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Method of Turbocharger Emulation on Engine Test and Application to Turbocompound System Optimisation

Matching turbocharging systems to an internal combustion engine plays an important role in engine development to meet stringent emission legislations and customer demands such as specific power output and fuel economy. Advanced turbocharging solutions such as variable geometry turbochargers, two-stage and turbocompound systems require an extensive simulation and hardware testing on engine dynamometer. GT-Power simulations were performed to evaluate the fuel economy potential of a turbocompound system compared to an equivalent rating heavy duty diesel engine. Simulation results were promising at rated speed and load. However at part loads, turbocompound results were less promising. This paper describes a novel engine testing approach that involves a virtual turbocharger emulator incorporated into an engine test facility via hardware-in-loop (HIL) testing system. The HIL testing offers engine performance optimisation without extensive hardware testing at a moderate cost in a shorter timeframe. Engine tests were conducted with real time control of a power turbine emulator valve for turbocompound system performance evaluation, and simulation results were validated against test data.