INDICATING AND COMBUSTION DEVELOPMENT TOOLS

September 2009

Alfred KristoferitschBusiness Development ManagerAVL List, Graz/Austria

2

CONTENT:

� The Indicating Measuring Chain

� Basics of Indicating and Parameters

� Indicating for Emission Reduction

� Contribution of Optical Measurement Tools

� AVL Combustion Measurement - Product overview

� Application Examples

INDICATING AND COMBUSTION DEVELOPMENT TOOLS

3

Cylinder Pressure

• High Pressure Sensor (piezo electric)

Crank Angle Signal

• Crank Angle Encoder

Amplifier

• Charge Amplifier

High Speed Data Acquisition

• Indicating System

Data Acquisition SW

• Control of HW

• Calculation / Analysis

Post Data Processing

• Post Data Processing Tool

Meaningful Measurement Results require … accurate Measurement tools

INDICATING AND COMBUSTION ANALYSISHow we notice combustion ?

4

Typical measurements

� Cylinder pressure

� Degree Crank Angle – crank angle

encoder / calculator

� Low Pressure measurement in intake

and exhaust manifold

� Line Pressure Sensors (max. 3000 bar)

� TDC Sensor - Top dead center sensor

� Turbo Speed Sensor

� Needle Lift Sensor / Valve Lift Sensor

� Ignition / Injection Timing

� . . .

INDICATING AND COMBUSTION ANALYSISHow we notice combustion ?

5

deg CA

bar

20

10

0

-15 +15

ααααpmax

Pmax

αααα dp/dαααα

dp/dαααα

MI DH 96IX E-23

Indicating parameters

• IMEP – Indicated Mean Effective Pressure

• Maximum Pressure; pmax

• Angle of Maximum Pressure

• Maximum Pressure Rise

• 50% Heat Release Angle

• Start and End of Combustion

• Cyclic Variation of Above Values (statistics)

• Cylinder Distribution of Above Values (statistics)

STANDARD EVALUATION OF THE CYLINDER PRESSURE

Pressure measurement for thermodynamic analysis: power, heat, energy balance

6

-60 -45 -30 -15 0 15 30 45 60

50

40

30

20

10

0

1000

800

600

400

200

1.0

0.5

0

Cylin

der

pre

ssure

Needle

lift

Combustion

chamber

pressure

Inject ion

line

pressure

Nozzle

needle

lift

Lin

e p

ressure

deg CA

bar bar

mm

MI DH 96IX E-21

STANDARD EVALUATION OF THE CYLINDER PRESSURE

7

Measurement /

Calculation ValuesResult

Values

Rate

of

hea

t re

lease

-

kJ/m

3 g

rddeg

Mass

fraction

burn

t-

%

TDCdeg CA

50

0

Angle of Integral Heat

αααα 5% StStart of combustion

αααα 50% Main burning activity

αααα 95% End of combustion

Center of gravity

of combustion αα GQGQ

100%

50%

0%

0α

αααααααα 5 5 αααααααα 50% 50% αααααααα 95%95%

ααGQGQααααααααGQGQ

MI DH 96IX E-27

THERMODYNAMIC RESULT VALUES

8

StatisticsStatistics

IME

PIM

EP

MaximumMaximum pipimmaa xx

MeanvalueMeanvalue pipiMM eeaann

MinimumMinimum pipimmii nn

CoefficientCoefficient VVpp ii

of of variancevariance

pipimmaa xx

pipiMM eeaann

pipimmii nn

pipi

ResultResult valuesvalues

2020degdegCACA

00

CycleCycle

3,43,4barbar3,03,0

00 2020 4040 6060 8080 100100

ααααmax

IMEPIMEP

MeasurementMeasurement

Cyli

nd

er

Cyli

nd

er

pre

ss

ure

pre

ss

ure

degdeg CACA

αααααααα

4040

3030

2020

1010

00

--6060 00 6060 120120 180180

bar bar

MI DH 96IX E-28

STATISTICAL EVALUATION OF CYLINDER PRESSURE SIGNALS

9

steps in

development

calibration on vehicle

development and

calibration on test bed

endurance test

test bed and vehicle

certification

pre- series

50 100 %0 Time

research

MI FM 98IX E-24

ENGINE DEVELOPMENT CYCLE

10

• misfiring

• knock

• steep temp / pressure rise

• too early combustion

• too late combustion

• partial combustion

(wall film, condensation/cold components,

over fueling, fat mixture, improper spray /

geometry, … )

