DelphiEngine test bench calibration methodology for Delphi Diesel common rail systemWord下载.docx

DelphiEngine test bench calibration methodology for Delphi Diesel common rail systemWord下载.docx

《DelphiEngine test bench calibration methodology for Delphi Diesel common rail systemWord下载.docx》由会员分享，可在线阅读，更多相关《DelphiEngine test bench calibration methodology for Delphi Diesel common rail systemWord下载.docx（19页珍藏版）》请在冰豆网上搜索。

BSFC:

BrakeSpecificFuelConsumption

TDC:

TopDeadCenter

PWM:

PulseWidthModulation

I/D:

InnerDiameter

ECU:

ElectronicControlUnit

HP:

HighPressure

I2C:

IndividualInjectorCharacteristic

APC:

Accelerometerpilotcontrol

ERPM:

EngineRevolutionPerMinute

APV:

ApplicationProgrammableVariable

APM:

ApplicationProgrammableMap

4.Testcelldefinitionandenginechecking

4.1.Instrument

Thetestcellshouldincludeallthenecessaryinstrumentsforperformancetest,andemissiontestifneeded.Generallybelowinstrumentsarerequiredinatestcell.

_dynamometerandcontrolunit

_fuelbalancerwithreasonableaccuracy

_fuelcooler

_cylinderpressuremeasurementequipment

_temperaturesensortomeasuretheexhausttemperatureforeachcylinder

_airfilterandflowmeter

_intercooler

_temperaturesensors

temperaturesensorsbeforeandafterintercooler,exhausttemperaturesensor,coolanttemperaturesensor,oiltemperaturesensorarenecessarytomonitortheenginestatusandkeeptheengineruninsafeconditions

Sensorstomonitorthefueltemperaturebeforepumpinlet,fueltemperaturesforinjectorreturnandpumpreturnareoptionalandwhichwillhelptomonitorthelowpressuresystem.

_pressuresensors

exhaustpressuresbeforeandafterturbo,oilpressure,airpressuresbeforeandafterintercooler

_emissioninstrumentifemissionmeasurementisrequired

_SteadyvoltagesupplytopowerECU;

10-16voltageisacceptable

_Atmospheremeterandhumiditymeter

4.2Lowpressuresystem

4.2.1Circuitfortestcell

Thepipeworkandfittingstobeminimum8mmI/D

Thepipeworkthatisincontactwithfuelshouldnotcontaincopperorzinc

Therecommendedgenericconfigurationofthelowpressurecircuitforatestcellisdescribedinthefollowingdiagram:

FUELCOOLER

（IFREQD）

4.2.2.PressureConditions

ThedepressionattheHPpumpinlet（measured50mmfromthepumpinlet）mustbeabove-400mbarinrelationtotheatmosphericpressure.

Ifthislevelisreached,STOPTESTandinvestigatecause.

ThepressureattheHPpumpreturn（measured50mmfromtheventurioutlet）mustbebelow300mbarabovetheatmosphericpressure.

Theselimitationsaregeneric,specificlimitationsforeachapplicationwillbeprovidedinsystemobjectivespecification.

4.2.3TemperatureConditions

Thefueltemperatureshouldbekeptas40-45degreeCatnormalrunningconditions.

Forthehottest,thetemperatureatpumpinletshallremainbelow85°

C（Peaktemperatureof90°

Ccanbeacceptedduring30secondswhenrunning）.Thelowpressurecircuitmustallowtheadditionalheatwhichcomesmainlyfromtheleakreturnoftheinjectors,tobedissipated.Thistemperaturecouldbeashighas110DegCathighengineloads.

IfthetemperaturedifferentialacrosstheHPpump,INLETtoRETURNexceeds50degC,STOPTESTandinvestigatecause.

Theselimitationsaregeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.

4.2.4FilterChangeInterval

Thefilterelementshouldbechangedafter200hoursofenginerunning.

Thislimitationisgeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.

Seealsofilterteamrecommendationofthefilteranalysis.

4.2.5Watersedimentor

Checkandemptyifneeded.Sameintervalasfilterchange

4.3Airinletandexhaustsystem

-monitorpressuredropacrossintercoolerifapplicable

-monitorbackpressure

4.4Electricalsystem

4.4.1.BatteryVoltage

ThesystemensuresnormalfunctionforbatteryvoltagesattheECUsupplypinconnectorsbetween10to16V.ThevoltageshouldbekeptsteadytoguaranteetheFIEsystemworkproperly.Ifthevoltageisnotatnormalcondition,somerecoveryactionsneedtobetakenintoaccounttoputbackthevoltagetonormalsteadyvoltagelevel.

Thesystemcanoperateforamaximumof1hourbetween16Vand18VatECUsupplypin,andthefunctionmaybedeteriorated.Duringjumpstart（between18Vand24VatECUsupplypin）,thesystemcanmeetatleastthefunctionalrequirementrelevantforthestartofvehicle,theover-voltage（between18Vand24VatECUsupplypin）timeshallbelessthan1minutewithambienttemperaturelessthan20°

C.

