Over the past years, the evolution of emission standards as well as the advent of Fuel economy targets has driven the need for higher controllability of boost pressure. This is a strong trend, which will continue to be true for both gasoline and diesel engine applications as we prepare for further evolutions of standards and introduction of fuel economy regulations. While engine boundary conditions have become harsher, fine, accurate and sustainable control of boost is challenging the way mechatronics components are engineered. This requires us to apply a System Engineering approach and improve our understanding of the behaviour of the entire control chain so that we can ultimately influence the design and drive performance at the System level. This paper describes key elements of the kinematic tools developed by Honeywell Turbocharger Technologies in order to optimize turbocharger control solutions. It includes details on CAE applications such as fluid dynamics, flexible multi-body dynamics and thermo-mechanical simulations and how they can be linked together to analyse a complete system. It highlights the importance of understanding the behaviour of the whole control chain from the actuator command to the turbocharger and engine response. The paper presents results from one main examples on a new waste-gate concept for Fixed geometry turbochargers primarily for gasoline applications. This examples show how kinematic tools can be applied to achieve controllability and durability targets while accelerating development cycle time.
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