� HC

� NOx

� NOx

� NOx

� HC, PM, soot

� HC, PM, soot

LINK BETWEEN COMBUSTION AND EMISSION

NOx

PM, soot

HC

� temp reduction - EGR

� premixed flame

� no unburnt fuel, stable combustion

11

-100 -80 -60 -40 -20 0 20 40 60 80 100

soft combustion

- low NOx

- low noise

- increased soot

- high HC

stiff combustion

- high NOx

- high noise

Rate

of

Heat

Rele

ase

INFLUENCE OF COMBUSTION ON EMISSIONS

12

NOX

HC

%

- 4 - 3 - 2 - 1 0 1 2 3 4 5 6deg CA

260

220

180

140

100

60

Em

issio

n

α

advanced retardedlowest SFC

SOI =

start of injection

COMBUSTION TIMING AND EMISSIONS

13

High Injection Pressure

Late Start of Injection

Pilot Injection

Injection Rate Control

Nozzle Hole Quality

Post Injection

NOX HC PM

Appl.

Effort

Power/

Torque Noise

Positive Effect Negative Effect

INFLUENCE OF INJECTION PARAMETERS

14

Limitation of Information derived from Combustion Pressure

• Flame quality – can not be evaluated

• emissions are directly linked to flame quality

Flame quality can be studied in detail with optical methods giving a deeper understanding of the actual combustion

Optical methods are grown up – they are no longer a scientific tool for R&D only

• tailored test bed solutions for typical problems are available

INDICATING AND COMBUSTION ANALYSISHow we notice combustion ?

15

� live pictures with full geometry

information or temperature

information

� only one picture per cycle

VISIOSCOPE

INDICATING AND COMBUSTION DEVELOPMENT TOOLS - VISIOSCOPE

16

advantage:

� good information over entire

cylinder cross section with highest

CA resolution

disadvantage:

� lower spatial resolution

VISIOLUTION

14%

8%

� up to 40 channels

INDICATING AND COMBUSTION DEVELOPMENT TOOLS - VISIOLUTION

17

advantage:

� rough information over entire

cylinder cross section and good

information on flame around spark

plug with highest CA resolution

disadvantage:

� lowest spatial resolution

VISIOSET

� up to 8 channels

-60 °CA 140

INDICATING AND COMBUSTION DEVELOPMENT TOOLS - VISIOSET

18

Exhaust

Inlet

Flame radiation is synchronous

with combustion pressure

-180 -90 0 90 180 270

Stationary part load, benchmark example

Flame radiation

speed

Stoichiometric, premixed

flame in warm engine:

all fuel evaporated and mixed

with air

VisoFlame

Spark Plug Probe

OPTICAL MEASUREMENTS – FLAME OKAY

19

Premixed flame radiation, then

ongoing surface diffusion flame

radiation

Premixed flame starts at

spark plug and ignites

wet surfaces fuel

-180 -90 0 90 180 270

Premixed flame not seen in photograph because of low intensity flame radiation. Very bright diffusion flame

Photograph by Witze, Green,Sandia

Premixed flame burning volume

charge yields combustion pressure

Early starting cyclein cold engine

OPTICAL MEASUREMENTS – SOOTING FLAME

20

Mixture conditions at cold start.

Schematic by Toyota, SAE 950074

-180 -90 0 90 180 270

Liquid film combustion:

very bright flame,

but low rate of heat release

Premixed combustion:

pressure rise

as volume charge burns

Ignition: little fuel vapor near

spark plug causes small flame

Ignition phase disturbed by

overfuelliing, fuel droplets

hitting the flame kernel

INDICATING AND COMBUSTION DEVELOPMENT TOOL - COLDSTART

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advantage:

� cheapest optical system

� excellent for transient soot

measurements

disadvantage:

� only one conical segment can be

viewed

VISIOFEM

� 2 channels

0

5

10

15

20

0 100 200 300

IMEP

bar

IMEP

opacity

visio-soot

INDICATING AND COMBUSTION DEVELOPMENT TOOLS - VISIOFEM

22

Urgent statement of a leading diesel car producer:

„Our CR injection systems operated in stationary engine tests

we manage to optimise for low soot and NOx.

