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Pressure indicating was used as long ago as in the development of steam engines and is therefore at least as old as the internal combustion engine itself. Whereas purely mechanical indicators were employed in the early days of internal combustion engines, today it is mainly piezoelectric transducers that are used to measure combustion chamber pressure and pressure curves in intake, exhaust and injection systems. Specially grown crystals are virtually the only things used nowadays as the piezo-materials (e.g. quartz, gallium orthophosphate, etc.). Apart from their excellent dynamic behaviour, their high measurement quality, their high stability and very good linearity, the metrological properties of these transducers above all are largely independent of temperature, which is of special importance in measurements on IC engines. The cyclic temperature drift in particular can be kept small with these transducers, which very often represents the decisive error factor in accurate thermodynamic observations of the engine phenomena. State-of-the art development methods, such as FE simulation especially, must also be used to ensure low error using modern piezoelectric pressure transducers. Not least because of the extensive possibilities of digital signal conditioning has pressure indicating become a standard development tool that, in addition to accurate thermodynamic analysis, also permits wide-ranging evaluation on the engine test bed itself. Despite, or rather because, of this sophistication in indicating technology, users need highly specialised know-how. This manual is intended to provide such basic know-how and to be used as a reference work in practical applications with piezoelectric engine instrumentation. I wish you every success in your measurement tasks.
O.Univ.-Prof. Dipl.-Ing. Dr.techn. Rudolf Pischinger Head of the Institute for Combustion engines and Thermodynamics, University of Technology Graz
Preface
Engine Indicating
Contents
Preface 1 Pressure Indicating in IC Engines
1.1 High Pressure Indicating 1.1.1 Indicating Parameters 1.1.2 Indicating Parameters Available on the Test Bed 1.1.3 Thermodynamic Analysis 1.2 Low Pressure Indicating 1.2.1 Gas Exchange Analysis 1.2.2 Development Work Based on Gas Exchange Analysis
I 1-1
1-3 1-3 1-4 1-5 1-6 1-6 1-7
2-1
2-3 2-3 2-4 2-7 2-8 2-9 2-11 2-12 2-12 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-20 2-22 2-23 2-24 2-24 2-25
3-1
3-1 3-1 3-3 3-3
Contents
3.1.2.2 Transmission Behaviour 3.1.2.3 Temperature and Heat Flow Influences 3.1.2.4 Acceleration Influence 3.1.2.5 Deformation impact 3.1.2.6 Chemical Influence and Deposits 3.2 Properties of the Charge Amplifier 3.3 Properties of the Measurement Cabling
4-1
4-3 4-3 4-3 4-3 4-5 4-6 4-6 4-7 4-8 4-8 4-8 4-12 4-17 4-18 4-18 4-20 4-22
5-1
5-1 5-1 5-2 5-5 5-5 5-5 5-6 5-9 5-9 5-12 5-13 5-15
6 Calibration
6.1 General 6.2 Type of Calibration 6.3 Calibration Using Dead Weight Tester
6-1
6-1 6-2 6-3
II
Engine Indicating
6.3.1 Construction and Function of Dead Weight Testers 6.3.2 Interference during Calibration 6.4 Important Instructions
7 Zero-line Detection
7.1 Reference Method 7.1.1 Fixed Point (Empirical) 7.1.2 Measured Pressure Curve in the Intake Pipe 7.2 Thermodynamic Zero-line Coefficient 7.2.1 Assumption of a Constant Polytropic Exponent 7.2.2 With the Aid of the Integral of the Heat Release 7.2.3 Comparison of Measured and Calculated Pressure Curve 7.3 Comparison of Methods
7-1
7-1 7-1 7-2 7-2 7-2 7-3 7-4 7-5
8-1
8-1 8-1 8-2 8-2 8-3 8-4
9-1
9-1 9-4 9-4 9-4 9-4 9-5 9-7 9-8 9-9 9-11 9-16 9-17 9-17 9-18 9-18 9-19 9-20 9-21 9-23
10 Trouble shooting
10-1
Contents
III
10.1 Pressure Transducer 10.2 Measurement Cabling 10.3 Charge Amplifier 10.4 Crank Angle Encoder 10.5 Data Acquisition and Evaluation (Indicating Equipment) 10.6 Calibration
IV
Engine Indicating
I
Before Nikolaus August Otto first put his engine into operation, he already calculated the anticipated pressure chart and expected work based on the gas laws. He was then later able to confirm them by measuring the cylinder pressure on his test engine. The mechanically recorded pressure traces were called indicator charts. Figure 1-1 shows an indicator chart of the first four-stroke engine recorded on 18 May 1876.
Indicator chart
Figure 1-1: Indicator chart recorded by Nikolaus August Otto (from Friedrich Sass: Geschichte des deutschen Verbrennungsmotoren-baus von 1860-1918") [22]
Although engine instrumentation has changed considerably since then, the concept of engine indicating has remained. In the old days the term engine indicating was applied to the measurement of in-cylinder pressure only. Today, however, the term is generally taken to mean the measurement of crank angle-based parameters, such as in-cylinder pressure, pressure in the intake and exhaust system, rapidly changing temperatures, and needle lift and line pressure, to name but a few. The one thing all these measurement parameters have in common is the fact that they create a direct reference to the instantaneous position of the piston, which permits assignment to the relevant cycle phase of the engine.
Advanced
1-1
The special significance of indicating technology for engine developers is that it allows excellent insight into the instantaneous events inside the engine at an acceptable cost The pressure inside the cylinder is still the central parameter that describes the incylinder phenomena. This manual therefore deals almost entirely with combustion chamber pressure measurement.
Tuning EGR Abstimmung AGR Limit Grenzwertberwachung value monitoring Efficiency determination Wirkungsgradbestimmung Combustion noise Verbrennungsgerusch Misfire detection Aussetzererkennung Engergy balance Energiebilanzen Friction mapping Reibungskennfeld Automatic eng. mapping automat. Kennfeldoptimierung Knock detection Klopferkennung
Schwingungsanregung Vibration excitation Einspritzverlaufuntersuchung Injection analysis mechanische stress Mechanical Beanspruchung
Over recent years, high and low pressure indicating has developed into a valuable, highly sophisticated analysis method for combustion optimisation. Both the sensors used and the computer-supported data acquisition have reached a sophistication today that not only allows us to use indicating as an operational measurement technology but also satisfies the accuracy demands that make it possible to obtain extensive information from the analysis of measured pressure curves (see Figure 1-2).
Indicating is the development tool for quick and high-quality optimisation of the engine combustion sequence. No other measurement procedure delivers so much information about the in-cylinder phenomena. When applied properly, indicating is a reliable and repeatable measurement procedure and can therefore be used as standard measurement technology on development test beds. [20]
1-2
Engine Indicating
BDC UT
UT BDC
High pressure indicating in the combustion chamber is usually carried out with piezoelectric pressure transducers, which are either installed in the combustion chamber direct or in a spark or glow plug adaptor.
1-3
Indirect indicating parameters are values that need other parameters (e.g. braking torque, crank gear geometry, etc.) for calculation in addition to the basic pressure curve. Before the start of combustion can be calculated, for example, the heat release (burn rate) curve first has to be calculated from the pressure curve. Table 1-1 shows a selection of direct and indirect indicating parameters.
Table 1-1: Indicating parameters Indirect indicating parameters - Indicated mean effective pressures IMEP IMEPHP, IMEPGE - Friction mean effective pressure FMEP - Start of combustion - Duration of combustion - Energy conversion - Mass burned fractions - Combustion noise Direct indicating parameters - Peak pressure pmax - Position of peak pressure pmax - Pressure rise dp/d - Position of max. pressure rise dp/dmax - Speed of the pressure rise dp/d2
The indicating parameters determined from high pressure indicating provide a basis for direct assessment of the engine.
Other indicating parameters will be calculated after the measurement has finished so that the engine developer can access them together with other measurement parameters on the test bed data acquisition system (i.e. on-line). That means that it is now possible to set up comprehensive automatic engine optimisation for
1-4
Engine Indicating
Efficiency Rate of heat release and thus ignition delay, start of combustion, duration of combustion and mass burned fractions Gas condition and thus the basis for pollutant formation
For a detailed description of the basic equations required for thermodynamic analysis, see for example [21].
1-5
4 3 2 1 0 -180 BDC UT -90 0 Saugrohr Intake 90 180 270 360 450 540
Exhaust
Auspuff
BDC UT
BDC UT
the measured pressure curves in the intake manifold, combustion chamber and exhaust the exact valve lift curves and flow coefficients.
It is important for gas exchange analysis that low pressure indicating is carried out together with high pressure indicating. In other words, three pressures are measured simultaneously on each cylinder: the intake manifold pressure, the combustion chamber pressure and the exhaust pressure. Only with such a configuration can complete heat release and gas exchange analysis of the engine be carried out.
1-6
Engine Indicating
the design of the gas exchange devices (intake manifold, exhaust), the design of the control devices (valve timing, cam shapes), the assessment of the gas exchange work, and the analysis of the intake and outlet mass flows (charge, residual gas, backflows).
If the gas-dynamic processes in the intake manifold/combustion chamber/exhaust system are not taken into consideration by the calculation routines used for the gas exchange analysis, it is important for the low pressure transducers to be placed as close as possible to the valves. Piezoresistive and piezoelectric pressure transducers are used for low pressure indicating. [13]
1-7
1-8
Engine Indicating
Figure 2-1: Structural diagram of the piezoelectric pressure measurement system with additional devices
Charge amplifier
The charge generated by a piezoelectric pressure transducer is converted to a voltage signal by means of a charge amplifier. The signal is then fed to the data acquisition and evaluation equipment (Indicating System) for further processing.
Measurement cabling
The measurement cabling is used to transmit the charge and voltage signals. Due to the low electrical charge output of pressure transducers, the connection between the transducer and the charge amplifier is of critical importance.
2-1
Very high insulation values and low noise are required both for the measurement cabling and the charge amplifier. The following equipment is also required before measurements can be carried out on the IC engine:
+ Chapter 9
A crank angle encoder mounted on the crankshaft of an IC engine delivers the time/angle basis for crank angle-related acquisition of the pressure curve.
Indicating equipment
Information: [9] Indicating Technology
+ AVL Product
The analogue output voltage signal of the charge amplifier is digitized and recorded by means of a so called indicating equipment. Indicating equipment comprises at least an Analogue/Digital converter (ADC), a data acquisition unit based on the crank angle (CAM-C Crank Angle Marker Control Unit) and a fast memory for temporary storage of the raw data. The data is taken from the memory and the indicating parameters calculated, stored, and displayed by means of a computer that, in some systems, is already integrated. Other equipment that may be required includes:
Display
The measurement signals can be visually checked on the indicating equipment itself or, if the indicating equipment has no display, via an oscilloscope.
2-2
Engine Indicating
Direct piezoelectric effect Description A mechanical deformation of a piezoelectric body causes a change in the electric polarisation that is proportional to the deformation.
F
++++++++++++++++++ ------------------
Reciprocal piezoelectric effect An external electrical Field E causes mechanical stresses proportional to the field, which alter the size of the piezo-crystal.
E E
For measuring mechanical parameters, especially of forces, pressures and accelerations Figure 2-2: Piezoelectric effects
Application
2-3
The phenomenon of the direct piezoelectric effect can described for the electrically free state of a piezo-crystal (achieved in experiments most easily by short-circuiting the transducers electrodes) by Equation 2-1.
Flow density
(2-1)
(2-2)
T ( = 1 to 6) Tensor of the mechanical stresses (with T1 to T3 for normal stresses x, y, z and T4 to T6 for tangential stresses yz, xz and xy) Each piezoelectric coefficient (dI) determines the relationship of a specific stress tensor coordinate (T) with a specific vector coordinate of the electrical flow density.
Charge output
Equation 2-3 then applies to charge output (Q) of the face of the crystal element covered by the electrodes. Q = A . D i . ni A ni face area (i = 1 to 3) components of the normal vector of the face (2-3)
2-4
Engine Indicating
Longitudinal Effect
The measuring elements are usually disc-shaped and the charge output occurs on the face itself where the force is applied, see Figure 2-3. If the crystallographic x-axis and the direction in which the force is applied are the same, the charge output is as shown in Equation 2-4 assuming a uniaxial stress condition.
Q = A . d11 . x = A . d11 .
F = d11 . F A
x
(2-4)
F r
Charge output
The charge output resulting from the longitudinal effect does not therefore depend on the geometry of the measuring element but purely on the force (F) applied. Several discs can be connected force-wise in series and electrically parallel to increase the charge output (sensitivity), see Figure 2-4. One advantage of this design is that it permits a compact and resistant measuring element. Not only that but the charge is output straight from the pressed faces so that contact problems in the charge pick-up are virtually excluded.
Figure 2-4: Increasing the charge output with the longitudinal effect
F
+ + + + + + + + + + - - - - - - - - - - - - - - - - - - + + + + + + + + + + + + + + + + + + + + - - - - - - - - - - - - - - - - - - + + + + + + + + + +
Q+
Q-
2-5
Transversal effect
The measuring elements are bar-shaped and the charge is output perpendicular to the faces to which the force is applied, see Figure 2-5. Assuming a uniaxial stress condition, the charge output can be determined using Equation 2-5 for a purely transversal cut (i.e. the longitudinal axis of the bar lies in exactly the direction of the crystallographic y-axis, one side face is perpendicular to the z-axis and the charge is picked-up on the faces perpendicular to the x-axis).
Q = A . d12 . y = l . b . d12 .
z
Charge output
F l = d12 . F . a. b a
(2-5)
F a
b y
In addition to the electrical properties of the piezo material used, the charge yield is determined in particular by the thinness of the measuring element (l/a). With a favourable edge ratio (l/a), greater polarisation charges can be achieved with the transversal effect but the dimensional design constitutes a practical limit due to the limited mechanical strength of the piezo material.
2-6
Engine Indicating
High output signal The piezoelectric sensitivity, which is determined by piezoelectric coefficient (di), is decisive for the amplitude of the output signal. The coefficients relevant to the generation of the measurement signal in the transducer should be as large as possible.
Good linearity There should be the best linear ratio possible between the measurement parameter (i.e. pressure) and the charge output.
High natural frequency High natural frequencies require high mechanical rigidity. Good insulation A high electrical insulation resistance is essential for low electrical drift and allows similar-to-static measuring with piezoelectric transducers.
+ Chapter 2.2.2
Good resistance
High mechanical strength High mechanical strength is essential when large forces, pressures and accelerations are to be measured and for the transducer to be resilient to mechanical impact.
Stability of the measuring properties and their immunity against external influences
Temperature and mechanical load Achieving a piezoelectric sensitivity that does not depend on temperature and mechanical load is a very difficult task. The choice of material and the orientation of the piezoelectric elements in relation to
2-7
the crystallographic axes can help to find the solution. Basically no pyroelectric effect should occur with the piezo materials used.
Pyroelectric effect: denotes the effect of the charge output of piezo materials under the influence of temperature.
Low price
Because of the unavoidable flaws and impurities in naturally grown quartz, nowadays we only use cultured quartzes (using hydrothermal synthesis) to obtain consistently high quality.