4.4.2.Powersupplyrequirements

ThepowersupplyconnectionsshouldhaveminimumDCresistance,ideally<

40mOhmstotal.

Inthecaseofdynamometerinstallationsthepowersupplyunit（PSU）shouldbechosentomanagethepeakcurrentrequirement,ieaminimumof25A.IdeallythePSUshouldbeoftheswitch-modetypeasthisisbettersuitedtotransientdemandchanges.ThesupplyshouldbelocatedascloseaspossibletotheECU（<

1.5m）tominimisevoltdrop.

4.5Enginecheckingbeforefirststart

Anenginestartattemptshouldonlybemadewith:

_anadequatefuelsupplysystem.

_afullyassembledhighpressurefuelsystem

_allthesensorsconnected

_thekeyswitchONtomaketheECUpoweron,butnostart

_allinjectorcorrectiondata（C2I）enteredintotheECU.

_faultlistbecheckedandallfaultsbeclearedbeforestartingtheengine.

Afterthefirststartoftheengine,（eitheranewengineorafterdismantlingofthefuelsystem）,theengineshouldbestoppedafteraperiodofbetween1and5minutesrunningatidletocheckforfuelleaks.AvisualONLYinspectionshouldbemadeofthelowandhighpressuresystem.

5Softwarerelease

Delphiwillreleasethesoftwareatthebeginningofanewapplication.

ThelevelofthissoftwarewillbedefinedbytheEMSteamandwilldependonthesystemfunctiondefinition.

6Systemlimitsdefinition

Beforeanyfullloadtests,enginelimitsandthesystemlimitsshouldbedefinedtoguaranteesafeoperation.

6.1.Purpose

Thissubjectdescribesthesystemlimitsthatshouldbetakenintoaccountwhenanapplicationiscarriedout.

6.2.Enginelimits

Theenginelimitsmustbeknownbeforestartinganengineonatestbench.

Themostimportantvaluestoknoware:

_themaximalcylinderpressure,

_themaximalenginespeed,

_themaximaltemperaturebeforeturbine,

_themaximalintakeairtemperatureaftertheturbocharger.

Note:

alltheseitemsarecustomer’sresponsibilities.Inordertomonitorthecylinderpressure,customerneedstomachineaspecificcylinderheadtoinstallthecylinderpressuregauge.

Exceedingtheselimitscoulddamagetheengine.Someautomatedtestsbenchesareabletolookafteruser-definedlimits.

Themaximalfueldemandshouldbedefinedbeforerunningtheengineonatestbench,topreventbringatoobiginjection,whichcouldmaketheengineexceedthemaxexhausttemperatureandcylinderpressurelimitsanddamagetheengine.Thetimingsshouldalsobeconsidered:

it'

simportanttoestimatethetimingslimitsforthemultipleinjections,whichcouldcausethemaxexhausttemperatureandcylinderpressure.

6.3.FuelSystemLimits

Toguaranteethesystemoperation,somelimitsmustbetakenintoaccount.

6.3.1.Fuelcharacteristics/customer’sresponsibility

ThecommonrailsystemistobeusedwithEN590fuels,orEMC5（ie:

EN590+5%ofester）.Ifothersfuels,orpoorqualityfuels,areusedthenthedurabilityofthesystemcannotbeguaranteedwithoutspecificmeasurestobedefinedwiththecustomer.

Delphireservestherighttorequestthecustomertoprovidethefuelspecification.

6.3.2.Railpressurelimits/Delphi’sresponsibility

Thedemandedpressuremustbewithinminimalandmaximallimitsthatvaryagainstspeed.Thislimitationisgeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.

Belowisagenericexample:

6.3.3.Fuellinglimits/Delphi’sresponsibility

Theminimumfueldemandforpilotinjectionisafunctionofrailpressure.Itisintendedtobeabletoguaranteethatatleast0.5mm³

/shotisinjectedintotheenginetakingintoaccountshot-to-shotandvariationofmeandelivery,ascontrolledbyAPC.

Belowisagenericexampleshowstheminimumdeliverylimit:

6.3.4.Pilotandmaininjectionsseparationlimits/Delphi’sresponsibility:

TakingintoaccounttheI2CandtheAPCstrategiesandlowbatteryoperation,theminimumuseableelectricseparationshouldbesetatthebeginningat1000µ

s（starttostart）.

Theshownexampleisgeneric.Specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecificationtoallowmorecalibrationpossibilities.

7Nozzledefinition/customer’sresponsibility

Oncetheenginelimitsandsystemlimitsarecreated,thenextstepinthedevelopmentprocessistochoosethehydrauliccomponentswhichwillallowtheperformancetargets.

7.1.Purpose

Thefirstpurposeoftheenginebenchdevelopment