UPDATE....
Talked to a friend over I/M on how it controls boost... here is my convo with him..... then i refine it at the bottom so that more of you can understand it.
Dustin~ says:
how does the wastegate and boost controller interact to control how much boost you run?
Jonesey says:
hold on, Ill explain it in a sec
Dustin~ says:
k
Jonesey says:
k
so, the turbo works by air going over the turbine
right?
Dustin~ says:
yes
Jonesey says:
well exhaust gases pass the turbine and spin it up
Dustin~ says:
yes
Jonesey says:
well the wastegate is an alternate port that bypasses the turbine
Dustin~ says:
i know this
Jonesey says:
Ok, so if there is no air going across the turbine it doesnt boost
if its all going through the turbine it overboosts
so, the boost controller regulates how open the wastegate door is
and that wg door position regulates flow across the turbine
Dustin~ says:
right
Jonesey says:
so thats how a boost controller works
in a turbo, less is more
so, if the air has a free flowing path to the wastegate the wastegate limits boost more
so by limiting the air to the wastegate, you increase boost pressure by holding the door shut longer
Dustin~ says:
i see
next time im over you will have to show me what line goes to what and the purpose
i know that the door opening is what controls how much boost it pushes but i want to know how the boost controller works the wastegate and i guess how a boost controller works.... all in all i might just have to see it and have you show me each step
Jonesey says:
the boost controller works by limiting air
K, think if you had a door actuated by you blowing in it
and this door opens
well, think how much harder youd have to blow to open the door if there was a kink in the line
the boost controller acts by RESTRICTING air to the wastegate
I cant "show" you how it works
I dont have anything to show you with
Dustin~ says:
i have that turbo and waste gate actuator
would that help?
Jonesey says:
yeah, that will show you how the wastegate works
but seriously, its simple to wrap your head around
restrict the flow from the turbo to the wastegate, and you increase boost
Dustin~ says:
i know the principle of the waste gate just not how the boost controller will hold the gate open and close.... i know air goes into the actuator and pushes against the spring to open the gate but how does it know how far to open and close it to keep a steady psi
Jonesey says:
the boost controller can do it different ways
you have your ball/spring design
so, it takes x amount of pressure to push the ball into the spring
and once thats achieved, it allows the door to open
if pressure drops below x the spring closes and the wastegate doesnt open
so thats a way to control it
you can use a bleeder type, where it literally just bleeds pressure off so it takes more to get there
and an electronic boost controller has valves that pulse. The controller unit knows how much PSI the turbo is putting out, and it has range of operation, so it knows how to pulse the door to keep it open where it wants it
thats how my profec-b works
Dustin~ says:
i see
Jonesey says:
it has a electronic solenoid controlled by the head unit. Head unit has a map sensor in it
map sensor tells head unit Im making x amount of boost, and the head unit can see my boost curve
so it controls it according to the knob settings on the unit
Dustin~ says:
i see
Jonesey says:
Im sorry if this isnt answering your question, but I cant SHOW you how a boost controller works
Dustin~ says:
ok that would help
Jonesey says:
you just have to wrap your head around the concept that limiting boost pressure to the wastegate is what controls boost, and any way you can do that achieves your goal
Dustin~ says:
once i get it in my mind what does what then i will have a much bigger understanding
Jonesey says:
do you have an air compressor?
Dustin~ says:
so with the car off is the gate open or shut?
yes
Jonesey says:
gate is shut
Dustin~ says:
k
Jonesey says:
gate is always shut until you start boosting
then the gate progressively opens
Dustin~ says:
so pressure goes into the line for the actuator and opens the valve accordingly
Jonesey says:
thats correct
as the turbo builds pressure, it pushes against the wastegate and opens it
boost controllers work by intercepting that signal and generally holding the gate shut till a preset amount of boost
it makes you spool faster, and boost harder till the gate opens
Dustin~ says:
ok got ya
THE REFINED PART>>>>>>>>>>>
Basically
look at these pictures
1
2
say the spring in the little canister (waste gate actuator) is 6 psi once the boost hits 6psi and the gate will be open so the exhaust pressure drops and you stop bosting as much then the dorr closes more and you boost more this just fluctuates as your boosting the rod you see in pic 2 pushes out of the actuator and opens the door accordingly depending on how much air pressure is in the top part of the canister. So on a stock car say a Audi 1.8t there is no boost controller. so once the the car starts boosting it starts to open the gate more and more leaking more and more exhaust pressure till you hit 6psi it is open, and it will open more and shut more depending how much boost the turbo makes regulating it close to 6psi. Now in picture 1 you see the purple line, it will have boost in it once the turbo creates positive air pressure, say I cut the hose or make it longer, run it up to your dash then install a boost controller then run the hose into the inlet on the boost controller then another line out of the outlet on the boost controller and back down to the wastegate. As the turbo boosts the controller reads how much boost your turbo is boosting. So till it gets close to your preset boost pressure (turn nob up or down on boost controller) it will start to open then send boost down to the wastegate actuator and let it open a little so you dont over boost. It will send pulses down to the actuator to keep your boost steady to the setting you have it set.
Now with out a boost controller as soon as you start boosting it is going right to your actuator and opening the gate more and more as your boost higher and higher till you hit 6psi or what ever size spring is in the wastegate.. with a boost controller it sends nothing till you reach the desired boost so the door is held shut and ALL exhaust gasses go through the turbine so in return you have less turbo lag and it boost much harder in the bottom end.
How the boost controller will let you boost more than the 6psi (spring) will let you is it will send 6 psi or more down to the spring to open the gate when you let off the throttle bust say you want 12 psi the controller withholds air from going to the wastegate so that the turbo boosts over 6 psi without the gate being opened, when you get to that 12psi mark the gate will slightly open and then pulse opening and closing to keep boost up to that 12psi mark without going over Due to the boost controller sending pulses of pressurized air to the actuator thus controlling the boost!!!