Hydrothermal synthesis: using this process quartz crystals are created in thickwalled steel autoclaves at pressures between 0.3 and 1.3 kbar and temperatures of around 400 C. Water with small additives of Na2CO3 or NaOH is used as the solvent. The material is transported primarily by convection. Large quartz crystals with a mass of more than 1kg take several weeks to grow.
Temperature significantly influences the piezoelectric properties of quartz. Figure 2-8 shows piezoelectric constant (d11) as a function of the temperature. (d11) already starts to significantly decrease in the most frequently used temperature range up to about 250 C and finally disappears completely at the conversion temperature of 573 C. In
2-8
Engine Indicating
addition, the load limit decreases with rising temperature due to twin formation.
Twin formation: in -quartz so called Dauphin twins (i.e. secondary twin formation) can form at high loads in certain areas of the crystal where the mathematical sign of the piezoelectric coefficients sometimes changes resulting in lower sensitivity. Whereas twins form at room temperature only at pressures of approx. 5.108 to 9.108 Pa, as the temperature increases, twin formation starts to occur at lower loads, and twin formation can be observed even in unloaded quartz just below the conversion temperature of 573 C. It has been found that twins, which formed under load can completely disappear again when the load is removed. But if the mechanical load is applied for a longer period, stable twins can also develop which result in a permanent reduction of the piezoelectric sensitivity.
Conventional measuring elements made of quartz can therefore only be used up to temperatures of about 200 to 250 C, which means that the measuring element requires appropriate cooling for applications in IC engines where temperatures much higher than 400 C can occur at the measuring position. To improve the thermal behaviour with the transversal effect may be utilized (by contrast to the longitudinal effect) by defining the cut of the crystal in such a way that the effective piezoelectric coefficient remains relatively independent of the temperature within a certain temperature range. At the same time, such crystal cuts do not usually have a strong tendency to form twins. They can therefore be used to make measuring elements suitable for temperatures up to approx. 350 C.
Thermally stable cut quartz
+ AVL Product
Information: [7] Gallium Orthophosphate (GaPO4)
2-9
6 5
Galliumortophosphate
d11[pC/N]
Quartz
Temperature [C]
-GaPO4 -Quartz
573 870
Highcristobalit
Tridymit
Figure 2-8: Temperature dependency of piezoelectric constant (d11) for quartz and Gallium Orthophosphate
2-10
Engine Indicating
represent
the
main
advantages
of
Gallium
temperature-resistant up to more than 900 C almost twice the sensitivity of quartz which remains virtually unchanged up to far in excess of 500 C (see Figure 2-8) high electrical insulation resistance up to high temperatures stable against stress-induced twin formation no pyroelectric effect
The excellent thermal behaviour and high sensitivity of Gallium Orthophosphate have made great advances over quartz possible especially when building uncooled miniature pressure transducers [24].
+ AVL Product
Tourmaline
Tourmaline is an aluminium borosilicate. Tourmaline crystals have the advantage that they cannot form twins, but have a relatively strong pyroelectric effect.
Langasite
The disadvantage of langasite is that its piezoelectric sensitivity depends relatively heavily on the temperature.
2-11
+ AVL Product
A wide range of piezoelectric pressure transducer designs is available for use in IC engines. We will illustrate the basic construction first by using the example of a water-cooled quartz pressure transducer using the longitudinal effect, shown in Figure 2-9.
Connector
Insulator Electrode
-
Measuring element
Figure 2-9: Construction of a piezoelectric pressure transducer based on the longitudinal effect (from AVL) Mounting thread M14x1.25
The pressure (p) to be measured acts via a pliable diaphragm and a short, rigid pressure plate on the piezoelectric measuring element. The function of the pressure plate is to create as even a mechanical stress state as possible in the measuring element. The compensation disc between the measuring element and pressure plate compensates for differences caused by thermal expansion. The measuring element and the diaphragm are surrounded by a water jacket and
2-12
Engine Indicating
intensively cooled during operation. That ensures that the measuring element only becomes a little warmer than the cooling water when used in the engine (typically up to about 10C, in extreme cases 20 C above the cooling water temperature). To increase the charge output the measuring elements usually comprise several disc-shaped elements. Each disc (here made of quartz) is coated with metal so that the electrical parallel connection is guaranteed by bridges with contact tongues and insulation zones (Figure 2-9 right). The pressure transducer housing is electrically connected to the positive electrode of the measuring element and thus represents the electrical ground. For the electric charge output, the negative electrode is connected to a connector, which is highly insulated against the Cooling housing. water Figure 2-10 shows by comparison a crosssection of a water-cooled quartz pressure transducer based on the transversal effect. Since with the transversal effect, the polarisation charges occur on the unloaded lateral faces, those faces are fitted with vapour-deposited electrodes contacted by a spiral spring.
nipples
+ Chapter 2.1.2
Electrode
Measuring Element
Diaphragm
Figure 2-10: Construction of piezoelectric pressure transducers based on the transversal effect (from Kistler) Mounting thread M14x1.25
2-13
+ Chapter 5
With the compact designs of modern IC engines the use of multiple valve technology, less and less installation space is available and miniature pressure transducers are now playing a more and more significant role in engine indicating. These transducers can also be installed on test engines without requiring any mechanical interventions (i.e. spark or glow plug adaptors). Figure 2-11 shows the construction of such a miniature pressure transducer (transversal effect). Miniature pressure transducers usually have to manage without watercooling which places extremely high demands on the piezo materials (i.e. use of GaPO4) and on the transducer design.
Measuring element
Figure 2-11: Uncooled miniature pressure transducer (from AVL) Mounting thread M5x0.5
+ Chapter 3.1.2.3
The temperature has less influence on the sensitivity (quartz) and thermal drift The insulation resistance is not decreased by high temperatures Direct water cooling permits the pressure transducer to be installed flush with the combustion chamber even in measurement positions subject to high thermal load
2-14
Engine Indicating
+ AVL Product
+ Chapter 3.1.2.2
2-15
RFG R
Long
Short Reset
CF CG
I I IIso INS
III
A V VO UA
UEI U
PT DA
C CCK
R INS RISO
2-16
Engine Indicating
When a charge is delivered from a piezoelectric pressure transducer (PT), there is a slight voltage increase at the input of the amplifier (A). This increase appears at the output substantially amplified and negative in other words, the output voltage has a negative polarity as opposed to the input voltage. The thus negatively biased negative feedback capacitor (CF) correspondingly taps charge from the input and therefore keeps the voltage rise small at the amplifier input. At the output of the amplifier (A) precisely the voltage (VO) sets itself that picks up enough charge through the capacitor to allow the remaining input voltage results in exactly (VO) when amplified by (A). Because the gain factor of A is very large (up to about 100 000), the input voltage (VI) remains virtually zero. The charge output from the pressure transducer is not used to charge, i.e. to increase the voltage at the input capacitances, but is drawn off by the feedback capacitor. Changes in the input capacitance - e.g. due to different cables with different cable capacitance (CC) therefore have virtually no effect on the measurement result. The output voltage (VO) of the amplifier is directly proportional to the charge output (Q) of the transducer and inversely proportional to the capacitance of the negative feedback capacitor (CF,), see Interrelationship 2-7: VO - Q / CF (2-7)
By activating appropriate capacitance values many measurement ranges (RANGE setting) may be realized.
+ Chapter 3.1.2.3
2-17
Time constant: denotes the characteristic time period for an RC unit (i.e. combination of resistor - capacitor) in which the capacitor would just be fully discharged if the discharge current stayed at its initial value (see Figure 2-14). In practice the voltage at the capacitor is still always the eth part of the initial value after the time constant () has expired.
The time constant can be determined mathematically from the product of resistance (R) responsible for the discharge and the capacitor capacitance (C). The time constant is 1000 s for typical values for the insulation resistance of 1013 and a capacitance (C) of 100 pF. The time constant can be increased to 10000 s at the same capacitor capacitance (C) by increasing the insulation resistance to a value of 1014 .
U V U0 VO
2-18
Engine Indicating
current (I) and insulation current (IINS) causes a drift in the output voltage signal. The result can be an inflow or outflow of charges depending on the polarity of the input offset voltage. The consequence of the individual drift effects can best be illustrated by means of a simple pressure jump, see Figure 2-15, top. In an ideal situation, the curve of the voltage at the amplifier output labelled would be produced in response to the pressure jump, which represents an analogue mapping of the pressure curve. However, the discharge process of the negative feedback capacitor that is due to the insulation resistance not being infinite, means that the result is a drift curve that looks like curve . The voltage at the output drops towards zero in accordance with an exponential function.
p
t U VO A Sttigung Saturation 5
Input-offset <0
6 1
Ideal Ideal
Linear drift curves like curves and occur when input currents at the amplifier input and/or leakage currents flow through the terminal insulation resistors of the cable and/or pressure transducer due to an input offset voltage. Without suitable countermeasures, such as Short mode, drift compensation etc. (see Chapter 2.2.3), the output voltage signal will drift in both cases until the amplifier is saturated (see for example).
+ Chapter 2.2.3
2-19
The output voltage can then only be returned to zero by closing the reset switch (see Figure 2-13) that effectively discharges the negative feedback capacitor. In practice, the drift effects described above rarely occur on their own but are usually superimposed on one another.
2.2.3
/ Source of errors
By connecting an additional resistor for negative feedback in parallel (RF) (SHORT mode - see Figure 2-13), the drift due to input offset can be restricted to a certain value and drifting into saturation can be prevented, see curve in Figure 2-15. This means that measurements are also possible in SHORT mode even when the insulation is not so good. It is usually only suitable, however, for monitoring purposes because the pressure signal is phase-offset due to the resultant dramatically reduced time constant depending on speed and RANGE setting and has a smaller amplitude. To illustrate this influence, Figure 2-16 shows the pressure differential curves determined using a reference transducer on a test engine at a speed of 2000 rpm. The signal from the transducer being tested was first acquired in SHORT mode and then in LONG mode - i.e. without connecting the negative feedback resistor, under the same load conditions. Measurements in SHORT mode cause errors similar to those due to cyclic temperature drift. Precision measurements are thus only possible in LONG mode and when maintaining the required insulation values.
+ Chapter 3.1.2.3
2-20
Engine Indicating
2
ZOT Ignition TDC UT BTC
UT BTC
Figure 2-16: Typical effect of SHORT mode on the measurement result at low speed and with low transducer sensitivity
Drift compensation
Some charge amplifiers on the market have an activatable electronic drift compensation. One possible type of drift compensation is implemented by feeding a compensation current to the input of the operation amplifier which is as large as the current discharged via the insulation resistors. The drift compensation must be deactivated during calibration of the piezoelectric pressure measurement system.
+ AVL Product
Information: [11] 3066A02 Piezo Amplifier
/ Source of errors
2-21
Bessel filter: the major advantage of the Bessel filter is its linear phase shift-to-frequency ratio. That means that any signal only experiences a single skew (apart from the desired amplitude attenuation of high frequencies). The signal shape is not then distorted. A Bessel filter is ideal for engine measurements because a skew can be compensated by shifting TDC.
/ Source of errors
When using electrical filters, it should be borne in mind that a certain skew will always result, which can cause errors. For example, a skew has a negative effect on the accuracy of the IMEP determination when a low pass filter is used. The higher the engine speed, the higher the lowest permitted filter frequency (rule of thumb: the main frequency of the cylinder pressure signal should not be more than 1 % of the filter frequency to avoid unacceptable skew).
2-22
Engine Indicating
+ Chapter 3.3
+ Chapter 2.2.2
Good screening
Adjacent cables and devices may cause interference signals in the measurement lines. Measurement cables should therefore never be placed near mains supply lines or other sources of interference and they should be kept as short as possible.
+ AVL Product
2-23
Figure 2-17: Basic effect of cable length on the upper cut-off frequency
Laying a low-ohm connection between the engine block and evaluation unit (the best way is with copper mesh of at least 10 mm2 cross-section) Inserting a differential amplifier (or isolated amplifier) between the charge amplifier output and the evaluation unit. The intermediately connected amplifiers must then be operated with their own, electrically segregated
2-24
Engine Indicating
power supplies. With some amplifiers available on the market, such differential amplifiers are already installed with appropriate supplies.
Using shielded input cables Laying the input cable separated from AC voltage-conducting lines and other interference sources Keeping the input cable as short as possible
2-25
2-26
Engine Indicating
3-1
Vibration / Shock
1000g
Tcool / 200 C
Deformation Stress
Accelerations
Structure-borne noise and also general vibrations of the engine cause accelerations at the pressure transducer. Acceleration values from engine vibrations can reach up to 1000 g at the transducer (or in extreme cases even up to 2000 g).
Deformation stresses
Gas and mass forces, and the thermal load result in deformation stresses of up to 200 N/mm2 at the pressure transducer mounting position.
3-2
Engine Indicating
In addition, deposits occur on the surface of the combustion chamber in both petrol and diesel engines and therefore also on the pressure transducer. That can also affect the measurement result.
The measurement range defines the pressure range in which the pressure transducer fulfils the defined specifications (see Figure 3-2).
Q [pC]
1000 800 600
FSO
400 200 0 25 50
Measuring range Mebereich
75
100
125
150
The specification limits may be exceeded in the overload range but that must not have any lasting effect on the measurement properties of the pressure transducer (see Figure 3-2). In the overload range, however, no clear relationship can be expected between the pressure and the output quantity.
3-3
Temperature range in which the pressure transducer fulfils the defined specifications. Connection cables lead to components that remain cool during operation. They therefore have a lower operating temperature range, as do transducer parts that only serve the purpose of signal transmission in cooler ranges (e.g. measurement probes).
O Lifetime [ ]
Number of load cycles over which the transducer retains its technical measurement properties. This represents a purely comparative number that is achieved on highly loaded engines. Favourable installation conditions prolong a transducers lifetime while extreme operating conditions, e.g. combinations of very high temperatures, pressure rises, deformations of the mounting position and corrosive environment, can shorten it.
Deviation of the pressure transducer characteristic from the best straight line with forced zero point.
+ Chapter 6
Sensitivity and linearity are quantities, which are determined by means of calibration. The sensitivity and linearity values always depend on the method used to determine them. Piezoelectric pressure measurement technology usually uses the best straight line with forced zero point method. This is the centre line which travels through the zero point and lies between two parallel straight lines that enclose the pressure transducer characteristic as closely as possible, see Figure 3-3.
3-4
Engine Indicating
FSO [%]
100 80 60 40 20 0 20 40 -A
best straight line beste Gerade with forced zeromit Zwangsnullpunkt point
+A Qmax
3
60 80 100
The mean sensitivity is defined as the gradient of the best straight line with forced zero point. The linearity (deviation) is specified in accordance with Equation 3-1 as a percentage of the full-scale signal (% FSO - Full Scale Output). Linearity deviation [% FSO] = A .........
A . 100 Q max
(3-1)
Distance of the straight lines enclosing the characteristic from the best straight line with forced zero point
Qmax ....Maximum value of the output signal (FSO) Piezoelectric pressure transducers show sensitivity scatter due to the way they are manufactured. The sensitivity specified for the individual types of pressure transducer represents a mean value, or what is called the nominal sensitivity. Before being despatched, each pressure transducer is calibrated by the manufacturer and the result (characteristic, sensitivity, linearity) documented on a calibration sheet. It should be borne in mind that running-in processes at very high temperatures and pressures can result in changes in sensitivity of the order of about 1 %.