But we do not understand how to optimise CR in transient mode!

How much pilot, pre- main- post injection ?

How many crank angle degrees in between ?

How do we adapt to changing load, boost pressure, residual gas ?

We need a real time, crank angle resolved transient data

acquisition for soot and NOx.“

VISIOFEM

optical sensor in glow plug adapter

fibre optics cable

optical amplifier

600nm 950nm

23

HOW TO READ THE DATA?

... we get traces of

- injection

- cylinder pressure

- flame intensity

flame intensity

� amount of soot

two-colour flame

evaluation

� temperature / NOx

= f (EOI)

trend verification with

Filter Smoke Number (FSN)0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0.18

-15 -10 -5 0F

SN

0.05

0.1

0.15

0.2

0.25

D_V

FE

M -

rel. u

nit

s

IMEP:5 bar

EOI5

figure of merit

24

combustion analysis with pressure transducers is a very powerful tool for engine improvement

with some simple algorithm the trend in emissions, noise or fuel consumption can be easily assessed

before going to detailed emission analysis the extend of improvement can be already assessedalso by means of optical measurement tools

CONCLUSION – COMBUSTION MEASUREMENT

Product Overview

AVL COMBUSTION MEASUREMENT

Alfred KristoferitschCombustion Measurement AVL Graz

26

Product Overview

Sensors

� Pressure Sensors

� Crank Angle Encoder

Amplifier

� Charge Amplifier

� Amplifier with more functions

Indicating Systems

� System Overview

� IndiCom

Post Data Processing

� AVL CONCERTO

27

� High thermal stability:

� temperature consistent up to 970°C

� no twin growth (compared to quartz)

� High piezoelectric sensitivity:

� high sensitivity in small sensors as well

(GU21C 35pC/bar)

� excellent distance between signal and noise

� No thermal sensitivity change

� assumption for correct measuring results

under all load point (typical

sensitivity change for AVL GU12P

between 20°C - 400°C : +0,5% / -0,2%)

SENSORSCombustion Pressure – AVL GaPO4

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SENSORSCombustion Pressure AVL - GaPO4

� Direct mounted

� preferred solution for highest accuracy

� ideal mounting position possible

� Spark Plug

� no additional bore in cylinder head required

� wide range customer spark plugs available

� sensor is as close as possible to the combustion

chamber – high accuracy / no pipe oscillation

� Glow plug

� no additional bore in cylinder head required

� sensor is as close as possible to the combustion

chamber – high accuracy / no pipe oscillation

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� AVL Chrank Angle Encoder 365C

�standard combustion engines

�optical measurement principle

� for mounting a free shaft end or belt pulley is required

� AVL Chrank Angle Encoder 365X

� open disc

� used for mounting situations without free shaft end, e.g. on drive side

� AVL Chrank Angle Encoder 365R

� designed for racing application

SENSORSCrank angle based measurement – optical sensor

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� Low Pressure Sensor

� Pressure measurement in Intake and exhaust manifold

� Line Pressure Sensors

� up to 3000 bar line pressure

� TDC Sensor

� Top dead center sensor

� Turbo Speed Sensor

� Laser sensor

� Needle Lift Sensor

� Valve Lift Sensor

SENSORSFurther sensors available:

31

AVL Amplifier Product Portfolio

MicroIFEM - 4 Channel amplifier

� 4 Ch. Piezo

� 4 Ch. Multi Purpose (MP)

� 2 Ch. Piezo / 2 Ch. MP

MicroIFEM

FlexIFEM

FlexIFEM – 1/2 Channel amplifier

� 1/2 Ch. Piezo

� MP available 2010

32

LCD Display

� Visualizes operation menu

� User-friendly setting of parameters

� Displays results or pressure curve

Calculation

� Provides cycle by cycle calculations

� Peak cylinder pressure pmax

� Engine speed

� Output of warning and alarm levels

FLEXIFEM – MORE VALUE

FlexIFEM Advanced

� Combustion Noise function

� Knocking (not yet available)

