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