O Natural frequency 1st order [kHz]
The lowest frequency of free (non-forced) oscillations in the measuring element of a fully assembled transducer. By contrast with the natural frequency, the basic resonance frequency defines the frequency of the measurement quantity at which the pressure
3-5
transducer outputs the output signal with the greatest amplitude. Where there is little attenuation, as is generally the case in piezoelectric pressure transducers, the basic resonance frequency is the same as the natural frequency 1st order. Figure 3-4 shows the result of a resonance frequency determination measurement of an uncooled miniature pressure transducer as an example.
Amplitude
AR
Frequency[kHz] Frequenz
A high natural frequency is important in particular for measurements at high speeds or knock measurements. The frequency of the measurement quantity or the parts of the signal of the measurement quantity that have to be acquired with great accuracy, should not be more than 20 % of the natural frequency of the pressure transducer used.
O Insulation resistance []
This is the ohmic resistance between the connection for picking up the electric charges and the pressure transducer housing, which represents electrical ground.
+ Chapter 2.2.2
The insulation resistance should be as high as possible (> 1013 at room temperature) to keep the influence of the electrical drift as low as possible.
3-6
Engine Indicating
Piezoelectric pressure transducers have a natural capacitance due to their construction that is primarily due to the electrodes of the measuring element and the capacitances of the connector and the line to the measuring element. This natural capacitance can be ignored when a charge amplifier is used. When an electrometer amplifier1 is used, on the other hand, not only the natural capacitance of the pressure transducer but also the cable capacitance and the input capacitance of the amplifier itself have to be taken into account.
Electrometer amplifier: in an electrometer amplifier, the voltage that occurs in the transducer as a result of the charge transfer is measured direct. The total capacitance in the transducer circuit is decisive for the output voltage. An electrometer system is therefore influenced by the cable length between the transducer and the amplifier. Because of its greater universality, however, the charge amplifier has become standard equipment in laboratory applications. But with its simplicity the electrometer amplifier has the advantage that it fits in the smallest spaces and is therefore integrated, for example, in many piezoelectric accelerometers.
+ Chapter 2.1.4
Temporary change in sensitivity when the operating temperature changes within the specified range. The change in sensitivity in piezoelectric pressure transducers is usually described by the temperature coefficient of the sensitivity which indicates
3-7
the actual change in sensitivity as a percentage of the nominal sensitivity per C within a specific temperature range. With small temperature changes, e.g. when water-cooled pressure transducers are used, the change in sensitivity is negligible or allowed for by the mean temperature coefficient. Otherwise the effect of temperature can be allowed by calibrating the pressure transducer at operating temperature, i.e. at the mean measuring element temperature that occurs during operation.
O Temperature drift
By temperature drift we mean the "pressure indicating" that is caused solely by the temperature changes at the pressure transducer and mounting position.
+ Chapter 4
Temperature drifts represent critical measurement errors in many measurements. In addition to the design of the pressure transducer, the temperature drift is mainly caused by the magnitude and sequence in which the pressure transducer is heated which also strongly depends on the installation position of the pressure transducer. In pressure indicating on IC engines, a clear distinction can be made between two temperature drift phenomena:
The maximum error pressure reading within a cycle related to a point at the start of the heating phase caused by the cyclic heating of the pressure transducer. This problem is more severe at low speeds. In other words, this is the errored pressure reading that occurs due to cyclic heating of the pressure transducer within a cycle. To illustrate the cyclic temperature drift, Figure 3-5 shows the result of an FEM simulation of an uncooled miniature pressure transducer. The temperature distribution and deformation of the transducer is resulting from the cyclic heat flow load is illustrated for three different points in the cycle
1
Electrometer amplifiers are virtually no longer used nowadays for measurements with piezoelectric pressure transducers on IC engines.
3-8
Engine Indicating
(25 CA before ignition TDC as well as 25 CA and 180 CA after ITDC). Pronounced deformations in the vicinity of the pressure transducer diaphragm can clearly be seen at the 25 CA after ITDC point. The loads on the measuring element due to the deformation finally result in the cyclic temperature drift shown at the bottom of the figure. [4]
Ignition TDC
Gasexchange TDC
Figure 3-5: Temperature distribution and deformation of a pressure transducer and curve of the cyclic temperature drift with cyclic heating at the front face (result of an FEM simulation)
Since in many cases the cyclic temperature drift acts over a large crank angle range, the influence on quantities that are integrated over a cycle (e.g. the indicated mean effective pressure (IMEP)) is considerable. Figure 3-6 shows the effect of a characteristic cyclic temperature drift curve on the determination of the indicated mean effective pressure and the energy
3-9
balance. By contrast, the effect of a pressure-proportional error of the same magnitude, as caused by a change in sensitivity, is much smaller.
Zylinderdruck [bar] Cylinder pressure [bar] 60 50 40 30 20 10 0 -90 -60 -30 0 ZOT 30 60
[%] 80 60 40 20 0 Abweichung im indizierten Mitteldruck Deviations in indicated mean effective pressure Deviations in the energy balance Abweichung in der Energiebilanz
ITDC
-30 0 30 60 90 120 150 180 210 BDC Ignition TDC ZOT UT Crank Angle [ CA] Kurbelwinkel [KW]
240
270
Figure 3-6: Deviations in indicated mean effective pressure and in the energy balance due to an error that is proportional to the pressure and due to cyclic temperature drift
Characteristic values to describe the cyclic temperature drift are determined firstly by unpressurised, cyclic heating of the transducer in a special tester and secondly in real engine operation by comparative measurement with a reference transducer.
3-10
Engine Indicating
2000 C, which means that heat flows of more than 100 W/cm2 can be produced. The pressure transducer is inserted in a solid, cooled steel plate, flush with the plate surface.
Angle Encoder Winkelaufnehmer
Power Supply Stromversorgung Speed (n) Drehzahl (n) I U Chopper Wheel Blendenrad Graphite radiant heater Graphitheizflche N2 2Atmosphere N - Atmosphre Water cooled wassergekhlt
Transducer Aufnehmer
Transducer
Figure 3-7: Tester for determining the cyclic temperature drift (diagram)
3-11
q
. qm . qu
30
150
180
The maximum pressure deviation of the pressure transducer that occurs in a cycle (in relation to the value of the measurement signal immediately before the heating phase) at a specific frequency of the chopper wheel and at a specific radiant heating is used as the characteristic value for the cyclic temperature drift.
3-12
Engine Indicating
This denotes the slow drift of the pressure signal after a load change, i.e. a change in the heating over a series of cycles. The load change drift manifests itself as a relatively slow pressure level shift, which is caused by a temperature change in the entire pressure transducer. This shift in level will only stop when the mean temperature in the pressure transducer no longer changes. The characteristic value for the load change drift is determined in real engine operation, by first running the engine at a specific load point and then changing to motored mode by shutting off the fuel supply thus producing a quick change in the mean heating effect on the pressure transducer (by a sudden load change), see Figure 3-9.
[bar] 50
Cylinder pressure
Zylinderdruck
40 30 20 10 0 0 2 4 6 8 10 12 14 16 18 20
Time [sec] Zeit
[bar] Niveauverschiebung
Level shift
Connecting line of one point each per cycle at same Crank Angle position in the low pressure range Permanent Zero-line Deviation bleibende Abweichung des Druckniveaus
The load change drift is called long-term drift or long- and medium-term drift in older publications.
3-13
The following characteristic values may be derived from the measurement signal thus acquired as shown in the bottom half of Figure 3-9:
O Maximum Zero-line Gradient dp/dt [mbar/ms]
Describes the change in the pressure level per time unit caused by the heat flow, i.e. the maximum drift gradient after the load change.. The Zero-line Gradient causes a clear incline in the pressure curve of the single cycle which is noticeable in the evaluation (IMEP, rate of heat release, etc.) just like other distortions of the pressure curve (e.g. cyclic drift, electrical interference, etc.).
O Permanent Zero-line Deviation [bar]
Zero point deviation 20 s after the change in heat flow. In this range, the load change drift has virtually no gradient any more the individual cycles are thus only shifted in level. Since zero-line determination is in any case necessary in piezoelectric measurements, this deviation has no effect. [3]
3-14
Engine Indicating
Pressure transducer output signal due to accelerations affecting the transducer. The acceleration sensitivity denotes the apparent pressure change that appears to take place at an acceleration of 1 g. The acceleration sensitivity of water-cooled pressure transducers is also influenced by the mass of the cooling water in the pressure transducer and feed hoses and is usually significantly higher than in non-cooled mode. For pressure measurements at measuring positions with high acceleration load, such as in intake or exhaust lines or in racing engines at high speed, pressure transducers with low acceleration sensitivity should be used. The extent of the influence of acceleration also depends to a large extent on the installation site, on the direction of the accelerations that occur in relation to the pressure transducer axis, and on the engine speed. Pressure measurements on revving racing engines often reflect a strong influence of structure-borne noise over the entire cycle. Figure 3-10 shows an example of the influence of acceleration. The highfrequency oscillations superimposed on the pressure signal are caused in this specific measurement arrangement by the impact of the intake and outlet valves on the valve seat and transmitted by structure-borne noise.
+ AVL Product
Zylinderdruck [bar] Cylinder pressure [bar] 60 50 40 30 20 10 0 Kurbelwinkel [KW] Crank Angle [CA]
Exhaust valve closes Inlet valve schliet Einlassventil closes
Auslassventil schliet
3-15
Deformation stresses at the measuring position result in load on the pressure transducer (and measuring element), which can produce errors in the pressure signal. The decisive thing for deformation sensitivity, apart from the design, is also the installation principle used for the pressure transducer. Plugin type pressure transducers are usually less sensitive to deformation than threaded types. [2]
Depending on the fuel used, various combustion products form in the engine which can result in corrosive damage to pressure transducers. Thanks to the use of corrosion-resistant materials and special coatings, such problems occur with todays state-of-the-art pressure transducers under very unfavourable conditions only (e.g. when the fuel used has a very high sulphur content). Deposits build up on the combustion chamber walls of both petrol and diesel engines. Combustion residues (soot particulate etc.) tend to form deposits on cooler surfaces in particular. Sooting occurs to a varying extent on the transducer diaphragm depending on the operating conditions and type of pressure transducer. The diaphragm becomes particularly rapidly sooted in measurements in the exhaust system using cooled pressure transducers. These deposits can have negative effects on the measurement result depending on the type of pressure transducer used. In particular when pressure transducers with heat shield are in operation for longer periods, the gap between the heat shield and diaphragm can be filled up with combustion residues, which changes the rigidity in the diaphragm area and thus the sensitivity. In extreme cases an IMEP error of 10% or more can occur. Information about the sensitivity of pressure transducers to sooting can be gained from the characteristic value: IMEP stability.
Deposits
/ Source of errors
3-16
Engine Indicating
Percentage of change in the indicated mean effective pressure (IMEP) over a defined runtime. IMEP stability is the percentage of the change in the indicated mean effective pressure (IMEP) over a defined runtime in relation to values determined with a reference pressure transducer. The engine is operated at a constant speed and load and the IMEP values derived from the pressure transducer being tested and a simultaneously operated reference transducer are then compared to determine the IMEP stability. The reference transducer is cleaned and calibrated at regular intervals to verify the continuity of the peripheral conditions.
3-17
Positive or negative sign of the output voltage with reference to the input charge
+ Chapter 2.2.1
Charge amplifiers have an inverting action, i.e. a negative input charge produces a positive output voltage.
O Sensitivity [mV/pC]
Ratio of the change in the output signal (voltage) to the associated change in the input quantity (i.e. charge). Especially when the output signal is to be digitized a sensitivity range should be selected that allows if possible the full input range of the A/D converter to be used.
+ Chapter 2.2.1
Different sensitivity ranges can be implemented in most charge amplifiers by activating different capacitance values for the negative feedback capacitor (i.e. RANGE setting). There are usually 4 measurement ranges (10, 100, 500 and 1000 bar). Charge amplifiers are usually designed in such a way that when the sensitivity of the pressure transducer used is set at the amplifier in pC/bar, a pressure change corresponding to the chosen measurement range (RANGE) produces a 10 V change in the output voltage. That means that the output voltage of the charge amplifier can be directly assigned to the pressure to be measured without separate calibration of the measurement system. The resulting error, however, can be up to one per cent which is why this method cannot be used for precision measurements.
O Sensitivity error [%]
/ Source of errors
Deviation of the actual transfer factor from the measurement value set at the charge amplifier in % of the measurement value.
+ Chapter 6
This error can be avoided by calibrating the entire measurement system using a dead weight tester.
3-18
Engine Indicating
Deviation from the ideal straight charge-voltage characteristic in relation to the maximum output voltage The linearity error of charge amplifiers is minimal (in the order of 0.01%) and therefore usually negligible.
O Lower cut-off frequency [Hz]
3
+ Chapter 2.2.2
-3 dB cut-off frequency of the charge amplifier in SHORT mode. The lower cut-off frequency essentially depends on the time constant of the amplifier. It is determined by the value of the negative feedback capacitor and the resistor connected in parallel to it. The lower cut-off frequency (fl) for -3 dB drop is calculated in accordance with Equation 3-2.
fl =
1 2 R F C F
(3-2)
RF ......... Resistance of negative feedback resistor CF ......... Capacitance of negative feedback capacitor The longest time constant and therefore the lowest possible lower cut-off frequency is given when the parallel resistance consists only of the insulation resistance of the negative feedback capacitor (LONG mode).
O Upper cut-off frequency [kHz]
+ Chapter 2.2.3
The upper frequency at which the amplitude is decreased by 3 dB for a sinusoidal signal. The upper cut-off frequency of modern charge amplifiers is in the order of about 100 kHz. Although higher values can be achieved, they are not necessary due to the limitation set by the usual values for the natural or resonance frequency of piezoelectric pressure transducers. The upper cut-off frequency can be limited by a plug-in low pass filter to defined, lower values.
3-19
Interference signal that occurs at the output without an input signal. The ripple and noise of the charge amplifier superimpose on the wanted signal and should be as small as possible. Values for ripple and noise are specified either as a root-mean-square value [mV RMS] or as a peak-to-peak value [mVpp].
3-20
Engine Indicating
Resistance between the inner conductor and the shield of the input circuit (cable) As for the pressure transducer and amplifier input, very high insulation values are required for the measurement cables used in the input circuit (> 1013 ), see Chapter 2.2.2.
O Capacitance [F]
Capacitance between the inner conductor and the shield of the input circuit (transducer including input cable) The capacitance affects the upper cut-off frequency of the measurement system (see Chapter 2.3). The influence of the pressure transducer capacitance is nearly always negligible and the influence of cables that are less than 15 m long is also insignificant.
O Noise charge [pC]
The noise charge in the cable caused by movement For the cables directly connected to the transducer and thus being subject to substantial movement special low noise versions must be chosen (values in accordance with MIL C17: < 2pC).
