Electric Turbocharger Boost Control via Power-Based Optimization
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Solution Overview
Problem
Conventional turbocharger control systems are inefficient due to the complexity of interconnected components and require extensive calibration, making it difficult to effectively coordinate exhaust gas flow power with electric motor power in electric turbochargers.
Innovation Solution
A control system that uses a wastegate valve and a controller to determine target parameters such as mass flow, boost, and motor power, based on a complete physics-based model of the turbocharger, to achieve torque requests and optimize wastegate valve positioning, independent of engine or component configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional turbocharger control strategies are used with multiple interconnected components, then the turbocharger can achieve the required boost control, but the calibration complexity and time required increase significantly
Solution Approach 1:
The patent extracts the turbocharger control problem from the complex multi-component conventional system and formulates it as an optimal control problem using a simplified mathematical model. By taking out the essential dynamics (mass flow, pressure, speed relationships) and removing the need to model every interconnected component separately, the system achieves effective boost control with dramatically reduced calibration complexity.
Solution Approach 2:
The patent changes the control parameters from traditional valve positions to physically meaningful parameters (mass flow rates, pressures, speeds) that directly appear in the mathematical model. This parameter transformation simplifies the control strategy by working directly with the fundamental physical relationships rather than trying to coordinate multiple valve actuators.
2Adaptability or versatility
If conventional turbocharger control techniques are used, then the system can operate with existing components, but extensive recalibration is required when other control calibrations change
Solution Approach 1:
The patent performs preliminary formulation of the control strategy based on fundamental physical principles that are independent of specific calibration values. By establishing the optimal control framework in advance using universal mass and energy conservation laws, the system becomes adaptable to different operating conditions and calibration changes without requiring time-consuming recalibration.
Solution Approach 2:
The mathematical model and control strategy are formulated to be universally applicable across different turbocharger configurations and operating conditions. The same optimal control framework works regardless of specific component variations, making the system versatile and eliminating the need for extensive recalibration when other control parameters change.
3Speed
If electric turbochargers are used to improve response time, then boost control speed increases, but coordinating exhaust gas flow power with electric motor power becomes complicated
Solution Approach 1:
The patent merges the electric motor power input and exhaust gas turbine power input into a unified optimal control framework. By combining both power sources in the mathematical model and treating them as interconnected energy inputs, the system automatically coordinates their interaction without requiring separate control strategies, simplifying the overall power management while maintaining fast response characteristics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces calibration costs and improves vehicle efficiency by providing proactive, adaptive boost control that compensates for changing operating conditions, enhancing performance and responsiveness.
Implementation Method 1
Kinetic energy of exhaust gas produced by combustion of the air and a fuel within the cylinders is then utilized to drive the turbine of the turbocharger
Implementation Method 2
A compressor, which is driven by a turbine, draws in ambient air and compresses it before it enters the engine at an increased pressure
Data Source
AI summary
A control system and method for controlling an engine comprising an electric turbocharger are presented. The system comprises a wastegate valve configured to control a pressure of exhaust gas in an exhaust system of the engine at a turbine of the electric turbocharger. A controller obtains a set of parameters that each affect exhaust gas energy; using the set of parameters: (i) determines a target mass flow into the engine and a target boost for the turbocharger to achieve a torque request; (ii) determines a target power for a compressor of the turbocharger to achieve the target engine mass flow and the target turbocharger boost; (iii) determines an electric turbocharger motor power target; (iv) determines, based on the target power for the compressor and the electric turbocharger motor power target, a target pressure ratio and a target mass exhaust flow for the turbine of the electric turbocharger.