Wastegate Position Sensor for Turbocharger Pressure Diagnostics
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Solution Overview
Problem
Modern diesel engines face challenges in accurately diagnosing faulty pressure sensors, particularly when multiple sensors show small deviations or when there are only two correlated sensors, as existing methods require additional costly and redundant reference sensors for calibration.
Innovation Solution
A method utilizing a wastegate position sensor to collect data within a defined measurement window, analyzing wastegate displacement to predict sensor output values and comparing them to actual values, setting an alert for potential sensor failures, thereby simplifying diagnostics and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional reference pressure sensors are added for sensor diagnostics and calibration, then measurement precision and reliability improve, but device complexity and cost increase
Solution Approach 1:
The patent uses exhaust manifold pressure as an intermediary reference to validate pressure sensor readings. Instead of adding more pressure sensors, the system leverages the known relationship between exhaust manifold pressure and turbocharger operation to create a virtual reference point for diagnostic comparisons.
Solution Approach 2:
The system creates a virtual copy of the expected pressure sensor behavior by calculating what the sensor reading should be based on wastegate position and exhaust manifold pressure relationships, then compares this virtual reading against actual sensor readings to detect faults.
2Reliability
If frequent calibration of reference pressure sensors is performed to ensure correct operation, then reliability improves, but loss of time and productivity decrease
Solution Approach 1:
The system performs self-diagnosis by using the wastegate position sensor and exhaust manifold pressure to automatically validate pressure sensor readings during normal engine operation, eliminating the need for external calibration equipment and procedures.
Solution Approach 2:
The diagnostic process operates continuously during normal engine operation rather than requiring periodic shutdowns for calibration. The system continuously monitors the relationship between wastegate position, exhaust manifold pressure, and pressure sensor readings to detect faults in real-time.
3Measurement precision
If external pressure calibration systems are used to calibrate reference pressure sensors, then measurement precision improves, but device complexity and cost increase
Solution Approach 1:
The patent uses exhaust manifold pressure as an intermediary reference to validate pressure sensor readings. Instead of adding more pressure sensors, the system leverages the known relationship between exhaust manifold pressure and turbocharger operation to create a virtual reference point for diagnostic comparisons.
Solution Approach 2:
The system creates a virtual copy of the expected pressure sensor behavior by calculating what the sensor reading should be based on wastegate position and exhaust manifold pressure relationships, then compares this virtual reading against actual sensor readings to detect faults.
Data Source
AI summary
An engine pressure sensor monitoring system uses the position of a wastegate in a turbo-charged engine when known and calibrated engine operating conditions occur to provide diagnostic information for various engine pressure sensors and for the operation of the wastegate itself. Discrete measurement windows are defined for engine conditions with specific values for parameters that may include rpm, torque, injection timing and fuel consumption. Other sensor readings for intake manifold pressure, turbocharger compressor output pressure, peak cylinder pressure, and wastegate valve position during these measurement windows should match predicted values. If measured and predicted values do not match, one or more sensors may be bad and an alarm may be raised.