O Screening
Protective sleeve around the signal lead Screening is used to prevent electromagnetic interference (the braided screen normally used in standard coaxial cables is usually sufficient).
3-21
3-22
Engine Indicating
very small, no measurement error, resistance to all external influences and very long lifetime.
Range of transducers available
As shown in Figure 4-1: Interrelation between measurement task, pressure transducer and installation , the pressure transducers available are basically distinguished by the type of cooling, the design, the installation possibilities and of course, their technical measurement characteristics. The decisive thing for users is to select a pressure transducer which meets the requirements for the relevant measurement task in terms of accuracy, stability, costs, etc. An important criterion in pressure indicating is the correct installation of the transducer on the test engine (defined by the type of installation, design and location of the measuring position) because it defines the operating conditions during the measurement (heat flow and temperature load, accelerations, etc.) and any effects on the measurement object itself (e.g. change in combustion chamber volume, change relating to the cooling situation, etc.). Since different transducers also permit different installations, the selection of a pressure transducer is in fact a complex weighing up of the influencing factors shown in Figure 4-1. On the whole, the aim when selecting or defining a pressure transducer and its installation is to find the best possible compromise to meet the measurement requirements.
Measurement task
Installation
4-1
Measurement task
Test engine Operational conditions Requirements regarding Accuracy Type of evaluation Stability/meas. duration Possibility and cost of installation
Pressure transducer
Cooling Fluid cooling Heat conduction Transducer design Plug-in sensor Scew-in sensor Probe Adaptation/component integratability
Installation
With mounting bore Position Design Access Glow plug /spark plug adaptors Design
Measurement properties Measurement range Sensitivity Linearity Natural frequency Lifetime Cyclic Temperature drift Stability ...
Figure 4-1: Interrelation between measurement task, pressure transducer and installation
4-2
Engine Indicating
the anticipated pressure range, the temperature and heat flow load, the expected accelerations forces and any chemical loads.
The test engine also determines the possibilities for the installation of the pressure transducer. Engine manufacturers rarely allow for the mounting situation of pressure transducers in the design of cylinder heads because they are usually only used during the development phase and ought not to affect the optimum shape of the series product. That is why the compact design of modern engines often makes compromise decisions regarding the site of the measuring position and type of installation necessary. Because the installation position has a major influence on the quality of the measurement, the user should pay due regard to this fact (see also Chapter 4.2.).
4-3
Pressure curve: pressure curve means that the pressure is measured over a time base or, as is customary in pressure indicating, over the corresponding crank angle position. That allows correct correlation of the instantaneous pressure values. The accuracy of the pressure curve measured in this way over the crank angle depends, of course, on the two measurement parameters, pressure and crank angle position.
Indicated mean effective pressure: the indicated mean effective pressure (IMEP) is determined pressure from the integral of the volume change work done the relevant pressure multiplied by the change in the work volume in relation to the swept volume. In addition to the influence that the accuracy of the determination of the TDC position has, it should also be noted that relatively small errors in the pressure curve can result in large errors in the indicated mean effective pressure (e.g. 0.1% error in the pressure results in an error in the IMEP of approx. 1% - depending on the engine load state). The mean effective pressure (MEP) has to be determined first before the friction mean effective pressure (FMEP) can be determined. Determining the FMEP to an accuracy of 10% requires not only the accurate determination of the mean effective pressure but also the determination of the indicated mean effective pressure depending on the load state to an accuracy of up to 12% because the proportion of the frictional power is only a fraction of the indicated power.
4-4
Engine Indicating
Task area
Direct (TDC determination) (TDC determination) TDC determination, mean effective pressure MEP TDC determination, p-intake pipe, p-exhaust TDC determination, wall heat, leakage, fuel and air volume, ... Indirect
Friction analysis
Measurement task Combustion chamber pressureevaluation Peak pressure pmax Maximum, minimum, amplitude (cycle) Pressure gradients dp/d derivation Misfire detection Qualitative curve before and after TDC Knock detection Frequency amplitude of high-frequency oscillations Friction mean IMEP effective pressure FMEP Charge mass, Pressure curve, residual gas, gas IMEP-gas exchange exchange work, ... Combustion chamber pressure, start of combustion, ignition delay, end of combustion, centre of gravity Energy conversion points Internal work over crank angle
Combustion analysis
4-5
The effects of the pressure transducer properties and the influences at the measuring point on the quality of the measurement result vary depending on the evaluation criterion, see Chapter 4.3.
4.1.2.3 Stability
The term stability is taken to mean quite generally the ability of a transducer or a measurement system to maintain its metrological properties over a relatively long period of time. Measurement tasks that place high demands on the stability are, for example, long-term monitoring and control of the work process based on the pressure curve or the use of pressure indicating as part of automatic engine optimisation. Where high demands are made on the stability of the measurement signal, cooled transducers should preferably be used and the transducers should only be used in the lower load range. Unfavourable installation positions should also be avoided. The characteristic value of the IMEP stability gives an important indication of the stability of the pressure transducer behaviour, especially its response to the effect of deposits on the diaphragm of the transducer, see Chapter 3. In the case of piezoelectric pressure measurement systems in particular, stability is also determined by the properties of the amplifier and measurement cabling. In addition to ensuring that the fewest possible changes occur in the metrological properties during very long measurements, the operational reliability in particular (e.g. certainty that the cooling system will not fail in cooled sensors) must be guaranteed. Here uncooled pressure transducers have advantages if they are installed in a correspondingly cool position.
4-6
Engine Indicating
Intervention in test engine Installation time and effort substantial Costs high Possible to select yes measuring position Accuracy high
the very pressure is measured that is decisive for the measurement task, errors due to the installation are kept to a minimum (e.g. pipe oscillations, etc.), the permissible operating temperature and heat flow load of the pressure transducer are not exceeded, the temperature fluctuations in the pressure transducer are kept as low as possible and the engine behaviour remains unaffected.
4-7
Although by comparison an installation using a glow plug or spark plug adaptor involves lower costs, the site of the measuring position cannot then be chosen freely and the measuring accuracy is usually lower. This is mainly due to the fact that the measuring position is often located in a highly thermally loaded environment so that the usual quartz pressure transducers can only be installed at a significant clearance from the combustion chamber (with the associated problems of pipe oscillations, overheating of the measuring elements, etc.). Significant improvements can only be achieved here with state-of-the-art piezo-materials (e.g. Gallium Orthophosphate).
The ideal measuring position is a place where the local pressure is representative for the measurement task and where the interference influences are minimal. Installation positions above the squish gap, above the impact site of the injection spray and in highly thermally loaded positions should be avoided if possible. Cool installation positions (for example, near the intake valve etc.) are preferable. Since in practice it is often impossible to fully achieve the ideal measuring position, resulting influences of unfavourable measuring position arrangements usually have to be taken into account.
4-8
Engine Indicating
are substantial differences in pressure in the squish gap, which can result in errored information when a pressure measurement is evaluated. Generally speaking, the following can be said about the installation of the pressure transducer in the squish gap:
Gas oscillations The strength of the squish gap flow varies in terms of time and space in particular if the position of the piston bowl is eccentric and if the crosssection increases in the area of the valve reliefs. The gas in the combustion chamber recess and the gas in the squish gap can manifest a coupled gas oscillation under excitation (e.g. start of combustion). Depending on the site of the measuring position therefore, the pressure transducer can be subject to gas oscillations of differing frequencies and amplitudes which can then significantly develop if the combustion has a high pressure rise speed.
Pressure [bar] Druck [bar]
65
Piston Kolbenbowl mulde Piston Kolbenrand edge
60
55
50
20
Figure 4-2: Influence on the measured pressure curve of a measuring position arrangement in the squish gap
To illustrate these influences, Figure 4-2 shows the pressure curves measured on a DI diesel engine at measurement positions above the piston bowl and piston edge. Significant gas oscillations are recognizable at the measuring position above the piston edge. Basically an arrangement whereby the pressure transducer is installed at the side with the short squish gap is advantageous in eccentric piston bowls.
4-9
Heat flow load When the pressure transducer is installed in the area of the piston bowl, a much higher heat flow load can occur due to the effect of the combustion than when the pressure transducer is installed at the piston edge, which results in higher cyclic temperature drift. If on the other hand, the pressure measurement error from the squish gap flow is acceptable, a pressure transducer can be installed at the outer edge of the cylinder head so that it remains in the shadow of the combustion radiation for longer. Installing the transducer recessed from the piston surface is advantageous in both arrangements because this can reduce thermoshock errors [4].
Marginal local pressure differences occur due to the high flow rates in the gas exchange phase and it is not the pressure that is representative of the total combustion chamber that is then measured. This can slightly distort the low pressure loop. High flow rates occur on the surface of the pressure transducer diaphragm especially in the immediate vicinity of the outlet valves resulting in an increase heat flow load (cyclic temperature drift). The cylinder head ceiling is usually hottest near the outlet valve. Figure 4-3 shows the temperature distribution in the cylinder head of a direct injection diesel engine calculated using the FE method. The temperature maximum occurs in the vicinity of the outlet valve seat. If the measuring position is selected somewhere here, the pressure transducer also reflects a high temperature, which can cause a change in sensitivity and a reduction in the pressure transducers loadability.
4-10
Engine Indicating
Figure 4-3: Temperature distribution at the cylinder head of a 2-valve DI diesel engine
4-11
Dead volume when the transducer is installed in an inclined position or recessed, Pipe oscillations when the transducer is installed recessed, Interference to the gas flow, Fuel deposits in the combustion chamber, Creation/machining of the measuring position, or Cool/hot positions due to cooled/uncooled transducers.
There are various types of transducers and adaptors that can be used to keep these influences to a minimum.
The ideal design
In general, the pressure transducer diaphragm should follow as far as possible the contour of the cylinder head ceiling (flush or approx. 0.5 mm recessed). The longitudinal axis of the pressure transducer should if possible be at right-angles to the cylinder head ceiling.
Flow recess
Usually however, it is only possible to install the pressure transducer in an inclined position due to the design of the cylinder head. A very inclined position is associated with the following negative effects due to the flow recess it generates:
a slight increase in the combustion chamber volume interference to the flow conditions at the installation site danger of fuel collecting (influence on emissions)
Indicating channel
4-12
Engine Indicating
When used in conjunction with a spark plug or glow plug adaptor, it is often necessary to recess the pressure transducer to keep the temperature and heat flow load at the transducer as low as possible. Figure 4-4 shows the heat flow load (top) and the cyclic temperature drift (bottom) at the piston bowl and piston edge measuring positions for two different installation depths.
Ignition TDC
Installation position Bowl-Flush Bowl 35 mm Edge flash Edge 35 mm
Heat Flux
Ignition TDC
Differential pressure
Installation Depth
Figure 4-4: Heat flow load and cyclic temperature drift as a function of installation position and depth
4-13
The indicating channel resulting from recessed mounting can, however, have the following negative effects on the measurement result:
Change in engine behaviour The increase in the dead volume produces slight changes in the compression ratio, which can affect the engine behaviour. Fuel can also collect in these areas, which has a negative effect on the emissions (HC in particular).
Pipe oscillations The indicating channel represents an acoustic resonator, which is excited by changes in pressure and produces oscillations. This effect is illustrated in Figure 4-5 where the measured pressure curves relate to indicating channels of different lengths. Five pressure curves from single cycle measurements are shown for each indicating channel length. They have been shifted in level to provide a clearer overview.
-20
-20
-20
Figure 4-5: Influence of the length of the indicating channel on the measured pressure curve
The frequency of this interference depends not only on the length of the indicating channel but also on the gas state, which makes the use of frequency filters for eliminating pipe oscillations difficult. Furthermore it is not easy to distinguish pipe oscillations from combustion chamber oscillations.
4-14
Engine Indicating
As shown in Figure 4-6, for design reasons there is usually an additional volume (V) in front of the pressure transducer in an installation with an indicating channel. This arrangement can be regarded as a simple Helmholtz resonator. In simplified terms, the following equation can be specified for the frequency of the pipe oscillation (f) [kHz]:
f=
R T cV r l V
RT 2
r2 V l
(4-1)
Isentropic exponent Gas constant [J/kg K] Gas temperature [K] Specific thermal capacity at constant volume [J/kg K] Radius of the indicating channel [m] Length of the oscillating gas column (in indicating channel) [m] Volume [m3]
Combustion Chamber
Figure 4-7 illustrates the relation to the length of the indicating channel and to the gas temperature (500, 1000 and 2000 K) for estimating the level of the frequency of pipe oscillations. The displayed values relate to an indicating channel radius (r) of 1.5 mm and a volume (V) of approx.11.8 mm3, which corresponds to the volume for a miniature pressure transducer installed front-sealed (mounting thread M5x0.5).
4-15
120 100
Frequency [kHz]
2000 K
1000 K
20
500 K
0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Delays in the pressure signal This effect occurs because the pressure wave first has to propagate through the indicating channel before it reaches the pressure transducer. However, it is only relevant in extremely long indicating channels (e.g. ships engines with indicating cock).
Increased temperature load In an unfavourable indicating channel arrangement, an increased heat flow load on the pressure transducer can occur due to high flow rates at the diaphragm.
4-16
Engine Indicating
when transversing oil and water jackets, the oil and coolant flow is not interfered with (i.e. the cooling function is not affected), no component is diminished in strength and the leakproofness of the adapted engine is guaranteed.
A detailed study of the cylinder head design is indispensable and technical manufacturing criteria should also be taken into account. See Chapter 5 for instructions on creating mounting bores and examples of installations.
4-17
+ AVL Product
Pressure transducers can be evaluated on the basis of their metrological properties. Moreover it is useful to make a distinction between typical categories of pressure transducers with specific characteristics, see Table 4-3. A sensible preselection can therefore be made if the characteristics specific to each category are taken into account.
Table 4-3: Pressure transducers for engine instrumentation
Heat conduction (uncooled) GaPO4 Screw-in M5 x 0.5
Mounting principle Type of cooling Piezo material Design
Probe 4.3
Plug-in 6.2
Plug-in 9.9
Direct (in cylinder head or components) or using an adaptor Spark plug/glow plug Requires extra space
Metrological characteristics
One group is made up of the water-cooled transducers. They include the widely used M10 and M14 pressure transducers with their screw-in design and the 9.9 mm plug-in models. The measuring elements of these transducers only reach temperatures of 20 C to 80 C during operation. The other group comprises the uncooled pressure transducers, which are much smaller so that they can fulfil measurement tasks even in the tightest of spaces. This group includes in particular pressure transducers with M5 thread design, 6.2 mm plug-in models and miniature pressure probes ( 4.3 mm) which are used mainly in glow plug and spark plug adaptors. Using GaPO4 technology means that these transducers can be
4-18
Engine Indicating
used at temperatures up to 400 C at the measuring element. Tests have even been successfully carried out at up to 500 C. Cooled pressure transducers are normally larger than uncooled ones and usually have a higher sensitivity, i.e. a better signal-to-noise ratio. Due to the very restricted space for mounting sensors in modern multiple valve engines, however, uncooled pressure transducers with good thermodynamic properties are being used more and more. Using GaPO4, which has about twice the sensitivity of quartz has now made it possible even with small uncooled pressure transducers to achieve similarly high sensitivities as previously achieved in larger transducers, and thus adequate signal-to-noise ratios.
ratio: Signal-to-noise ratio the lower the sensitivity is, the smaller the signal-to-noise ratio. In extreme cases, the wanted signal can be superimposed on by the same magnitude of interference so that the pressure curve cannot be evaluated. Generally speaking, it can be said that transducers with a sensitivity >10 pC/bar are unproblematic in measurement operations.
