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Wastegating the Turbocharger
A New Approach to Wastegating the Turbocharger 2006
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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
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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
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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
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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
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Legacy Actuator vs Synchronic Actuator Unlike the legacy actuator, the Synchronic actuator geometry is a self centering geometry under pressure
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Spring Pre-Load Force = 20 PSI Compressed Uncompressed
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Spring Rate Amount of Compression A D C B 1" 4" 3" 2"
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Spring Rate A D C B Amount of Compression 5 psi
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Legacy Diaphragm Wastegate Synchronic Wastegate
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Legacy Wastegate Flexible Diaphragm Actuator 2-Port, 2-Chamber, Surface Actuator Unequal Actuation Surface Areas 1 Axis for Valve Guiding Spring-Biased
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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
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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
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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
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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
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Main Disadvantage of the Legacy Diaphragm Wastegate . . .
Response Time
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Main Disadvantage of the Legacy Diaphragm Wastegate . . .
The Diaphragm Pressure is wasted on stretching the diaphragm before acting on the valve Response Time
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While the legacy diaphragm WG stretches the diaphragm,
Synchronic Wastegate has already lifted the valve
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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
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The legacy wastegate only allows adjustment
of spring pre-load to control when the wastegate opens and the resultant boost level.
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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.
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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.
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The reduction in overall valve lift then produces boost creep.
Spring Rate = 25 lbs./in. Spring Rate = 25 lbs./in.
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Advantages of the Synchronic Approach
to Wastegating Adjust Spring Pre-Load
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Advantages of the Synchronic Approach
to Wastegating Adjust Spring Pre-Load Vary Spring Rate Only
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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
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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
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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
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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
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Adjust Spring Pre-load
Change Out Springs of Different Rates
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A D C B (Unused) Actuator Level Boost Control
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Boost-Only Pressure Signal
Boost = 4 psi C Boost-Only Pressure Signal D
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Boost-Only Pressure Signal
Boost = 5 psi C Boost-Only Pressure Signal D
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Boost-Only Pressure Signal
Boost = 6 psi C Boost-Only Pressure Signal
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Boost-Only Pressure Signal
Boost = 7 psi C Boost-Only Pressure Signal
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Boost-Only Pressure Signal
Boost = 8 psi Boost-Only Pressure Signal D
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Boost-Only Pressure Signal
Boost = 10 psi Boost-Only Pressure Signal D
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6 Built-In Boost Levels Higher Boost C + D C + A D + A C + D + A C D
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Flow Control Different size valve seats allow for fine tuning of flow and performance
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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
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ECU/Solenoid Boost Control
Chamber B Pneumatically Sealed Chamber
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ECU/Solenoid Boost Control
Chamber B Solenoid Boost-Only Pressure Signal
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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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Thank You Come Visit Our Booth #246544 Main Hall
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