Powertrain Optimization

Collaborators: 8 total, in collaboration with Hanwha Aerospace, BorgWarner Korea, Tenergy

This project aimed to improve the performance of a turbocharged diesel engine under high-altitude operating conditions. The focus was on maintaining target power output and fuel efficiency despite the reduced air density associated with increased altitude. 

• Evaluate whether the powertrain using Hyundai CI engine can achieve the required power output at the target altitude. (specific figures withheld under NDA)

• Define the operational limits of the turbocharger system under reduced air density.

• Identify methods to increase engine output under high-altitude conditions.

• Calibrated 1D engine simulation models using real-world experimental data.

• Performed high-altitude engine simulations in GT-Power/Suite to optimize a Hyundai CI engine equipped with a two-stage turbocharging system.

• Evaluated compressor and turbine performance, with particular focus on operational limitations at reduced atmospheric pressure.

• Analyzed the effects of various control strategies on turbocharger efficiency, engine output, and fuel consumption while ensuring compliance with industrial standards for exhaust and CO₂ emissions.

• Delivered technical findings and performance optimization proposals to industrial partners. 

GT-Power, GT-Suite, Origin, Microsoft Office

1-stage Turbocharger System Simulation Model

2-stage Turbocharger System Simulation Model

• Successfully demonstrated the feasibility of two-stage turbocharging in maintaining power output under high-altitude conditions.

• Simulation results were validated against experimental data with less than 6% deviation.

• Observed only a 10% power reduction at the target altitude with the two-stage system compared to sea level.

• Effective control of the low-pressure turbocharger contributed to enhanced engine performance and stable power delivery even at high altitude.

Aligning the simulation model with real engine performance data required multiple iterations of parameter tuning and validation. This challenge underscored the critical role of experimental feedback in refining simulation accuracy and taught me the value of patience and precision in model calibration for real-world applications.