Uncooled pressure transducers usually have higher natural frequencies due to their design and size and are therefore more suitable than cooled transducers for certain measurement tasks (e.g. knock detection, measurements at high speeds etc.).
frequency: Natural frequency: the frequency (frequency spectrum) of the measuring signal, that has to be acquired with great accuracy, should be less than 20 % of the natural frequency of the pressure transducer used. The natural frequency of a typical pressure transducer for combustion chamber indicating is between 50 and 200 kHz depending on the model.
Uncooled transducers generally have a higher cyclic temperature drift and above all a higher load change drift than cooled transducer. Furthermore, greater changes in sensitivity can be expected due to the higher operating temperatures for uncooled pressure transducers despite the use of GaPO4 as the piezo material. Cooled pressure transducers are more stable in their behaviour in terms of load and operating duration.
4-19
Design
As mentioned above, a distinction is made between pressure transducers with plug-in and threaded design, and the special designs. Plug-in transducers have the basic advantage that the achievable measurement accuracy is largely independent of the tightening torque and of thermomechanical stresses in the cylinder head during operation. The disadvantage of plug-in transducers, however, is that they are more timeconsuming to mount and remove.
Mounting principle
Pressure transducers are mounted either directly in the test engine or by means of an adaptor. Uncooled pressure transducers with threaded design and the miniature pressure measurement probe designs have the particular advantage that they can be used in spark plug or glow plug adaptors. A detailed description of the installation principles is given in Chapter 5.
4-20
Engine Indicating
Table 4-4:
Type of evaluation (measurement task) Qualitative curve before and after TDC Integral values (energy conversion, mean Different. values (heat release, dp /d Frequency, amplitude of high-frequency oscillations. Maximum, minimum, amplitude (cycle)
Effect of Measurement range Lifetime (cycles) Sensitivity Linearity Natural frequency Acceleration sensitivity Shock resistance Temperature resistance (transducer) Change in sensitivity over temperature Cyclic temperature drift (heat flow pulse) Zero-line gradient (load/heat flow change) Zero point deviation (load change) IMEP stability (behaviour in continuous operation) Deformation Indicating channel Gas flow Key No effect
W
W W C W C W W C
W W W W W W W W W W
W W C W C W W C
W W C
W W C
C W W C
W W C
W W
Warning! Effect only avoidable through careful choice of transducer, measuring position design, handling etc. Calculable effect (e.g. 1% change in property means 1% change in pressure signal) Significant effect Substantial effect
4-21
If the decision is taken not to make any intervention in the test engine, only uncooled miniature pressure transducers or pressure measuring probes can be used which are installed by means of spark plug or glow plug adaptors depending on the type of engine (petrol or diesel engine). No or very little choice of measuring position and pressure transducer is then possible. Such an arrangement can fulfil the measurement requirements, the measurement can be carried out. If not, one conceivable approach is to reduce the requirements. If that is not possible, it should be reconsidered whether installation via a mechanical intervention in the test engine might not after all be possible which permits much better results. Otherwise, a measurement is not possible.
If the decision is in favour of an intervention in the test engine, it is sensible first of all to select a pressure transducer from one of the categories shown in Chapter 4.3. All the transducers of that category can then be considered for the detailed selection based on pressure transducer properties. The next step is to define the type of installation, the measurement site, the design of the measuring position, etc. which very considerably determine the operating conditions and thus the effects on the pressure transducer.
4-22
Engine Indicating
The information about the extent of the effects and the metrological properties of the selected transducer should be used to check whether the requirements can be fulfilled and, if so, the measurement can be started. If the requirements cannot be met, other optimisation loops have to be implemented for the selection of pressure transducers and their installation until a suitable combination is found. If that is not possible, the measurement requirements should be reconsidered. Otherwise, accurate measurements are just not possible.
4-23
Measurement task
nein no
yes ja
Operation conditions (kind of Install., measuring position, shaping of the measuring position ...)
yes ja
yes ja
nein no Vernderung der Change of Anforderungen requirements mglich? possible? nein no Mglichkeit of Possibility mechanischer mechanical Intervention? Eingriff? nein no No Measurement possible
nein no Andere Other combination Kombination of Transducer Ein Aufnehmer /install.? bau? nein no Vernderung der Change of Anforderungen requirements mglich? possible? nein no No Measurement possible
yes ja
ja yes
yes ja
yes ja
Performing of measuremnt
4-24
Engine Indicating
+ Chapter 4.2.2.2
G M12D AG 0 1
5-1
Long, thin glow plugs are best catered for specially developed pressure measuring probes to achieve a position close to the combustion chamber and thus an undistorted measurement signal (see Figure 5-2). If the diameter of the bore is so small (< 4.3 mm) that the pressure measuring probe has to be recessed behind the sealing surface, specially designed damping volumes in the adaptor ensure that possible signal distortion due to pipe oscillations in the gas channel are significantly reduced.
Temperatures at the pressure transducer
The highest measurement quality can only be achieved with optimally matched adaptors. The gap between the glow plug bore and the adaptor is of great significance in terms of the thermal load on the transducer. The larger the gap, the greater the temperature increase in the area of the transducer and the greater the effect on the measurement signal. That is why glow plug adaptors are manufactured to customer specifications to the exact dimensions of the glow plug bore. Even with adaptors optimized in this way, temperatures of 400 C or more can still occur at the transducer, which makes it necessary to use suitable piezo materials (Gallium Orthophosphate ).
Figure 5-2: Glow plug adaptor with pressure measuring probe
Cold start
Glow plugs improve cold start characteristics in diesel engines. Problems can arise during cold starts when a glow plug adaptor is installed instead of the original glow plug. The start characteristics are hardly affected, however, at normal ambient temperatures. [15]
5-2
Engine Indicating
adaptors fulfil a dual function. On the one hand, like standard spark plugs they ignite the mixture in the cylinder, and on the other, they hold the pressure transducer. The requirement to bring the diaphragm of the transducer (Pressure Measuring Probe) as close as possible to the combustion chamber necessitates a very slim insulator. The assembly of the adaptor / transducer unit and the subsequent mounting to the engine should be carried out by engineers familiar with handling / mounting sensitive pressure transducers
GU12P GM12D
5-3
Figure 5-3, left). The combustion chamber is connected to the pressure transducer by a relatively long connection channel.
Advantage: low cyclic temperature drift due to low heat flow load Disadvantage: pipe oscillations
Advantage: minimum pipe oscillations even at high engine speeds Disadvantage: cyclic temperature drift is greater than with recessed installation (corresponding to the usual pressure transducer installation close to the combustion chamber)
When using spark plug adaptors, ensure that the suitable Heat range is selected for the engine. That is why spark plug adaptors are available with different heat values.
Heat range: the spark plug should be so hot during operation that deposits on parts that protrude into the combustion chamber burn without self-ignition occurring (i.e. selfcleaning). The heat range is a measure of the heat conductivity of the spark plug. We make a distinction between so-called cold and hot spark plugs. Cold plugs are used primarily for high-performance engines and for ranges close to full load whereas hot spark plugs are used mainly in engines that are predominantly operated in partial load state. Different heat values can be achieved by suitable selection of design and materials.
Furthermore, the Spark position (particularly in direct-injection petrol engines in stratified partial load operation) and the electrode gap of the spark plug adaptor must be the same as the values for the original spark plug.
Spark position: spark position is taken to mean the position of the electrode in relation to the plug face.
Spark plug indicating is used especially for knock tests, engine map optimisation and for monitoring mode (e.g. peak pressure monitoring).
5-4
Engine Indicating
+ Chapter 4
5
The ideal installation position
+ Chapter 4.2.2.2
5-5
7 .5 min
1 4 min
G M12D 1 . 5 Sta hl 4 G G , Al
Q C 33D Q H33D
M 5 x0 . 5
0 . 5min
M 1 0 x1
5-6
Engine Indicating
1 0 .5 min
Figure 5-5 shows an installation with adaptor sleeve for a small uncooled pressure transducer and Figure 5-6 for a water-cooled one.
1 8 min
5
AH 0 1 2 1 0 ma x 11.5 Stahl . 5 steel 4 G G , Al G M12D 7 . 5 min M 7 x0 . 7 5 20
Figure 5-5: Example of the installation of an uncooled pressure transducer with adaptor sleeve
12
5-7
2 6 min
Q C 33C Q H3 3C
0 .5 min
7 min
M 1 4 x1 . 2 5
If O-rings are used, the dimensions, tolerances and surface quality specified by the O-ring manufacturer must be observed when preparing the measuring position in order to ensure the necessary leakproofness. The function of the Oring seal is to compensate any possible inaccuracies that can occur when machining the cylinder head bore which is usually inclined. An O-ring also compensates changes in length due to the thermal expansion of the cylinder head and adaptor sleeve. As an alternative, a bond can be created using an elastic bonding agent (e.g. LOCTITE 290), but in that case, the gap between the cylinder head and the adaptor sleeve should be smaller than 0.05 mm.
5-8
20
151
Engine Indicating
Once the installation is complete and the adaptor sleeve is sealed, the part that protrudes from the cylinder head into the combustion chamber should be machined or cut off to restore the contour and surface quality of the cylinder head ceiling. Before a cylinder head with an adaptor sleeve fitted can be used for measurements, the sleeve installation must always be checked for leaks. This is done in a water bath. The cooling water and/or oil channel of the cylinder head must be cleared out with compressed air before the sleeve is installed. Leakage problems can still arise later during measurements, however, which in extreme cases can cause damage to the engine due to Water slap.
Water slap: water gets into the combustion chamber due to leaks in the adaptor sleeve. If the volume of water entering the combustion chamber is greater than the compression volume, the forces that then occur can kink the conrod and thus irreparably damage the engine.
/ Source of errors
1
Water slap can also occur with a direct-installed water-cooled transducer if the transducers cooling water gets into the combustion chamber as a result of a faulty transducer.
Sealing surfaces have not been machined properly Damage to the O-rings during installation or removal of the sleeves Sleeve has worked loose due to improper installation or removal of the transducer Different thermal expansion coefficients between cylinder head and adaptor sleeve
+ AVL Product
5-9
cylinder head is the same as in the example, i.e. at right-angles to the bore axis, the bore can be drilled centred at the defined measuring position.
Figure 5-7: Pressure transducer and bore ready for transducer installation
The bore is then finished in one go using a stepped drill (Figure 5-8 left). Special attention must be paid to the exit situation of the drill. If the measuring position is in a curvature or if the angle between the exit surface and the bore axis deviates significantly from 90 , material must be clamped to the combustion chamber end to stop the drill from running off centre as it exits. Figure 5-8 centre shows the next process, i.e. thread tapping, with a drilling socket being used so that the drill can be accurately guided. The bore has to be deburred and cleaned of all chips and shavings by means of the mounting tool before the transducer is installed as shown on the right of Figure 5-8.
5-10
Engine Indicating
5-11
The work stages necessary for the installation are shown in Figure 5-10 to Figure 5-14.
5-12
Engine Indicating
5
Arbeitsschritt 1 Workstage 1 Arbeitsschritt 2 Workstage 2
Arbeitsschritt 3 Workstage
Figure 5-10: Work stages for single sleeve and inclined bore axis
Workstage Arbeitsschritt 4
Because the surfaces of the material to be drilled are not at right-angles to the bore axis an initial centering must be machined with a single-lip drill, see Work Stage 1. If a single-lip drill is not available, a starter cut has to be made on the surface at right-angles to the bore axis to prevent the stepped drill from running off centre. Since the measuring position also lies in a curved surface, a piece of material shaped to the contour of the cylinder head has to be clamped to the head from the combustion chamber side before Work Stage 2 is carried out so that the stepped drill does not break or run off centre when it exits. In Work Stage 3 the thread is tapped for securing the adaptor sleeve. A drill socket is used to ensure that the screw tap is accurately guided. It is advisable to leave the counter piece clamped to the cylinder head for the tapping work as well because otherwise the tool can become damaged. Work Stage 4 shows
5-13
how a single-lip drill is then used again to re-drill the sealing surfaces. Afterwards the bore has to be deburred and cleaned of all chips and shavings. The quality of the O-ring sealing surface must also be checked.
Workstage 5 Arbeitsschritt 5
Figure 5-11: Work stages for installing the adaptor sleeve
Workstage 6 Arbeitsschritt 6
Work Stages 5 and 6 describe the installation of the adaptor sleeve. It consists of the adaptor itself in which the pressure transducer is later installed, and a separate sealing sleeve, which can be slipped over the adaptor. The next thing is to decide the correct position of the sealing sleeve on the adaptor. To do that, the adaptor is temporarily installed and the sealing sleeve pushed into the correct position. The position is marked so that the adaptor and sealing sleeve can be brazed or bonded together in exactly that position after removal from the bore. Next step is to shorten the part of the sleeve, which protrudes the hexagon. Before the finished adaptor sleeve is installed, the O-ring is inserted in the groove provided for it and the bonding area carefully cleaned of all grease ready for bonding. For perfect sealing the adhesive should be a high-temperature resistant, low-viscosity one-component adhesive (e.g. LOCTITE 648) or an appropriate twocomponent adhesive (e.g. UHU plus or ARALDITE). It has to be applied evenly to the thread and sealing surface of the cylinder head bore, and to the thread of the adaptor sleeve before the sleeve is mounted in the bore. When the adhesive has hardened, the part of the adaptor protruding into the combustion chamber has to be shortened and shaped to the contour of the combustion chamber. (Work Stage 6). Figure 5-12 shows how the pressure transducer is then installed using a suitable mounting tool.
5-14
Engine Indicating
5-15
Workstage 1 Arbeitsschritt 1
Workstage 2 Arbeitsschritt 2
Workstage 3 Arbeitsschritt 3
Figure 5-13: Work Stages for multiple seals and perpendicular bore axis
The bore is then deburred and cleaned of chips and shavings. The adaptor is temporarily installed and the correct positions of the sealing sleeves are marked. After the adaptor has been removed from the bore again, the sealing sleeves are brazed or bonded to the adaptor and the O-rings are fitted into the grooves provided for them. The bonding surfaces should then be meticulously cleaned before the adhesive is applied evenly to the thread and the sealing surface of the adaptor and cylinder head bore and the adaptor sleeve is screwed into the finished bore (Work Stage 4). Work Stage 5 involves cutting off the adaptor at the combustion chamber end. The cut has to be processed to match the contour and surface quality of the cylinder head ceiling. Finally in Work Stage 6, the pressure transducer is installed using a suitable mounting tool.
