Beruflich Dokumente
Kultur Dokumente
DVT
OCT
TDC
BDC
LPP
BSFC
BMEP
MBT
MBTL
TLA
BLA
AFR
Definition of terms
Crank angle- the measure of rotation based on the engine movement- one
complete revolution = 360 degrees crank angle.
Stoichiometric-a mixture(typically air and fuel) where the reacting
components are present in proportions to react fully.
Four stroke engine-an engine with a power stroke on alternate cycles-as
opposed to a two stroke engine
Misfire(petrol only)-an event where the combustion event does not take
place or where a flame builds and is prematurely extinguished.
Lean limit- the highest air-fuel ratio at which the engine will run with a
certain level of misfire.
Knock-the detonation of the end gas in the cylinder under high load, or
high pressure conditions.
Force (N)
Translational:
Work (J)
d 2x
F =m 2
dt
F
d
Power (W)
dW
dx
=F
dt
dt
W = Fx
P=
W = T
dW
d
=T
P=
dt
dt
Rotational:
d 2
T=J 2
dt
Engine Torque
The fundamental output of the engine
Usually expressed in Nm or BMEP
Torque is measured by a dynamometer or an in-line device
BMEP is the accepted figure used to compare the performance of
engines of differing capacities.
RPM
T 2
60 P
60
BMEP =
=
=
swept _ volume
swept _ volume
swept _ volume RPM
( Pa )
(psi)
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Emission equipment
Thermocouples
Pressure transducers (in cylinder measurement)
Turbine flow meters
Smoke measurement
Fuel measurement
Blow-by measurement (blow-by: gas past the rings into the crankcase)
Air flow measurement
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Dynamometers
Types
Water dynamometer
DC dynamometer
AC dynamometer
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Dynamometer testing
Dynamometer testing of heat engines started long before Mr Otto made the
internal combustion engine popular.
Engineers in the early 1700s with the new steam powered reciprocating
engines needed a means of measuring power, in order to further develop their
engines.
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15
Friction Brake
Early systems were very primitive, a person was required to pour water on the blocks to
prevent them from burning!
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Friction Brake
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Power measurement
P = T = 2 RPM Wr
60
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Torque measurement
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Froude Dynamometer
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Water Dynamometer
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DC Dyno
The resisting torque can be adjusted rapidly and can be controlled by computer.
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AC Dyno
AC units are generally more expensive then DC units as the control / drive system is
more complicated
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(i)
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Constant torque
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Typical dynamometer
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Eddy current
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DC ~ AC Generator
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Operating quadrants
Type of machine
Hydraulic sluice plate
Variable fill hydraulic
Hydrostatic
DC electrical
AC Electrical
Eddy current
Friction Brake
Quadrant
1 or 2
1 or 2
1,2,3,4
1,2,3,4
1,2,3,4
1&2
1&2
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DC or AC Electrical dyno
Constant torque corresponding to maximum current and excitation
Performance limited by maximum permitted power out put of the
machine
Maximum permitted speed
NB Quadrants, 1,2,3 & 4
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DC ~ AC Generator
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48
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50
Shaft encoder
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53
54
55
56
57
58
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Weighing method
(fuel mass)
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Flo-Tron system
Rotameter
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Fuel Spill-Back
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Engine Speed
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65
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A worked example
2.4 Litre Euro 3 engine. 75 kW at the flywheel at a rated speed of
4,100rev/min. Specific fuel consumption at net peak torque is 255g/kWh.
Therefore,
Fuel = 0.255x75=19.125 kg/h.
SG of this fuel lay between 0.815 and 0.855 kg/litre thus approximate fuel:
19.125 kg = 15.58 Litre
Given 3.8 litre of typical diesel fuel = 155 x 106 joules (147,000 Btu)
15.58 litre diesel fuel = 635.5 x 106 joules
1 kW.h = 3.6 x 106 joules
Hence 19.125 kg fuel: 635.5 x 106 /3.8 x 106 =176.53 kW
Energy in = 176.53 kW
Energy to flywheel = 75 kW
This equates to 42.58% efficiency but true figure would be 35%
Engine Testing and Instrumentation
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Total in to
system
Energy share
176.53 kW
176.53 kW
Power
75kW (42.2%)
Heat to coolant
33kW (18.6%)
Heat to oil
4.5kW (2.5%)
Heat to Exhaust
53.1 kW
(29.9%)
Convection &
Radiation
11kW ( 6.8%)
Total out
176.53kW
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UEGO AFR
Meter
Comb Data
Acquisition
System
Throttle, Dyno
Load, Coolant
Oil Temp, Air
Temp Control
Ignition Angle
Meter
Test Room Operators
Cell Log (electronic pilot)
PCM Controller
Display
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Dynamometers
Dynamometer Types Absorption & Motoring
- Absorption Eddy Current (2 pole) Absorbs Engine Torque Only
- Motoring D.C. Machine (4 pole) Absorbs and Motors Engine.
