Maximizing Versatility and Minimizing Costs: Turbocharger Design Optimization using an Adjustable Actuator Bracket

It is evident that the environmental pollution has become one of the major issues all over the globe, which is the cause of some of the major problems including Health problems for all human, animals and for the plants and vegetation also. So, there rises a need to overcome this problem and find the solutions for a better future. In this study, research was done around automobiles and found out some of the best techniques, currently being used to reduce emissions from the exhaust, and among them, Turbocharging was identified as a potential solution, which can help reduce automotive emissions from the IC engine, while improving the power output, performance and maintaining the good fuel efficiency at the same time. So, this was selected as area for further research and study. Using DFMA method, various experiments and analysis were performed during the process and a versatile design of turbocharger was identified, which can, not only bring down the overall cost of turbocharger, but can also help in reducing the time required to manufacture same turbochargers with multiple inlet and outlet connections and orientations by avoiding unwanted time required for redesigning, validation, and analysis of new component, which is required in the current designs. It was observed that when compared with two different currently used designs for actuator mounting, the concept got 5% to 52% cost savings than other, already available designs. Also, the analysis results were found to be good for the concept and if required, only the optimization in thickness can be done to use it in different application where the vibrations in the engine can vary from the assumptions and the minimum natural frequency required is varied. The analysis was performed assuming different operating conditions and using different actuator type and mounting position on the compressor housing.