Investigation of Performance Differences and Control Synthesis for Servo-Controlled and Vacuum-Actuated Wastegates

Turbocharging plays an important role in the downsizing of engines. Model-based approaches for boost control are going to increasing the necessity for controlling the wastegate flow more accurately. In today’s cars, the wastegate is usually only controlled with a duty cycle and without position feedback. Due to nonlinearities and varying disturbances a duty cycle does not correspond to a certain position. Currently the most frequently used feedback controller strategy is to use the boost pressure as the controller reference. This means that there is a large time constant from actuation command to effect in boost pressure, which can impair dynamic performance. In this paper, the performance of an electrically controlled vacuum-actuated waste-gate, subsequently referred to as vacuum wastegate, is compared to an electrical servo-controlled wastegate, also referred to as electric wastegate. Their performance is investigated with the two actuators installed on a turbocharged inline four gasoline engine in an engine test bench. Furthermore, different control synthesis designs for these different actuators are investigated. A state-feedback controller with standard models for the electric wastegate is described and implemented, which gives a position-controlled wastegate. One main difference between vacuum and electric wastegate is that the latter has a position sensor. To make an extended comparison between the solutions, the vacuum wastegate is also equipped with a position sensor and controller using standard controller design methods. The controllers are implemented and compared both in a simulation environment and evaluated in an engine test bench. In addition, for the electric wastegate, both soft-landing and tightening features are also implemented and investigated. Their aim is to improve the lifetime and behavior at or near the closed position.