- A.C. Machine (4 pole) Fast Response Engine Speed or Load based
control strategy
- Move from Water to Air Cooling (AVL).
- Future Move to low Inertia Synchronous for
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Emission Analyser
Cost 100K+
Regular calibration
verification checks
using alpha std gas
Control System
Analyser Banks
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TDC
Firing
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Transducer Glow
Plug Adaptor
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DELPHI
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Transient Test
Throttle steps to support transient fuel calibration
Powertrain by Simulation
NEDC drive cycles
Full Powertrain testing
Drive Cycles, Powertrain Durability, Real world Fuel
Economy
Engine Testing and Instrumentation
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Usage /
Capability
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Limited Calibration
Fuel
open loop, closed loop, WOT fuelling, AFR distribution
Spark
MBT, borderline, min RON spark, offsets for temp, fuel, air & EGR
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- Usage / Capacity
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Improved Calibration
Calibration Robust for Transient Point-to-Point movement within Map
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Transient/Motoring Testing
Typical types of parameters calibrated
Air
Load prediction, throttle mapping, manifold dynamics, inferred
load, min load line, idle speed control, coast down
Fuel
Transient fuel, tip-in, back-out, idle fuel, EVAP
Spark
Tip in detonation, transient spark, feedback spark (idle)
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Corrected
Torque
Test No
Volumetric
Efficiency
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Oil Pressure
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Global
Initiative
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ASAP3
(RS232)
Shared
SharedMonitor
Monitor
Caltool
CaltoolPC
PC
Router
RouterPC
PC
(Ethernet)
(RS422)
(USB/RS2
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Scramnet
Scramnet
Scramnet
Scramnet
EMCO
EMCO
NN
Indimaster
Indimaster
PC
PC
(ATI,
(ATI,Inca,
Inca,etc)
etc)
or Memory
Emulation
F
EF
ME
M
Dyno/Engine
Control
Calibration
Calibration
Tool
Tool
ACN
Puma
Puma
PC
PC
Fibre-optic
Ring Circuit
PCM
PCM
Temporary
Serial Link
Temporary
Analogue
Link
Scramnet
Scramnet
Emissions
Fuel Flow
DAQ etc
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Procedure Advantages
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- -
102
Data Analysis
Summary
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Implementation
Increased System Support
Robust Data
Network
Numerous Data
Types
Increased Data
Parameters
Solution
Different Test-Beds
In-House / EP
Combustion Systems
Calibration Tools
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Implementation
Increased Data Generation Affects Customer
Operation
More Data Generation
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Implementation
New Facility / Test Needs Require Communicating
Up-Front Communications
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Engine Testing
and Instrumentation
References: www.fordracing.net
www.fordrallyesport.com
www.fordracing.com
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110
7500
Throttle
(%)
100
Time (sec)
115 111
Turbo
Charger
Throttle
Control
Exhaust
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P
o
w
e
r
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Froude Consine
High performance
dynamometer
18,000 rev/min
1,000 BHP
Continuously rated
Oil mist lubrication
Shaft Inertia,
bursting speed ?
Engine Testing and Instrumentation
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Extra running time spent on a test bed will shorten the engines useful
life at the track.
Test rapidity is required
Instrumentation is critical and must be accurate, a 1% change in out
put of a formula 1 engine is significant, and a 2% improvement is a
major breakthrough !
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Powertrain By Simulation
Facility requirements
Main Features
Usage / Capability
- Full Vehicle Equivalent Drive Capability (Full Simulation)
- Generate Full Engine-Map Calibration under Controlled Conditions
- Dyno and Control System become the Simulated Vehicle
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Vehicle Parameters
Vehicle, Flywheel, Clutch Masses
Road Load Conditions for given Vehicle
Gear Ratios / Efficiencies (Manual and Auto)
Driver Characteristics
Simulated Throttle and Clutch Gear Change Operation
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Dynamic Operation
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Powertrain Operation
-
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Test-Bed Types
- Steady State
- Transient
- Powertrain By Simulation / Dynamic
- Full Powertrain
Adaptable to Support Differing Phases of
Development Process
- Facility Type provides Desired Capability
- Upgradeable at Minimum Cost, Equipment
- Flexibility to support increased Customer
Test Requirements
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