5-16
Engine Indicating
Workstage 4 Arbeitsschritt 4
Workstage 5 Arbeitsschritt 5
Workstage 6 Arbeitsschritt 6
5-17
5-18
Engine Indicating
6 Calibration
6.1 General
Calibration is used to determine the relationship between output and input parameters (i.e. transmission function). Known values for the input quantity are predefined for this purpose and the corresponding output signals are recorded. Each component of the piezoelectric pressure measurement system (i.e. pressure transducer, charge amplifier and A/D converter) has a certain transfer function, see Figure 6-1. Basically it is possible to determine the transfer function of the entire measurement system from the transfer functions of the individual components.
Pressure Transducer Druckaufnehmer
Druck Pressure [bar] [bar] Ladungsverstrker Charge Amplifier Spannung Voltage [V] [V] A/D-Wandler A/D Converter steps
/ Display on
Einzelkomponenten
pC / bar
Transferfunction bertragungsfunktion of Transducer and Charge Amplifier
V / pC
steps / V
/ Source of errors
Unfortunately, this procedure has the disadvantage that the individual errors can add up to a large sum error. Furthermore, possible changes in the characteristics
Calibration
6-1
(i.e. sensitivity, linearity) of the various components are not taken into account. In practice the situation where charge amplifiers or A/D converters are calibrated separately for lack of calibration devices hardly ever arises usually the manufacturers specifications tend to be used which can change during the operating time of the devices. For measurements with high accuracy requirements therefore, it is absolutely necessary to calibrate the entire measurement system.
Multi-point-calibration
A multi-point calibration is always carried out when particularly high accuracy requirements are placed on the measurement or there is a suspicion that changes have occurred in the linearity (for example, in the pressure transducer due to overheating). The pressure transducer is subjected to a series of pressure values. The result of a multi-point calibration is the so-called characteristic from which a mean sensitivity and the linearity can be determined.
Single-point calibration
In most applications, however, a single-point calibration is sufficient because the linearity deviations of the pressure transducer and the other components of the pressure measurement system are minimal. Here the calibration is carried out at a value that is about 80 % of the maximum values (expected from the measurement).
6-2
Engine Indicating
a hydraulic cylinder with weighted plunger a device for producing pressure (e.g. hand pump, hand wheel) a 3-way changeover valve for creating the calibration jump a (heatable) holder for mounting the pressure transducer a pressure gauge for visually checking the system pressure a system of hydraulic lines for connecting the above components a set of weights for loading the plunger
The primary plunger is actuated by a hand wheel and spindle or a hand pump to create pressure. As of a certain system pressure the movable secondary plunger with the weights on it is raised because the hydraulic system is completely sealed at one end by the pressure transducer and the 3-way changeover valve. The pressure in the system is determined only by the total secondary plunger mass plus the added weight. The pressure is usually displayed on a pressure gauge to provide a visual check.
Functioning principle
Calibration
6-3
belasteter loaded Zustand condition gewichtsbelasteter secondary piston Sekundrkolben DruckaufTransducer nehmer
Heatable beheizbare housing Aufnahme 3-way 3-Wege switch-over Umschaltventil valve weight loaded
Manometer
HydraulikHydraulicsystem system
Primary Piston Primrkolben
Figure 6-2: Schematic representation of the construction of a dead weight tester design
The diaphragm of the pressure transducer is subjected either to the system pressure (Figure 6-2, loaded state) or ambient pressure (Figure 6-2, unloaded state) with the aid of a 3-way changeover valve. Each time the system is switched to ambient pressure, a little hydraulic fluid escapes into an expansion vessel (not shown in the diagram). This causes the secondary plunger to move downwards slightly longitudinally. When the transducer is then subjected again to system pressure, it is important to ensure that not too much hydraulic oil has escaped and that the secondary plunger is resting against the contact surface. If necessary, the level should be adjusted by pumping in more hydraulic oil using the hand pump or hand wheel. The secondary plunger is made to rotate during the calibration process in order to minimise the influence of friction between it and the cylinder.
6-4
Engine Indicating
pK =
F g = (M SK + M Z ) A SK A SK
plunger force secondary plunger area, secondary plunger mass, added mass (weights) mean gravitational acceleration (9.81 m/s)
(5-1)
el 3.1.2.1
Some dead weight testers have a heatable receptacle for mounting the pressure transducer so that the calibration can be carried out at the probable operating temperatures and thus temperature-based changes in sensitivity can be taken into account.
Temperature calibration
Belastung Loading
Pressure Druck
Entlastung Relief
Calibration
6-5
/ Source of errors The effect of electrical drift during calibration is shown in Figure 6-4. When the
RESET switch on the charge amplifier opens, a significant drift in the output signal can be observed which is superimposed over the entire calibration process. If during the unloading jump not difference (AB) is determined exactly but difference AC is determined by time-offset acquisition, the error caused by the electrical drift is included in the calibration result. To prevent such errors, state-of-the-art data acquisition systems allow the calibration jump to be recorded exactly from which the calibration value can then be calculated.
A
AB
RESET ffnen open B
AC
Error Fehler
Time Zeit
Belastung Loading
Entlastung Relief
/ Source of errors
Due to the leakage problems in the changeover valve, high pressure dead weight testers have an arrangement as shown in the top half of Figure 6-5 with (nonswitchable) needle valves for producing the pressure jump. The loading valve is closed before the unloading valve is opened. The pressure at the pressure transducer also changes in an undefined way due to the change in volume that occurs, see bottom half of Figure 6-5. To determine the calibration value correctly, it is imperative to ensure that the difference is used between the value displayed immediately before the loading valve closes which corresponds to the pressure defined by the load of the applied weights, and the value immediately after the unloading valve opens.
6-6
Engine Indicating
Transducer Druckaufnehmer
pK
Time Zeit
Belastung Loading
Entlastung Relief
Figure 6-5: Unloading jump in high pressure dead weight testers with loading and unloading valve
Calibration pressure
Piezoelectric pressure transducers are usually calibrated at about 80 % of the anticipated measurement pressure (except in measurements in the gas exchange system where they are calibrated at 100 % of the expected measurement pressure). In any case, the selected calibration pressure must always be in the upper half of the measurement pressure range, otherwise the measurement accuracy will be too low, particularly in the peak pressure range.
Calibration
6-7
When is it sufficient to set the gain rather than carry out calibration?
If the quality requirements for the measurement result are not high or no dead weight tester is available, the assignment of pressure to output signal can be determined by setting the sensitivity value of the pressure transducer used on the charge amplifier. In that case, a pressure jump corresponding to the RANGE setting produces a voltage of 10 V at the charge amplifier output.
6-8
Engine Indicating
7 Zero-line Detection
Due to their working principle, piezoelectric pressure transducers can only measure the changing pressure content (pMeas), i.e. only the pressure changes in the cylinder, and not the physically correct absolute pressure (p). The measured pressure curve (pMeas) therefore has to be adjusted in accordance with Equation 7-1 by the amount (pn) (zero-line shift).
p( ) = pMess ( ) + pn (7-1) The technical literature features a whole range of methods for determining the zero-line level. They differ mainly only in terms of accuracy and necessary computational work. Since a correct pressure curve forms the basis of an accurate heat release calculation, correct zero-line detection is of central importance. The chapters below deal with the most frequently applied methods.
pn = pFix
Ambient pressure
Re f 1 pMess ( ) N + 1 = Re f N / 2
+N / 2
(7-2)
Often the ambient pressure (e.g. 1 bar) serves as the reference value, which is set to the cylinder pressure at gas exchange TDC (GETDC). This approach, however, only provides adequately accurate zero-line detection in unthrottled naturally aspirated engines. In other types of engine and engine map points, this type of adjustment can cause errored results
Zero-line Detection
7-1
because the cylinder pressure at gas exchange TDC no longer corresponds to the ambient pressure.
7-2
Engine Indicating
p2Mess + pn V1 = =C p1Mess + pn V2 This then produces Equation 7-4: C p1Mess p2Mess 1 C The following values are recommended as the polytropic coefficient (n): pn = for diesel engines and for petrol engines in motored operation: n = 1.37...1.40 for petrol engines with combustion: n = 1.32...1.33
(7-3)
(7-4)
The following ranges are recommended for the two crank angle values (1) and (2):
1 = 100 CA 2 = 70 CA
This type of zero-line detection is very often used in practice because it offers good accuracy, despite of its simplicity and quickness of calculation. The main uncertainty of this method is associated with the use of a constant polytropic coefficient (n) which in fact changes over the crank angle range. The crank angle interval should therefore not be too large in order to minimise this influence. Another weakness of this method is the fact that interference noise is often superimposed on the pressure curve in this crank angle range. In some cases, the interference signal from valve impact (structure-borne noise when the inlet valve hits the valve seat at inlet closes) or the effects of structureborn noise at very high speeds (e.g. in racing engine) affect thermodynamic zeroline detection so severely that the results can be fairly wrong.
Zero-line Detection
7-3
dQ
d = 0
(7-6)
The zero-line shift has to be estimated first as initial value using one of the methods described above, before the necessary parameters can be calculated. The zero-line shift is then adjusted iteratively. This principle using the integral heat offers high accuracy but is not suitable for real-time zero-line detection due to the necessary computation times.
7-4
Engine Indicating
short term drift/thermoshock in the pressure transducer interference signals due to acceleration excitation of the pressure transducer (at valve closes, high speeds) interference signals due to electrical effects (ignition voltage, injector control)
When deciding on the method, it should therefore be borne in mind that an apparently suitable one can easily lead to errored results (Table 7-1).
Table 7-1: Assessment of zero-line detection methods
Peak pressure pmax Duration of combustion Combustion delay Position of 50% energy conversion Energy balance Additional metrological effort Accuracy Method suitable for realtime
o no
moderate
o o o o o (yes)
moderate
+ o + + o yes
good
+ o + + o no
good
+ + + + + yes
very good
yes
yes
yes
yes
no
Zero-line Detection
7-5
7-6
Engine Indicating
Q < 1000 pCRIns > 5x1012 Q > 1000 pCRIns > 1x1012
Charge (Q) is calculated from the product of the pressure transducer sensitivity in pC/bar and the pressure jump in bar.
Take care to keep oil and water away from the connector. Do not touch the connector insulator with your hand and do not blow it out with compressed air (i.e. always place the cap on the connector before cleaning the cooling water galleries with compressed air). Pressure transducers and piezo-input cables should preferably be treated as a single assembly. The cap should always be placed onto the connector at the free end of the piezo-input cable to close it off. If the piezo-input cable is unscrewed from the pressure transducer, the cap should be screwed on to the connector of the pressure transducer to close it off.
8-1
The transducers cooling water gallery should be emptied after a watercooled pressure transducer is removed from its mounting position. At relative humidity levels higher than 50 %, pressure sensors and piezoinput cables should be kept in a moisture-proof container (desiccator) together with a drying agent (e.g. blue gel).
Clean the connectors of pressure transducer and connecting cable (they must be completely clean, free of grease and dry). Use purified petrol, isopropanol or ethanol, a fine-hair brush and a non-fraying cloth to clean them. Pulling them in an ultrasonic bath for about 10 minutes improves the cleaning effect, but the solvent should only ever be used once. If necessary, the pressure transducer should be dried without the piezo-input cable at 120C (normally for a period of 8 hours, or a maximum of 72 hours). If that does not restore the high insulation resistance, we recommend returning the pressure transducer to the manufacturer for inspection and/or repair. Piezo-input cables can be dried in accordance with the manufacturers instructions.
/ Caution
Special attention should also be paid to the cooling water galleries of pressure transducers. If they become blocked by scaling, they can be cleaned by pumping a standard descaler solution through them (e.g. amino acid, ethanoic acid, formic acid) or leaving it in the galleries for a while to dissolve the scale (until the characteristic flow rate for the transducer is restored) and then rinsed out with distilled water. After rinsing, the cooling water galleries should be cleaned by centrifuging or blowing out as should also be done when a pressure transducer is removed from its mounting position.
8-2
Engine Indicating
/ Caution
/ Caution
8-3
Decrease in the high insulation resistance (clean the transducer, see also Chapter 8.1) Rupture or damage to the cooling water nipple (replace the nipple)
Slight mechanical damage to the sensor housing (machine to restore the installation dimensions)
8-4
Engine Indicating
9-1
Figure 9-1 illustrates the principle of the discretization of analogue signals. The signal amplitude is represented by the next lowest discretization level at each discretization step of the basis (i.e. crank angle) (in the AVL scheme). If we compare the coarse crank angle and amplitude resolution with the fine one, we can see how important it is to choose an adequate resolution and sampling rate. Whereas at a coarse resolution the high-frequency parts of the analogue signal are not acquired, they can be rendered well when the signal is discretized at a fine resolution.
Analog signal Analogsignal coarse digital signal grobes Digitalsignal fine digital signal feines Digitalsignal
grobes Digitalsignal coarse digital signal fine digital signal feines Digitalsignal
Figure 9-2 shows that choosing an insufficient sampling rate can in extreme cases even result in completely distorted representation of the actual analogue signal and also of the integral value (e.g. indicated mean effective pressure). When a coarse sampling rate is used, only the local minima are acquired and the
9-2
Engine Indicating
analogue signal is then incorrectly discretized as a rising curve trace. At a fine resolution, however, the analogue signal is discretized correspondingly well. Figure 9-3 shows another example of the effects of an inadequate crank angle resolution when indicating measurements are carried out on knocking combustion cycles. Whereas the high-frequency pressure oscillations are clearly shown at a sufficiently fine resolution, (fig. at the left) they are only just discernible or completely unrecognisable at a crank angle resolution that is too coarse.
100 90 80 70 60 50 40 30 20 10 0 -20 0 20 40 60 100 90 80 70 60 50 40 30 20
9
coarse angle resolution
-20 0 20 40 60
10 0
In practice, a 12 bit resolution (4096 steps) or a 16 bit resolution (65536 steps) is usually used to discretize the signal amplitude. High-frequency parts of the signal (e.g. pressure oscillations due to knocking combustion) require sampling rates of 0.1 CA for discretization of the basis.
9-3
Optical sensors Inductive sensors Other: Hall-type sensors, capacitive sensors, etc.
9.2.1.1 Optical Sensors
+ AVL Product
The measurement principle is based on light barriers. The backlighting or reflection lighting method is used depending on the configuration. Optical crank angle encoders satisfy high accuracy requirements (even with small dimensions) due to the possibility of highly accurate structuring of specially developed marker disks. Another advantage is that they are less susceptible to interference, especially when using optical fibres working in the vicinity of large electrical interference fields. The crank angle resolution is usually less than 1CA.
9-4
Engine Indicating
Inductive
Optical
Figure 9-5: Possible mounting positions for sensor head and marker disk
9-5
X1 R1 R
Marker disk Markenscheibe
Figure 9-6: Crank angle encoder with and without integrated sensor
9-6
Engine Indicating
Arm
(Glass)
Sensor head
Sensorkopf
Sensor head Sensorkopf Bearing Lagerung Marker disk (Steel) Markenscheibe (Steel)
Housing Gehuse
with integrated sensor mit Eigenlagerung without integrated sensor ohne Eigenlagerung
Figure 9-7: Examples of crank angle encoder designs with and without integrated sensor (from AVL)
Angle encoders are more or less sensitive to soiling depending on their design. Angle encoders without integrated sensor are generally more sensitive to soiling because of their open design. To prevent measurement errors with such encoder versions therefore, the background lighting method is used for scanning the slots in the marker disk. With regard to the material for the marker disk, steel is virtually the only material that can be considered for manufacturing and strength reasons (because large disk diameters are necessary for sufficient accuracy). Crank angle encoders with integrated sensor generally use the reflection method in which marks lithographically applied to a glass disk are scanned. The small glass disk with this encoder version can easily handle even the severest loads at the angle encoder mounting site.
