability while meeting NVH requirements. For the development of a new generation of wastegate control systems a unique load prediction model was duly developed. This model is based on a combination of well-known load and stress evaluation and simulation methodologies. In addition to these simulation methodologies, design improvement verification was backed up by the use of hardware testing at both component and system levels. An interesting development to materialise from the verification process are the non-contact laser measurement and high speed movement visualisation technique being operated under real engine conditions.