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

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

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DelphiEnginetestbenchcalibrationmethodologyforDelphiDieselcommonrailsystem

EnginetestbenchcalibrationmethodologyforDelphiDieselcommonrailsystem

CONTENTS

1.Purpose

Thisdocumentproposesengineoptimisationmethodologyonenginetestbenchfromthebeginningoftheprojecttothestartoftheproduction.

Optimizingengine'ssettingsonatestbenchisacompulsorystepinaproject.Itisusedtodefinethefirstsetofcalibrationinordertorunengineproperly.Then,tochoosehydraulicsystemdesignwhichreachesperformancesandemissionstargets.Afterthat,itallowstodefineoptimumsettingsforalargeamountofcalibrationsandtovalidatesystemfunctionalitiesontheproject.Finally,Testbenchwillbeusedtoquantifyscatteringandtodemonstrateenginecapabilityforextremecases.

2.Scope

ThisdocumentappliestobenchtestforenginesequippedwithDelphicommonrailsystem.

3.Definitions

VI:

ValveIn

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.

Thislimitationisgeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.

Belowisagenericexampleshowstheminimumdeliverylimit:

6.3.4.Pilotandmaininjectionsseparationlimits/Delphi’sresponsibility:

TakingintoaccounttheI2CandtheAPCstrategiesandlowbatteryoperation,theminimumuseableelectricseparationshouldbesetatthebeginningat1000µs（starttostart）.

Theshownexampleisgeneric.Specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecificationtoallowmorecalibrationpossibilities.

7Nozzledefinition/customer’sresponsibility

Oncetheenginelimitsandsystemlimitsarecreated,thenextstepinthedevelopmentprocessistochoosethehydrauliccomponentswhichwillallowtheperformancetargets.

7.1.Purpose

Thefirstpurposeoftheenginebenchdevelopment