9-7
9-8
Engine Indicating
The speed range within which the angle encoders specifications are guaranteed. Crank angle encoders can normally be used for speeds up to 20,000 rpm or more for special applications (e.g. racing engines).
O Crank angle resolution
Crank angle resolution means the smallest step width to be represented in the discretization of the crankshaft motion. High-frequency parts of the signal require a crank angle resolution 0.1CA.
O Accuracy
The accuracy is a measure of the extent to which the measurement value deviates from the reality. The achievable accuracy without taking into account errors relating to mounting or the engine itself is better than 0.05CA in dynamic mode.
O Lifetime
Describes the number of revolutions over which the specified characteristics are maintained. The lifetime is purely a comparative parameter, which can be exceeded if the operating conditions are favourable. Conversely extreme operating conditions can shorten a devices lifetime. However, a lifetime of more than 106 revolutions can be expected, even under unfavourable conditions.
O Thermal resistance
Resistance of the angle encoder to thermal loads at the mounting surfaces and in the environment without affecting its function. Crank angle encoders have to have the following thermal resistance capabilities to cope with their mounting site:
9-9
Temperature at the mounting surfaces: (determined by the sensor) Ambient temperature: (determined by the converter electronics)
O Vibration resistance
Resistance to sensor accelerations in an axial and/or radial direction without impairing the angle encoders function. Typical values are 250 g, with peaks of 1000 g.
O Electromagnetic compatibility (EMC)
Defines the interference environment in which a device can still be operated without impairment to its functions. Crank angle encoders usually have to satisfy the interference immunity requirements specified in Standard EN1326
O Contamination resistance
Resistance to functional impairment due to contamination from external components. A device must be resistant to all standard operating materials (i.e. fuels, coolants and lubricants) and cleaning agents.
O Leakproofness
Resistance to media penetrating the device and impairing its function under the conditions stated in the Standard. The relevant Standard is Degree of Protection IP54.
9-10
Engine Indicating
XM3
XH3
Actual position
(Anschluss)
Angle encoder with integral bearing X = XH1H2H3 M2 Winkelaufnehmer mit Eigenlagerung: X=X+X+X +XM3 M1+X Angle encoder without Winkelaufnehmer ohneintegral bearing X=X+X M2 Eigenlagerung: X = XM1+X H1H2
9-11
Xi
Engine-based error
Engine-based errors occur due to geometric and positional deviations of the crankshaft, due to crankshaft torsion or due to relative motion in the stabilising support or sensor head in relation to the crankcase. These types of error can be limited by selecting the measuring site accordingly.
Geometric and positional deviations of the crankshaft (XG) These are radial deviations of the marker disk axis from the ideal engine axis at the mounting point of the angle encoder or marker disk, see Figure 9-10. In angle encoders without integrated sensor, this error can be influenced by the choice of mounting position for the sensor head (pick up). Only in sensor head position 2 do relative motions of the marker disk in the direction shown by the arrow result in angle errors, see Figure 9-10. The same motion produces no errors in sensor head position 1. Axial shifts within the specified limits are unimportant. Causes of possible deviations may be a crankshaft that is already deformed, a sag in the crankshaft caused by the combustion pressure or a displacement of the crankshaft in the main bearings. This error should be borne in mind in particular in long or flexible crankshaft ends.
9-12
Xi
Engine Indicating
R
ideal ideale engine axis Motorachse
deformed crank
XG
9
R XG
without integrated sensor
Figure 9-10: Errors due to geometric and positional deviations of the crankshaft
Crankshaft torsion Torsion in the crankshaft has a direct effect on the crank angle error. To minimise this error, it is advisable to mount the crank angle encoder as close as possible to the cylinder where the indicating measurement is to be done. Crankshaft torsion results in the same crank angle error in both angle encoders with and without integrated sensor.
9-13
Relative movements of the stabilising support or sensor head (XV) in relation to the crankcase In a similar way to the geometric and positional deviations of the crankshaft, relative movements of the stabilising support or the sensor head in relation to the crankcase also result in measurement errors and in extreme cases, in synchronization errors (Figure 9-11). These occur among other things when the oscillation velocity is greater than that of the marker disk and thus one or more angle marks are detected more than once. Vibrations at the mounting site of the stabilising support or the sensor head are the commonest cause of such errors.
Xv Xv
Sensor window shifted due to vibration Sensor window in correct position
R
Xv
Figure 9-11: Error due to relative movement of stabilising support or sensor head in relation to the crankcase
Figure 9-12 shows how angle error depends on positional error (X) for different marker disk diameters. The positional error is made up of installation errors (XI), errors due to geometric and positional deviations of the crankshaft (XG) and errors due to relative movement of the stabilising support or sensor head (XV). The major advantage of angle encoders with integrated sensor is obvious. This encoder design obtains the large support radius necessary for good accuracy by means of a supporting arm of appropriate length (with an angle encoder that can be as small as you like). On the other hand, in an angle encoder without integrated sensor, the diameter of the marker disk determines the accuracy, which means that the disk diameter has to be very large for good accuracy.
9-14
Engine Indicating
0.5 Wi 0.4 nk elf 0.3 ehl er 0.2 [K W] 0.1 0 0 0.1 0.2 0.3 0.4 0.5
Position error X [mm] Positionsfehler X [mm]
X=XI +XG+XV
D=140mm
D
Figure 9-12: Effects of positional errors on the accuracy of crank angle encoders
Furthermore, the crank angle error resulting from crankshaft torsion has to be added to this crank angle error. This additional angle error is identical for both angle encoder versions.
9-15
9-16
Engine Indicating
=14
5 -1 -5 -10 -15 1
-2 =14,22
2 [CA] [KW]
-0.5 -1 -1.5
=14
=22
-20 =14
-2
Figure 9-13: Effect of an angle error on the energy balance and friction mean effective pressure (diesel engine)
If the TDC position is too early, which means a shift to the right in the cylinder pressure curve, it has the effect that there is too low a pressure as the piston rises and too high a pressure as the piston descends. An apparently longer afterburn phase and a higher energy conversion (QB) are the result. The converse occurs when the TDC position is too late. The effects of angle shifts are also felt in the indicating work (i.e. indicated mean effective pressure IMEP), which is greater when TDC is too early and vice versa. This results also in larger (smaller) friction mean effective pressures ( pf ).
9-17
Stellung b
90
Position a
Position b
Stellung a
The statically determined top dead centre deviates from the TDC that prevails during engine operation (i.e. dynamic TDC) because the mechanical structure of IC engines is not ideally rigid. Therefore, dynamic TDC determination methods are to be preferred.
9-18
Engine Indicating
9.6.2.2
Top Dead Centre Determination Based on the pressure curve of a motored engine
This dynamic TDC determination method is based on the cylinder pressure curve measured in the motored engine mode with subsequent angle determination of the curve maximum. Due to the flat signal curve in the vicinity of TDC, however, and also because of the limited resolution steps of the ADC, this cannot be done simply by taking the pressure maximum. Mathematical methods must be applied for more precise determination of the angle position of the curve maximum in order to achieve an acceptable accuracy. A well functioning algorithm for this purpose is described in chapter 9.6.2.4, Figure 9-18 (AVL algorithm).
measured pressure curve (with Schleppdruckverlauf mit heat and leakage losses)
-10
-5
10
Crank Angle [CA] ] Kurbelwinkel [KW Figure 9-15: Thermodynamic loss angle
9-19
pressure curve, thus shifting the pressure curve until the distance between the pressure maximum and the engine TDC corresponds to the thermodynamic loss angle.
9-20
Engine Indicating
Alignement range
-100
-50
50
100
Heat transfer, leakage and the mass in the cylinder have to be taken into account in the calculation of the pressure curve in the compression phase. The accuracy of the angle adjustment depends on how accurately these quantities are taken into account. Commercial programs for pressure curve analysis offer plenty of ways to determine the TDC position using this approach.
+ AVL Product
Information: [10] TDC sensor
9-21
Measurement principle
The functional principle is based on a capacitive measurement procedure in which the sensor measures the changes in capacitance between the piston and the sensor head. The capacitance changes in inverse proportion to the distance between the piston and the sensor head.
9-22
Engine Indicating
valve motions during gas exchange can affect the capacitance between engine ground and sensor tip and therefore distort the result.
Bisection points TDC-position determined by average of the Bisection points
TDC-Sensor signal
Determination of the actual TDC position from the output signal of the sensor cannot be done using the signal maximum due to the flat signal curve in the vicinity of TDC and due to the limited resolution of the signal sampling. Rather the following algorithm is used: The amplitude is measured in the rising branch at angle (A1,2, ...) and the corresponding angle (B1,2, ...) in the falling branch with the same signal amplitude, see Figure 9-18. This process is repeated a number of times and the position of top dead centre determined from the results (centre line). A suitable angle range for (A1, 2, ...) is, for example, from 15CA to 5CA before TDC.
9-23
offers the least accuracy, but the method is significantly more accurate if reliable values are available for the loss angle. [1]
Effort
TDC-Sensor
Thermodynamic alignement
( )
(Accuracy depending from the quality of the loss angle) small medium high
Accuracy
Figure 9-19: Time and effort, and accuracy of different TDC determination methods
9-24
Engine Indicating
10 Trouble shooting
Table 10-1 lists the problems that frequently occur in the measurement signal and according to the listed significance their possible causes. We recommend proceeding to remedy the problem quickly. The effects of problems that can be so small that they are not visible until the measurement values are evaluated, are identified by -. The listed problem codes and measures for trouble shooting are described in Chapters 10.1 to 10.6, the problem codes being divided into the following groups:
Pressure transducer Measurement cabling Charge amplifier Crank angle encoder Data acquisition and evaluation Calibration
101 - 118 201 - 206 301 - 310 401 - 402 501 - 502 601 - 604
+ Chapter 10.1 + Chapter 10.2 + Chapter 10.3 + Chapter 10.4 + Chapter 10.5 + Chapter 10.6
10
The following category is also included to cover influences (see Table 10-2) that do not derive from measurement errors, but which nevertheless have an effect on the measurement signal:
001 003
Trouble shooting
10-1
Table 10-1:
Effect
No measurement signal
- Occasional jumps or irregularities in the 202 401 118 measurement signal - Sudden change in level of the 104 103 202 measurement signal up or down with no load change
Truncated measurement signal 304 502 113 201 402 401 604, 110, 102, 117,
- Proportional error over entire 306 102 601 602, 603, measurement range, or expected peak 101, 103, 116, 501, pressure or IMEP not reached 115, 117 - Changes in measurement signal or IMEP 111 104 103 101, 113, 200, 401 at unchanged operating point (i.e. continuous operation) - Measurement signal superimposed high-frequency oscillations
by 204 302 107 109, 001 205,
108,
- Measurement signal superimposed by low- 302 203 frequency oscillations synchronous with the mains - Measurement signal superimposed by low- 108 105 110 frequency oscillations synchronous with the engine - Slow drift of measurement signal at 201 113 305 unchanged load
10-2
Engine Indicating
Measurement signal changes level after an 106 engine load change Mean level change at load change is not 106 307 308 properly reflected
Measurement values in the vicinity of TDC 109 002 003 not plausible Pressure proportional error to the in the 116 309 gas exchange range
Table 10-2: Real effects Description and how to avoid them
Combustion chamber It is not the task of the measurement to oscillations (high-frequency) avoid combustion chamber oscillations but try selecting a less troublesome measuring point or use filters. Squish-induced flow (dynamic pressure changes around TDC) Measuring positions with a strong squishinduced flow are only suitable to a limited extent for accurate measurements and should be avoided. Their influence only affects a small angle range around TDC, however, and may therefore not present a problem with every measurement task Pressure measurements in prechamber or swirl chamber provide only very approximate information about the phenomena in the main combustion chamber
10
002
003
Trouble shooting
10-3
Change in pressure Re-calibrate transducer characteristics during running in Change in sensitivity due to Use cooled pressure transducers or influence of temperature transducers with GaPO4 technology. Calibrate the pressure transducer at the expected operating temperature. Maintain cooling water at a constant temperature (return cooling). Permanent change in Replace transducer. metrological characteristics Use pressure transducer, which can of the pressure transducer withstand high temperatures. Reduce the thermal load on the transducer by using due to overheating recessed-type installation, by improving the cooling or choosing a cooler measuring position. Failure of pressure Shut down engine immediately and do transducer cooling not switch on cooling; let pressure transducer cool down with the engine, then remove it and check it. Cyclic temperature drift Use pressure transducers with low cyclic temperature drift. Reduce the heating or thermal load on the transducer by using recessed-type installation, by improving the cooling or choosing a cooler measuring position. Load change drift Use pressure transducers with low load change drift. Reduce the heating or thermal load on the transducer by using recessed-type installation, by improving the cooling or choosing a cooler measuring position. Use pressure transducers with low Mechanical oscillation acceleration sensitivity. excitation (e.g. caused by valve impact, speeds > 10000 rpm)
+ Chapter 3.1.2.1
102
103
104
+ Chapter 3.1.2.1
105
+ Chapter 3.1.2.1
106
+ Chapter 3.1.2.2
107
10-4
Engine Indicating
Code Description of error 108 Effect of acceleration forces due to vibrations on pressure transducer, cable, cooling water hoses and cooling system Pipe oscillations
Remedy Use pressure transducers with low acceleration sensitivity. Lay or position cables, cooling water hoses and cooling system on vibration free parts of the test bed. Mount the pressure transducer flush or mount it with short, oscillation-optimised indicating channel. Use plug-in type pressure transducers or choose a suitable measuring position. Clean the pressure transducer. Use pressure transducers that are not sensitive to soot. Descale; Use decalcified cooling water. Restore high insulation resistance by cleaning the connections on the pressure transducer or by heating it to dry it. Reduce the thermal load on the transducer by using recessed-type installation, improving the cooling or choosing a cooler measuring position. Use charge amplifiers with drift compensation; Use SHORT mode on the charge amplifier. Choose a suitable measuring position. Choose a suitable measuring position. Mathematical compensation. Check calibration range. Use multi-point calibration. Replace pressure transducer. Replace pressure transducer
+ Chapter 3.1.2.2
109
110 111
112 113
Deformations of the mounting position Change in the metrological characteristics of the pressure transducer due to sooting Scaling of cooling water galleries Insulation problems due to moisture, contamination or too high operating temperatures
10
+ Chapter 2.2
Squish-induced flow Influence of a divided combustion chamber Non-linearity of the pressure transducer Faulty pressure transducer Contact problems in pressure transducer
+ Chapter 4 + Chapter 4
Trouble shooting
10-5
+ Chapter 2.3
201
202
Restore high insulation resistance by cleaning the connectors or by heating. Lay cables where it is cool. Use charge amplifiers with drift compensation. Use SHORT mode on the charge amplifier. Ruptured cable, contact Check connections on the pressure problems or loose cable transducer and the various measurement system components. connection Insulation problems due to moisture, contamination or too high operating temperatures Use an equipotential bonding line (with large cross-section) between engine and measuring ground. Use an isolating transformer. Segregate the supply grounds of the charge amplifiers when more than one pressure transducer is used. Influences due to Use shielded cables. electromagnetic fields Change the way cables are laid. Triboelectrical effect due to Use low-noise cables. cable movement Secure cables to non-vibrating components. Cable short circuit Replace cable. Ground loop problems due to different potential between engine, ground and measuring ground (potential difference)
+ Chapter 2.4.1
203
204 205
206
10-6
Engine Indicating
+ Chapter 2.2.2
309
310
Use mains filters and isolating transformers. Ground the charge amplifier by pressing the RESET switch. Select correct measurement range. Ground the charge amplifier by activating the RESET switch. Use drift compensation. Improve the insulation. Input offset is not zero Correct the charge amplifier. Sensitivity set incorrectly on Adjust sensitivity setting. charge amplifier Charge amplifier is in Use LONG mode. SHORT mode Drift compensation is Deactivate drift compensation. activated on the charge amplifier Non-linearity of charge Ground the charge amplifier by pressing amplifier the RESET switch. Use drift compensation. Use SHORT mode on charge amplifier. Faulty charge amplifier Replace charge amplifier.
