Physical Modeling of a Turbocharger Electric Waste-Gate Actuator for Control Purpose

Paper #:
  • 2017-24-0003

  • 2017-09-04
Gasoline Engines have typically a waste gate actuator to control the boost pressure. The electrification of the vehicle and combustion engine components leads to new challenges of application of electric actuators in engine components, like turbochargers, which are faced with relatively high ambient temperatures. Another challenge is a simulation and prediction of the mechanical load on the actuator and kinematic components at different application scenarios, which can help to find the optimal solution which fulfills the durability, controllability, etc. targets. This paper deals with a physical dynamic model of an electric waste-gate actuator and kinematic components. The modeling includes a thermal, electrical and mechanical parts of the turbocharger control system and is validated on test-bench and engine measurements including pulsation effects. Modeling of the e-actuator self-heating effect includes identification of the different thermal resistances and capacities between the actuator housing and DC motor winding. Performance of the DC motor depends significantly on the winding temperature. Thermal behavior of the investigated system is modelled and identified from oven-measurements at different thermal conditions up to 150°C. Furthermore, a parametric model of the electric parts of the actuator including temperature dependency is derived and identified on measurements. Linkage parts, amplification of the actuator torque due to kinematics layout and dimensions are modelled with sufficient detail including friction. Forces in the kinematics are identified from engine test-bench force measurement. The influence of the pulsation on the mechanic load on the linkage components at different WG flap angles can be shown and discussed. Finally the thermodynamic quantities like WG mass-flow can be simulated. Model has clearly defined interfaces and can be integrated in the control oriented engine model. This allows fast calculation of WG port thermodynamics of the exhaust path of the engine. The developed and identified model allows one to have a deep insight into the WG actuator dynamic behavior at limit thermal conditions.
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