ACTUATOR DESIGN FOR A TURBOCHARGER

By
B.Purushothaman
C.Muthuselvan
V.S.Sundaram
ACTUATOR ASSEMBLY FOR A TURBOCHARGER
Basic principle of turbocharger:
Turbocharger are well known devices for supplying air to the intake
of an internal combustion engine at pressures above atmospheric (boost
pressure). Exhaust gas from the engine drives the turbine wheel mounted
on the shaft. Rotation of the turbine wheel rotates a compressor wheel
mounted on the other end of the shaft within a compressor housing. The
compressor wheel delivers compressed air to the intake manifold of the
engine, thereby increasing the engine power.

Turbocharger with wastegate:

A wastegated turbocharger has a bypass passageway between the
exhaust inlet and exhaust outlet portions of the turbine housing to enable
control of the turbocharger boost pressure.The main function is the
bypass passage way will open when the pressure level of the boost air
increases to a predetermined level, thus allowing the some of the exhaust
gas to by pass the turbine wheel preventing the boost pressure from rising
further.`Inorder to control the bypass passage way a actuator is needed.
 INTRODUCTION
•The actuator also
includes a rod
interconnecting the
housing and the
waste gate exhaust •An adjustable
valve through the actuator for a waste
second opening. The gate exhaust valve
actuator further of a turbocharger
includes a pivotal includes a housing
mounting bracket having a first
connected to the opening therein for
housing adjacent the communication with
second opening. One the pressure outlet
or more flange of the turbocharger
portions extend and a second
radially outward from opening therein
a central body remote from the first
portion which has an opening.
aperture therein for
receiving the rod.
 INTRODUCTION CONT.

•The actuator also includes a fastener for

selectively clamping the bracket to the
housing such that the bracket can rotate and
tilt with respect to housing when the fastener
is loosened and is held in a fixed positioned
once the fastener is tightened.

• The actuator utilizes a flat elastic diaphragm

at a seam between two portions of the house
to divide it into first and second chambers
respectively and provide increased durability.

•One of the spring guides for mounting the

rod assembly to the housing can be threaded
into the housing so as to provide axial
adjustment, which translates into a change to
the preload on the spring and thereby the
boost pressure setting of the turbocharger.
DIAPHRAGM
 A tough, flexible seal
 No Sliding friction
 Truncated cone or top
hat shape
 No leakages and
pressure loss
 No breakaway friction
 High sensitivity
CONSTRUCTION
 A Layer of specially woven fabric,
impregnated with a thin layer of elastomer
 Fabric for high tensile strength
 Permits free circumferential elongation
 Prevents axial distortion
 Flange clamped to the cylinder
 Centre fastened to the piston head
 Life depends on
 Operating pressure
 Amount of axial and circumferential stresses
 Material use
 Effective area
 Ae = .7854 Dc – Dc-Dp
2
 Half stroke
 Term is used to designate the stroke capability
 Max.distance from neutral position
 Elastomer ,fabrics selected based on
 Temperature ,pressure capability and application
 Actuator action

pressure
Actuator cap design
 Pressure from the compressor is sent to the
actuator
 Main force acting is pressure
 Thickness=p x d / 2 x σ
 σ= 40mpa (allowed pressure)
 D diameter of the cap
 P pressure acting on cap
Spring design
FORMULAE USED
Spring Design:
 Spring Index ,(C) = D/d
 Solid Length ,(Ls) = n*d (mm)
 Free Length ,(Lf) = Solid length + maximum deflection + clash allowance
 = n*d + ymax + 0.15*ymax (mm)
 Stiffness of Spring, (K) = W/ymax (mm)
 Pitch, (p) = Lf/(n-1) (mm)
 Natural Frequency, (f) = ((K/m)^0.5)/2 (Hz)
 Deflection, (ymax) = (8*W*C)/(G*d) (mm)
 Induced Shear Stress (τ) = (Ks*8*W*C)/(л*d3) N/mm2
Where:
D= Diameter of spring (mm)
d= Diameter of wire of the spring (mm)
n= Number of coils
W= Maximum load (N)
ymax= Maximum deflection (mm)
m= Mass of the spring (kg)
G= Modulus of rigidity (0.8 * 105 N/mm2)
 ACTUATOR SPRING DESIGN

