Woodward: on-highway transportation efficiency gains | electronic turbocharger wastegate actuator

Abstract

On-highway transportation remains a major contributor to global petroleum consumption, yet the engines convert only a small fraction of fuel energy into useful motion, with the majority lost as waste. While prior research has demonstrated that turbocharging can significantly improve engine performance and efficiency, limitations—such as the wastegate being controlled pneumatically—continue to constrain its full potential. In response, this project investigates opportunities to enhance turbocharger performance through improves wastegate control within Woodward's on-highway engines. Specifically, the objective is to evaluate if replacing the conventional pneumatic actuator with a more precise and responsive electronic actuator would show improvement in the engine’s efficiency. To support this effort, a comprehensive trade study was conducted to determine the optimal way to approach operating within the harsh engine conditions, tight space parameters, and high force specifications. After designing and manufacturing an actuator to mount to the engine, steady and transient tests were conducted to determine the overall performance of the product. Results indicate that by having control of where and when the wastegate was positioned, the engine had better boost pressure control than when the engine was equipped with a pneumatic actuator. With better boost control, the combustion process wastes less fuel which in turn makes the engine more efficient. If the design and implementation were to be matured further, these improvements have the potential to increase overall engine efficiency over all of the transportation sector. This work contributes to ongoing efforts to advance transportation efficiency by demonstrating how targeted innovations can yield meaningful gains, supporting both industry goals and initiatives toward more sustainable energy use.