Wastegating the Turbocharger A New Approach to Wastegating the Turbocharger 2006

Legacy Actuator vs Synchronic Actuator Port D Port C Port B Port A Port A Port B Legacy Piston Actuator - 2 port design Synchronic Piston Actuator - 4 port design

Legacy Actuator vs Synchronic Actuator Chamber A Chamber A Chamber B Chamber C Chamber B Chamber D Legacy Piston Actuator - 2 chamber design Synchronic Piston Actuator - 4 chamber design

Legacy Actuator vs Synchronic Actuator Surface A Surface A Surface B Surface C Surface B Surface D Legacy Piston Actuator - 2 surface design Synchronic Piston Actuator - 4 surface design

Legacy Actuator vs Synchronic Actuator Pressure to each port & chamber acts on their respective surface area. The force produced by the pressure depends on the surface area

Legacy Actuator vs Synchronic Actuator Unlike the legacy actuator, the Synchronic actuator geometry is a self centering geometry under pressure

Spring Pre-Load Force = 20 PSI Compressed Uncompressed

Spring Rate Amount of Compression A D C B 1" 4" 3" 2"

Spring Rate A D C B Amount of Compression 5 psi

Legacy Diaphragm Wastegate Synchronic Wastegate

Legacy Wastegate Flexible Diaphragm Actuator 2-Port, 2-Chamber, 2-Surface Actuator Unequal Actuation Surface Areas 1 Axis for Valve Guiding Spring-Biased

Synchronic Wastegate 4-Port, 4-Chamber, 4-Surface Actuator Design Billet Aluminum Piston Actuator 4 Axes for Valve Guiding Spring-Biased Ratiometric Actuation Surface Areas

Response Time Diaphragms can tear Disadvantages of the Diaphragm Wastegate Diaphragms can tear Diaphragm durometer changes with temperature Could get harder or softer Stretchability is variable

Response Time Slow response Non-linear actuation Disadvantages of the Diaphragm Wastegate Slow response Non-linear actuation Pressure has to stretch diaphragm before moving the valve

Response Time You can only adjust spring pre-load Disadvantages of the Diaphragm Wastegate You can only adjust spring pre-load You cannot reap the benefits of adjusting spring rate No control of the valve’s rising rate ratio per pound of boost

Main Disadvantage of the Legacy Diaphragm Wastegate . . . Response Time

Main Disadvantage of the Legacy Diaphragm Wastegate . . . The Diaphragm Pressure is wasted on stretching the diaphragm before acting on the valve Response Time

While the legacy diaphragm WG stretches the diaphragm, Synchronic Wastegate has already lifted the valve

With Synchronic Wastegate spring rate can be changed with the same pre-load, to change the amount of valve lift per pound of boost Spring Rate A Spring Rate B Spring Rate C D D D Boost-Only Pressure Signal 5 psi

The legacy wastegate only allows adjustment of spring pre-load to control when the wastegate opens and the resultant boost level.

Spring rate cannot be increased independent of pre-load Spring rate cannot be increased independent of pre-load. Higher boost is achieved with a combination of increase pre-load and rate. Spring Rate = 25 lbs./in. Spring Rate = 25 lbs./in.

As you increase spring rate, the diaphragm will have to stretch more to accommodate the resistance. Spring Rate = 25 lbs./in. Spring Rate = 25 lbs./in.

The reduction in overall valve lift then produces boost creep. Spring Rate = 25 lbs./in. Spring Rate = 25 lbs./in.

Advantages of the Synchronic Approach to Wastegating Adjust Spring Pre-Load

Advantages of the Synchronic Approach to Wastegating Adjust Spring Pre-Load Vary Spring Rate Only

Advantages of the Synchronic Approach to Wastegating Adjust Spring Pre-Load Vary Spring Rate Only 6 Different Built-In Boost Levels Without a Boost Controller

Advantages of the Synchronic Approach to Wastegating Adjust Spring Pre-Load Vary Spring Rate Only 6 Different Built-In Boost Levels Without a Boost Controller Variable Exhaust Flow Control

Advantages of the Synchronic Approach to Wastegating Adjust Spring Pre-Load Vary Spring Rate Only 6 Different Built-In Boost Levels Without a Boost Controller Variable Exhaust Flow Control Ability to Keep WG Closed Without Using CO2

Advantages of the Synchronic Approach to Wastegating Adjust Spring Pre-Load Vary Spring Rate Only 6 Different Built-In Boost Levels Without a Boost Controller Variable Exhaust Flow Control Ability to Keep WG Closed Without Using CO2 Potential For Anti-Lag Feature

Adjust Spring Pre-load Change Out Springs of Different Rates

A D C B (Unused) Actuator Level Boost Control

Boost-Only Pressure Signal Boost = 4 psi C Boost-Only Pressure Signal D

Boost-Only Pressure Signal Boost = 5 psi C Boost-Only Pressure Signal D

Boost-Only Pressure Signal Boost = 6 psi C Boost-Only Pressure Signal

Boost-Only Pressure Signal Boost = 7 psi C Boost-Only Pressure Signal

Boost-Only Pressure Signal Boost = 8 psi Boost-Only Pressure Signal D

Boost-Only Pressure Signal Boost = 10 psi Boost-Only Pressure Signal D

6 Built-In Boost Levels Higher Boost C + D C + A D + A C + D + A C D

Flow Control Different size valve seats allow for fine tuning of flow and performance

Tuning With a Determine and set maximum boost pressure Determine flow requirements and select appropriate valve seat Vary spring rate depending on overall valve lift requirements Adjust pre-load to achieve target initial wastegate opening Use a controller to lower boost pressure for conditions that don’t require maximum performance

ECU/Solenoid Boost Control Chamber B Pneumatically Sealed Chamber

ECU/Solenoid Boost Control Chamber B Solenoid Boost-Only Pressure Signal

Anti-Lag? Boost/Vacuum Signal Exhaust manifold vacuum between gears and under decel is bypassed through the WG eliminating loss of inertia

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