D mm d mm ID mm DEFL MM LOAD LF LS mm PRES N/MM^2 C n PITCH mm K N/mm Ks ţ N/MM2

1 0.1 0.8 75 0.145 100 25 0.185 10 516.44 0.245225 0.001936 1.144833 423.5883
5 0.5 4 75 3.631 100 25 0.185 10 103.288 1.226125 0.048408 1.144833 423.5883
10 1 8 75 14.52 100 25 0.185 10 51.644 2.45225 0.193633 1.144833 423.5883
15 1.5 12 75 32.68 100 25 0.185 10 34.42933 3.678375 0.435675 1.144833 423.5883
20 2 16 75 58.09 100 25 0.185 10 25.822 4.9045 0.774533 1.144833 423.5883
25 2.5 20 75 90.77 100 25 0.185 10 20.6576 6.130625 1.210208 1.144833 423.5883
30 3 24 75 130.7 100 25 0.185 10 17.21467 7.35675 1.7427 1.144833 423.5883
36 3.6 28.8 75 188.2 100 25 0.185 10 14.34556 8.8281 2.509488 1.144833 423.5883
40 4 32 75 232.4 100 25 0.185 10 12.911 9.809 3.098133 1.144833 423.5883
45 4.5 36 75 294.1 100 25 0.185 10 11.47644 11.03513 3.921075 1.144833 423.5883
50 5 40 75 363.1 100 25 0.185 10 10.3288 12.26125 4.840833 1.144833 423.5883
56 5.6 44.8 75 455.4 100 25 0.185 10 9.222143 13.7326 6.072341 1.144833 423.5883
60 6 48 75 522.8 100 25 0.185 10 8.607333 14.7135 6.9708 1.144833 423.5883
65 6.5 52 75 613.6 100 25 0.185 10 7.945231 15.93963 8.181008 1.144833 423.5883
70 7 56 75 711.6 100 25 0.185 10 7.377714 17.16575 9.488033 1.144833 423.5883
75 7.5 60 75 816.9 100 25 0.185 10 6.885867 18.39188 10.89188 1.144833 423.5883
80 8 64 75 929.4 100 25 0.185 10 6.4555 19.618 12.39253 1.144833 423.5883
85 8.5 68 75 1049 100 25 0.185 10 6.075765 20.84413 13.99001 1.144833 423.5883
90 9 72 75 1176 100 25 0.185 10 5.738222 22.07025 15.6843 1.144833 423.5883
100 10 80 75 1452 100 25 0.185 10 5.1644 24.5225 19.36333 1.144833 423.5883
110 11 88 75 1757 100 25 0.185 10 4.694909 26.97475 23.42963 1.144833 423.5883
120 12 96 75 2091 100 25 0.185 10 4.303667 29.427 27.8832 1.144833 423.5883
125 12.5 100 75 2269 100 25 0.185 10 4.13152 30.65313 30.25521 1.144833 423.5883
130 13 104 75 2454 100 25 0.185 10 3.972615 31.87925 32.72403 1.144833 423.5883
 With waste gate vs without waste gate

2.9
2.7
2.5 Series1
pressure ratio

2.3 Series3
2.1
1.9
1.7
1.5
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
engine rpm
Lift off point
Lift off point
 Point at which valve starts to lift

 Lift of pressure

Depends on
 Preload of spring
Each TC has to be set this point separately
 Due to tolerance variations
Operations
Under low boost conditions
 Waste gate valve remains closed

 Spring selection

 Initial setting of waste gate valve and actuator

Above max.boost pressure

 Waste gate valve opens

 Max.boost pressure is predetermined

Operations
 Reciprocal motion Rotation of valve
of actuator rod stem
 Pivotable arm
 For accurate operation
– Diaphragm alignment within the canister
– Rod alignment along the axis of actuator can
Initial setting
 Various methods
 Weld to set
 Adjustable length actuator rod
 Two part actuator rod
• Weld to set
 The actuator can, rod and lever assembled and
mounted on TC
 WG valve clamped shut position in TC/HSG
Initial setting
 Actuator can is pressurized to the lift off
pressure
 Prior to that point, valve stem and lever arm are
welded together
• Adjustable length actuator rod
 Consists of a threaded rod end
 Set point is done by adjusting length of actuator
rod
Initial setting
 Two part actuator rod
 Connected via a spherical joint
 Avoids pre-assemble and adjustable length
actuator rod
 Reduces cost of pivoting and wear of that
Advantages of turbine bypass
 It is simplest form of boost presssure control.
 Within the chosen turbine size the torque
characteristic requirement at low engine
speeds can be met and good vehicle
driveability achieved.
 When the specific boost pressure is
achieved, part of the exhaust gas is
bypassed so that the boost presssure
remains in the same level for specific engine
speed
Electronic boost pressure
control