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FLEXIFEM Advanced – Combustion Noise Meter

� Stand alone charge amplifier with integrated combustion noise function

� Comparability to

� Analog AVL 4050 Combustion noise meter

� AVL combustion noise function in IndiCom

� Download your own transfer (MFFR) curve

� Updates via software

� Further algorithms planned : e.g. AVL CKI

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AVL INDICATING SYSTEMSLIGHT LINE

NEW

• Cost-Effective Solution for Standard Indicating applications

• Light System with full upgradeability to Advanced Indicating System

• Ideal for combustion investigation on 4-6 cylinder engines

• Easy-to-use IndiCom Light Interface

• 0.1 deg. CA measurement resolution up to 11000 rpm with max. 1530 measuring points per cycle

• IEEE1394 Firewire interface

IndiModul Start IndiSmartIncluding Charge Amplifier

35

Graphical User Interface:

� very easy to use

� workflow oriented architecture

� built-in plausibility control

� fast and seamless PUMA integration

� wide range of standard calculations

� extension packages for Diesel and

Gasoline engines

� AVL Sensor Data Management SDM

INDICOM LIGHT SOFTWARE

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LIGHT LINE SPECIALS – UNIVERSITY PACKAGE

Development package

� IndiModul Start (8 channels)

� IndiCom Advanced

� Coldstart

� Knock Analysis

� Noise Analysis

� 1x Micro IFEM (Piezo orMultipurpose)

� 365C Crank Angle Encoder

� 2x uncooled Piezo-Tansducerswith mounting tools

� Concerto with 5 NW licenses

� Care Support (2 years withoutSW subscription)

37

IndiModul IndiSet IndiMaster

AVL INDICATING SYSTEMSAdvanced Line

38

� Detailed analysis of the indicating data (IFile)

in the office

� Investigation of the correlation between

combustion values and testbed results

� Sophisticated diagrams and graphical objects

for clear result presentation

� Advanced calculation library, easy to use with

CalcGraf and Formula Editor

� Automated data processing with scripting

DATA POSTPROCESSINGWITH AVL CONCERTO

39

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0 0.1 0.2 0.3 0.4 0.5

Adjustment using pressure

coeffscoeffs of of

discharge discharge

(customer)(customer)

Valve lift Valve lift

(customer)(customer)

ppcylindercylinder

ppexhaustexhaust, ,

TTexhaustexhaust

Geometry of cylinder and ports Geometry of cylinder and ports (customer)(customer)

GCA

PPintakeintake, ,

TTintakeintake

Adjustment using pressure

Filter, Adjustment and Combustion Analysis

0

1 8 0

6 9 0

40

Together atthe Test Bed

� Application of Simulation

Tools at the Test Rig

� Indication and Simulation

Together

1-d Thermodynamic

Simulation

Indicating

� short loop between simulation and measurement

41

Fibre

Optic Light Guide

Illumination Unit

Crank Angle Signal

PC

Endoscope

Camera

AVL VISIOSCOPE - SYSTEM OVERVIEW

42

camera-connection

ø 4 or

7mm

rod lenses Objective lens

ø 8mm

Light

entrance

cooling ducts

straight forward

viewobliqueview

obliqueview

viewing direction

rod lenses with integrated fibres

rod lenses with cooling channel

0°30° 70°

obje

ct

67 °

obje

ct

67 °

cooled endoscope

uncooled endoscopes

AVL VISIOSCOPE - OPTICAL ACCESS

43

Crank AngleCrank Angle

Rep

eti

tio

ns

Rep

eti

tio

ns

--8,58,5°°

11

22

33

44

nn

--6,56,5°° --4.54.5°° --2.52.5°° --0.50.5°°

55

AVL VISIOSCOPE - RECORDING TECHNIQUE

44

Example Visioscope Diesel Flame

45

Example Visioscope Diesel Flame / Flame Temperature

46

Example Visioscope DI Gasoline

47

Example Visioscope Gasoline Wall Wetting

48

THANK YOU FOR YOUR ATTENTION