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Modeling and Simulation of Electro-Hydraulic
Actuation System for VNT (Variable Nozzle Turbine)
Turbocharger using Physical Modeling Tools
Muralidhar Manavalan
8th August 2012
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Agenda
• Introduction
• Description of Electro-hydraulic actuation system of the VNT
Turbocharger.
– Boundary diagram of a Electro-hydraulic actuation system.
• Modeling in Simscape & SimHydraulics
• Model Calibration with Test Rig data
• Model Applications
• Final Remarks & Conclusion
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Introduction
• What is a Turbocharger?
– Turbine driven supercharger
– Turbine is driven by the waste exhaust
gases (from IC Engine)
• Turbocharging Benefits
– Lower Size & Weight
• 1.9 liter(90 kg) Turbocharged Engine is
equivalent to 4.3 liter (210 kg) naturally
aspirated engine
– Increased power density
– Fuel Economy
– Improved emissions
Turbocharger
Schematic Diagram of
Turbocharged Engine
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Introduction
• VNT Turbochargers
– Provide more turbine power
and thus air flow at low engine
speed, without over speeding
or over boosting at high engine
speed.
– Electro Hydraulic Actuation
• Uses lube oil supplied for
bearings for actuation muscle.
• Position feedback provides
closed loop vane position
control.
Electro Hydraulic Actuation
VNT Mechanism
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Electro-hydraulic actuation system of the VNT Turbocharger
• Solenoid Control valve, controls differential oil pressure across
the actuation system piston, thereby providing positional control
of a VNT vane set.
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Boundary diagram of Electro hydraulic actuation system
Boundary of
Analysis
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Model of the Electro-hydraulic actuation system of the VNT
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Electro Hydraulic Actuator model - Top level
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Electro Hydraulic Actuator model - Subsystems
• Solenoid Model – Computes the solenoid force, which moves the
spool of the oil control valve.
• Spool Translational Movement Model
• Oil Control Valve (OCV) – 4/3 proportional control valve
• Supply lines from OCV to the Cylinder
• Hydraulic Cylinder – Converts hydraulic energy into translational
mechanical motion.
• Rack and Pinion– converts piston rod translational motion into
rotational motion of the pinion.
• Vane Position Sensor– Converts pinion rotational motion into a
sensor output voltage.
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Simscape model: Solenoid
• The model computes the solenoid force, which moves the spool
of the oil control valve. It has a built-in “Force Map” and
“Permeance Map” which were generated from Magnetics
simulation model.
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Simscape model: Spool Movement
• The spool movement is modeled as a spring-mass-damper
system.
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SimHydraulics Model: Oil Control Valve
• 4/3 proportional control valve, is modeled by four variable orifice,
created by a cylindrical sharp-edged spool moving in sleeve that
has a rectangular slot.
• Filters are placed at supply port (P) and Control Ports A & B.
Vent passage to the Tank is modeled by a hydraulic pipeline.
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SimHydraulics Model: Supply lines & Hydraulic Cylinder
• Supply lines from Oil Control Valve to the Hydraulic cylinder inlet
are modeled as hydraulic pipelines. 'Double-Acting Hydraulic
Cylinder' block models Hydraulic piston. Spring-mass-damper
models the piston rod movement.
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Electro Hydraulic Actuator Model Response Studies
Co
mm
an
d c
urr
en
t to
Co
ntr
oll
er
(A)
Time(s)
VP
S(v
olt
ag
e)
Time(s)
Cra
nk-s
haft
An
gle
(deg
ree)
Time(s)
Oil
flo
w r
ate
(lp
m)
Time(s)
Model Input
Model output/response
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Model Calibration with Test Rig data
Hydraulic Test Rig
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Model Calibration with Test Rig data
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Model Applications
• OEM control algorithm development.
• Trade studies
• Product team design optimization
– Monte Carlo simulation on component dimensions and their effect
on system performance.
• Fundamental system stability analysis.
– Convergence for all parameters or define limitations
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Conclusions & Remarks
• Benefits of deploying physical modeling tools in our design
process:
– Quickly assemble a multidomain simulation model (Hydraulic +
Mechanical + Electric) and generate data to support decision making
– Understand design space by evaluating and optimizing the dynamic
performance of hardware before prototypes were built.
– Study design alternatives and evaluate „What if‟ scenarios, during
conceptual design stage.
– Significantly reduced program risk by uncovering system
incompatibilities earlier in the design stage.
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Acknowledgements
• The speaker would like to acknowledge:
– Honeywell Technology Solutions for permission to publish this paper
– Significant Technical contributions and Review of the material from
following Systems Modeling & Analysis Technologists:
• Adithya Rao
• Bommaian Balasubramanian
• M Prasath
– Management support from:
• Niranjan Kalyandurg
• Peter Davies