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GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
Dr. Robert Fairbrother, development simulation GCADipl.-Ing. Rudolf Gande, development gasoline engines
Georg Salentinig, development software
Dr. Thomas Leifert, product management GCAIng. Johann Krammer, product management BOOST
AVL List GmbH
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Everybody belives the test result
except the test engeneer.
Nobody belives the analysis result
except the analyst.
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content: ● GCA / GCA-online
● low end torque: potential and risk
● test cell and measurement set-up
● low end torque: application
● GCA-online at the test cell
GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
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AVL GCA: WORKING PRINCIPLE
Exhaust pressure curve
Intake pressure curve
Cylinder pressure curve
Combustion analysis
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GCA WORKFLOW
GeometryBore, Stroke, etc.
MeasuredCylinderPressure
Trace
Operating PointSpeed, BMEP, Massflows, etc.
GeometryBore, Stroke, etc.
MeasuredCylinderPressure
Trace
Operating PointSpeed, BMEP, Massflows, etc.
COMBUSTIONANALYSIS
COMBUSTIONCOMBUSTION
INTAKE VALVE
INTAKE PRESSURE
EXHAUST PRESSURE
EXHAUST VALVE
INTAKE VALVE
INTAKE PRESSURE
EXHAUST PRESSURE
EXHAUST VALVE
COMBUSTIONCOMBUSTION
flow coeff.
flow coeff.
CalculatedPressures
andMassflows
GAS EXCHANGEANALYSIS
CalculatedPressures
andMassflows
GAS EXCHANGEANALYSIS
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ααααα d
dmh
d
dQ
d
dQ
d
dVp
d
umd BBBB
Wf
cc −−+−=
)(
dQf: heat release by combustion after fuel injection
COMBUSTION ANALYSIS
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GCA_C_*_Exhaust_Boundary
e.g.
GCA_C_Pressure_Exhaust_Boundary
BURN_C_ROHR
(Only values after start of combustion are used
and are normalized by BOOST) GCA_C_ROHRGCA_C_Pressure
GCA_C_Valve_Lift_ExhaustGCA_C_Valve_Lift_Intake
GCA_C_Mass_Flow_Intake GCA_C_Mass_Flow_Exhaust
GCA_C_*_Intake_Boundary
e.g.
GCA_C_Pressure_Intake_Boundary
GCA_C_*_Intake
e.g. GCA_C_Pressure_Intake
GCA_C_*_Exhaust
e.g. GCA_C_Pressure_Exhaust
Pressures & Flows
GAS EXCHANGE ANALYSIS
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CPU: Intel Core-i or Intel Xeon with 4 or more cores at 3GHzRAM: 4 GBOS: Windows 7 (32/64bit) or Windows XPInterfaces: GigaBit Ethernet, CD-ROM,
PCI-E and RS232 or ExpressCard (on Notebooks)
GCA-ONLINE PC REQUIREMENTS
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content: ● GCA / GCA-online
● low end torque: potential and risk
● test cell and measurement set-up
● low end torque: application
● GCA-online at the test cell
GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
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TURBOCHARGED GASOLINE ENGINES
FULL LOAD TREND
Increasd O2 content in exhaust gas due to scavenging
Torque gain by scavenging engine operation
O2
EM
ISS
ION
(%
)
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BMEP POTENTIAL
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AIR FUEL RATIO
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OXYGEN EMISSION
O2 (%)
Oxygen Emission
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content: ● GCA / GCA-online
● low end torque: potential and risk
● test cell and measurement set-up
● low end torque: application
● GCA-online at the test cell
GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
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test cell setup and measurement parameters
PC IndiCom
CAN-card
Ethernet
ETAS
λλλλ
LAVS_41
1 UEGO Probe
CAN
Gigabit Ethernet
CAN
simultanous knock monitoringCAN � IndiCom � PUMA
2 • INDIMODUL 622
ECU
Appl. PC
INCA
4 p Cyl
1 p In abs
1 p Ex abs
PUMA Interface
F-FEM_AIN200 Hz
∆∆∆∆t inj
t Ign
1 T In
1 T Ex
TCPIP
ES610
1 UEGO 1 VVT In
1 VVT Ex
n, TRQ
m fuel (734)
m Intake Air
••
2 • microIFEM
(Sensi Flow)
λλλλ
(TM)
TRG, CDM
365C
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Piezo Resistive Low Pressure Sensor
for Exhaust ManifoldLP11DA with AE04
Piezo Electrical High Pressure
Spark Plug Sensor ZI31
with optical access
to the Combustion Chamber
Piezo Resistive Low Pressure Sensor
for Intake ManifoldLP11DA
PRESSURE SENSORS IN USE
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content: ● GCA / GCA-online
● low end torque: potential and risk
● test cell and measurement set-up
● low end torque: application
● GCA-online at the test cell
GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
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STATE OF THE ART ENGINE
4 cylinder GDI gasoline engine of a series passenger car:
Engine type: 4 cylinder gasoline, in lineConfiguration: GDI, VVT, 16 valves, 1 stage Turbo ChargerPower: Pe = 180 kWTorque: Trq = 380 NmDisplacement: Vtotal = 2.0 lCompression ratio: ε = 9.7
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LOAD STEP
Low end torque:
LOAD STEP
within 25 cycles
by cam phase shift
Scavenging
PedalPosition
Residual Gas Content
Engine Speed
IMEP
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VALVE SHIFT
The maximum valve overlap
load step: corresponding shift
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SCAVENGING MODE
mass flow
before load step
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SCAVENGING MODE
mass flow
during scavenging
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LAMBDA IN SCAVENGING MODE
Lambda measured in exhaust
versus calculated for cylinder
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content: ● GCA / GCA-online
● low end torque: potential and risk
● test cell and measurement set-up
● low end torque: application
● GCA-online at the test cell
GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
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CONCLUSIONS
• A complete gas exchange and combustion analysis tool was introduced which can be used online at the test bed or on the vehicle
• The tool can be used to overcome the limitations of slow feedback of available sensors (eg: A/F, m) as well as providing important additional information
• Development engineers at the test bed have immediate and direct access to accurate gas exchange and combustion analysis data that cannot be measured
•
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Everybody belives the test result
except the test engeneer.
Nobody belives the analysis result
except the analyst.
Everybody
not only
even
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GCA ONLINE
SUPPORTING THE ENGINE CALIBRATION PROCESS BY FAST GAS EXCHANGE AND
COMBUSTION ANALYSIS DIRECTLY AT THE TEST BED
Dr. Robert Fairbrother, development simulation GCADipl.-Ing. Rudolf Gande, development gasoline engines
Georg Salentinig, development software
Dr. Thomas Leifert, product management GCAIng. Johann Krammer, product management BOOST
AVL List GmbH
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CALIBRATING EXHAUST EMISSION
delivered / not trapped
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LAMBDASensor
LAMBDA SENSOR LOCATION
Turbocharger shaft
GCA is cylinder and cyclic specificLambda Sensor is cylinder averagedand time delayed