+ Chapter 2.2.2
10
+ Chapter 2.2.3 + Chapter 2.2.3
Trouble shooting
10-7
402
Sensitivity is set incorrectly Correct sensitivity setting. on indicating equipment Indicating device has Select correct measurement range; use overshot range indicating equipment with automatic measurement range monitoring.
10.6 Calibration
Code Description of error Remedy Calibrate the entire measurement system.
+ Chapter 5
601
602
603 604
Pressure transducer was not calibrated together with the components used for the measurement Pressure transducer was not calibrated at operating temperature Calibration pressure not constant Incorrect calibration values
Check dead weight tester; Vent the hydraulic lines. Check dead weight tester and transducer (insulation, linearity). Deactivate drift compensation on charge amplifier
10-8
Engine Indicating
11 LINK List
11
Link List
11-1
11-2
Engine Indicating
12 Bibliography
[1] Angstrm H-E.: Cylinder pressure indicating with multiple transducers, accurate TDC-evaluating, zero levels and analysis of mechanical vibrations, 3rd International Indicating Symposium, Mainz 1998 AVL Application Notes MI-006-2000: Zylinderkopf und Montagebohrung Deformation (Cylinder Head and Installation Bore Deformation), AVL LIST GmbH, 2000AVL Application Notes MI-007-2000: Lastwechsel und Lastwechseldrift (Load Change and Load Change Drift), AVL LIST GmbH, 2000 AVL Application Notes MI-008-2000: Zyklische Temperaturdrift und Einfluss auf das pi (Cyclic Temperature Drift and Influence on IMEP), AVL LIST GmbH, 2000 AVL Product Information MI-002-96: AVL Echtzeit-Klopfanalyse fr Ottomotoren (AVL Realtime Knock Analysis for SI Engines), AVL LIST GmbH, 1996 AVL Product Information: Druckaufnehmer fr die Motormesstechnik (Pressure Transducers for Engine Instrumentation), AVL LIST GmbH, 2001 AVL Product Information: Gallium Orthophosphat GaPO4, AVL LIST GmbH, 2000 AVL Product Information: IFEM Indizier-Frontendmodul (IFEM Indicating Front End Module), AVL LIST GmbH, 2000 AVL Product Information: Indiziertechnik (Indicating Technology), AVL LIST GmbH, 2000 AVL Product Information: OT-Sensor (TDC Sensor), AVL LIST GmbH, 2001 AVL Product Information: Piezoverstrker 3066A02 (3066A02 PiezoAmplifier), AVL LIST GmbH, 2000 AVL Product Information: Winkelaufnehmer (Crank Angle Encoder), AVL LIST GmbH, 2001
[2]
[3] [4]
12
[5}
[6]
Bibliography
12-1
[13]
Beran R., Figer G., Wimmer A., Glaser J., Prenninger P., Mglichkeiten fr die genaue Messung von Ladungswechseldruckverlufen (Possibilities for the Exact Measurement of Gas Exchange Pressure Curves, 4th International Indicating Symposium, Baden-Baden 2000 Feler, H.: Berechnung des Motorprozesses mit Einpassung wichtiger Parameter (Calculation of the Engine Process with Adjustment of Important Parameters), Dissertation, Technical University of Graz, 1988 Glaser J., Winkler J.: Indizieren mit Glhkerzenadaptern (Indicating with Glow Plug Adaptors, AVL Product Information MI-020-95, AVL LIST GmbH, 1995 Glaser, J.: Fehler von Quarzdruckaufnehmern und Probleme bei der Druckindizierung von Verbrennungsmotoren (Quartz Pressure Transducer Errors and Problems in Pressure Indicating on IC Engines), Dissertation, Technical University of Graz, 1983 Hohenberg, G.: Experimentelle Erfassung der Wandwrme in Kolbenmotoren (Experimental Acquistion of the Wall Heat in Piston Engines), Habilitation Thesis, Technical University of Graz, 1980 Klell M., Wimmer A.: Ein Verfahren zur thermodynamischen Bewertung von Druckaufnehmern (A Method for Thermodynamic Evaluation of Pressure Transducers), Motortechnische Zeitschrift MTZ 50, 1989 Merzhuser T.: Motorberwachung- und Regelung auf Basis einer kontinuierlichen Zylinder-Spitzendruckmessung (Engine Monitoring and Control based on Continuous Cylinder Peak Pressure Measurement), 3rd International Indicating Symposium, Mainz 1998 Mhlgger M., Teichmann R., Indizieren eine Philosophie? Anforderungen, Wnsche und Mglichkeiten aus der Sicht des Anwenders (Indicating a Philosophy? Requirements, Wishes and Possibilities from the Point of View of the User), 4th International Indicating Symposium, Baden-Baden 2000 Pischinger, R., Kranig, G., Taucar, G., Sams, Th.: Thermodynamik der Verbrennungskraftmaschine (Thermodynamics of Internal Combustion Engines), Springer Publishing Vienna, 1988 Sass, F.: Geschichte des deutschen Verbrennungsmotorenbaus von 1860 1918 (History of German Internal Combustion Engine Engineering from 1860 1918
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
12-2
Engine Indicating
[23] [24]
Tichy, J., Gautschi G.: Piezoelektrische Metechnik (Piezoelectric Engine Instrumentation), Springer Publishing Berlin Heidelberg New York, 1980 Wimmer, A., Glaser, J.: Welche thermodynamischen Aussagen sind mit Miniaturdruckaufnehmern mglich? (What Thermodynamic Information can Miniature Pressure Transducers Give Us?), Paper for 2nd Indicating Symposium in Offenbach/Main, May 1996
12
Bibliography
12-3
12-4
Engine Indicating
13 List of Figures
Figure 1-1: Indicator chart recorded by Nikolaus August Otto (from Friedrich Sass: Geschichte des deutschen Verbrennungsmotoren-baus von 1860-1918") [22] .................................................................................1-1 Figure 1-2: Application areas of indicating technology............................................1-2 Figure 1-3: Cylinder pressure curve over an engine cycle........................................1-3 Figure 1-4: Low pressure curves over one cycle ......................................................1-6 Figure 2-1: Structural diagram of the piezoelectric pressure measurement system with additional devices ........................................................................2-1 Figure 2-2: Piezoelectric effects ...............................................................................2-3 Figure 2-3: Measuring element for the longitudinal effect ......................................2-5 Figure 2-4: Increasing the charge output with the longitudinal effect .....................2-5 Figure 2-5: Measuring element for the transversal effect .........................................2-6 Figure 2-6: Quartz crystal.........................................................................................2-8 Figure 2-7: Crystal structure of Gallium Orthophosphate ......................................2-10 Figure 2-8: Temperature dependency of piezoelectric constant (d11) for quartz and Gallium Orthophosphate .............................................................2-10 Figure 2-9: Construction of a piezoelectric pressure transducer based on the longitudinal effect (from AVL) Mounting thread M14x1.25..........2-12 Figure 2-10: Construction of piezoelectric pressure transducers based on the transversal effect (from Kistler) Mounting thread M14x1.25 .........2-13 Figure 2-11: Uncooled miniature pressure transducer (from AVL) Mounting thread M5x0.5....................................................................................2-14 Figure 2-12: Charge amplifier (e.g. from AVL) .....................................................2-16 Figure 2-13: Circuit diagram of a charge amplifier ................................................2-16 Figure 2-14: Definition of the time constant when discharging a capacitor ...........2-18 Figure 2-15: Electrical drift effect ..........................................................................2-19 Figure 2-16: Typical effect of SHORT mode on the measurement result at low speed and with low transducer sensitivity..........................................2-21 Figure 2-17: Basic effect of cable length on the upper cut-off frequency...............2-24 Figure 3-1: External influences on the pressure transducer ......................................3-2 Figure 3-2: Measurement and overload range ..........................................................3-3 Figure 3-3: Sensitivity and linearity .........................................................................3-5 Figure 3-4: Resonance frequency spectrum..............................................................3-6 Figure 3-5: Temperature distribution and deformation of a pressure transducer and curve of the cyclic temperature drift with cyclic heating at the front face (result of an FEM simulation)..............................................3-9
13
List of Figures
13-1
Figure 3-6: Deviations in indicated mean effective pressure and in the energy balance due to an error that is proportional to the pressure and due to cyclic temperature drift..................................................................3-10 Figure 3-7: Tester for determining the cyclic temperature drift (diagram) .............3-11 Figure 3-8: Curve of heat flow density in the tester................................................3-12 Figure 3-9: Load change drift.................................................................................3-13 Figure 3-10: Influence of structure-borne noise in the measured pressure signal...3-15 Figure 4-1: Interrelation between measurement task, pressure transducer and installation............................................................................................4-2 Figure 4-2: Influence on the measured pressure curve of a measuring position arrangement in the squish gap..............................................................4-9 Figure 4-3: Temperature distribution at the cylinder head of a 2-valve DI diesel engine.................................................................................................4-11 Figure 4-4: Heat flow load and cyclic temperature drift as a function of installation position and depth ...........................................................4-13 Figure 4-5: Influence of the length of the indicating channel on the measured pressure curve ....................................................................................4-14 Figure 4-6: Indicating channel with additional volume ..........................................4-15 Figure 4-7: Pipe oscillation frequency as a function of indicating channel length and gas temperature ...........................................................................4-16 Figure 4-8: Flow chart for pressure transducer selection........................................4-24 Figure 5-1: Glow plug adaptor with pressure transducer..........................................5-1 Figure 5-2: Glow plug adaptor with pressure measuring probe................................5-2 Figure 5-3: Different designs of spark plug adaptors ...............................................5-3 Figure 5-4: Front and shoulder-sealing direct installation ........................................5-6 Figure 5-5: Example of the installation of an uncooled pressure transducer with adaptor sleeve ......................................................................................5-7 Figure 5-6: Direct installation of a cooled transducer with adaptor sleeve...............5-8 Figure 5-7: Pressure transducer and bore ready for transducer installation............5-10 Figure 5-8: Work stages for installing a transducer................................................5-11 Figure 5-9: Cylinder head with two installed pressure transducers ........................5-12 Figure 5-10: Work stages for single sleeve and inclined bore axis.........................5-13 Figure 5-11: Work stages for installing the adaptor sleeve ....................................5-14 Figure 5-12: Installing the pressure transducer.......................................................5-15 Figure 5-13: Work Stages for multiple seals and perpendicular bore axis .............5-16 Figure 5-14: Installing adaptor sleeve and transducer ............................................5-17 Figure 6-1: Calibration methods...............................................................................6-1 Figure 6-2: Schematic representation of the construction of a dead weight tester design...................................................................................................6-4 Figure 6-3: Calibration jump ....................................................................................6-5 Figure 6-4: Influence of electrical drift during calibration .......................................6-6 Figure 6-5: Unloading jump in high pressure dead weight testers with loading and unloading valve .............................................................................6-7
13-2
Engine Indicating
Figure 9-1: Principle of signal discretization............................................................9-2 Figure 9-2: Influence of angle and amplitude resolution on the discretization.........9-2 Figure 9-3: Influence of the resolution on the display of knocking combustion.......9-3 Figure 9-4: Inductive and optical transducers...........................................................9-5 Figure 9-5: Possible mounting positions for sensor head and marker disk...............9-5 Figure 9-6: Crank angle encoder with and without integrated sensor.......................9-6 Figure 9-7: Examples of crank angle encoder designs with and without integrated sensor (from AVL)...............................................................................9-7 Figure 9-8: Manufacturing errors ...........................................................................9-11 Figure 9-9: Installation error ..................................................................................9-12 Figure 9-10: Errors due to geometric and positional deviations of the crankshaft .9-13 Figure 9-11: Error due to relative movement of stabilising support or sensor head in relation to the crankcase ........................................................9-14 Figure 9-12: Effects of positional errors on the accuracy of crank angle encoders 9-15 Figure 9-13: Effect of an angle error on the energy balance and friction mean effective pressure (diesel engine).......................................................9-17 Figure 9-14: Method for static TDC determination................................................9-18 Figure 9-15: Thermodynamic loss angle ................................................................9-19 Figure 9-16: TDC determination by means of thermodynamic adjustment ............9-21 Figure 9-17: Construction and mounting of a TDC sensor.....................................9-22 Figure 9-18: TDC signal evaluation .......................................................................9-23 Figure 9-19: Time and effort, and accuracy of different TDC determination methods..............................................................................................9-24
13
List of Figures
13-3
13-4
Engine Indicating
14 List of Tables
Table 1-1: Table 4-1: Table 4-2: Table 4-3: Table 4-4: Table 7-1: Table 10-1: Table 10-2: Indicating parameters Important measurement tasks with evaluation criteria and additional measurement parameters Adaptation with and without intervention in the test engine Pressure transducers for engine instrumentation Effect of pressure transducer properties and installation on signal evaluation Assessment of zero-line detection methods Effects on the measurement signal and possible causes of error Real effects Description and how to avoid them 1-4 4-5 4-7 4-18 4-21 7-5 10-2 10-3
14
List of Tables
14-1
14-2
Engine Indicating
15 Index
Acceleration....................... 3-2, 3-15, 10-5 Accuracy requirements..............4-24, 9-4 Adaptor sleeve .............................5-6, 5-12 Analogue/Digital converter ................ 2-2 Angle measurement.............................. 9-1 Bessel filter ............................................2-22 Cable length..........................................2-23 Calibration.............................6-1, 6-3, 10-4 Capacitance ..........................................3-21 Capacitive..............................................9-23 Change in sensitivity ...................3-7, 4-23 Characteristic........................................... 3-4 Charge amplifier ............................2-1, 2-16, 3-18, 6-1, 10-7 Charge amplifiers.................................3-18 Charge output ........................................ 2-4 Chemical influence .....................3-2, 3-16 Cleaning.................................8-1, 8-3, 10-5 Combustion chamber pressure measurement.......................................... 1-2 Combustion noise ................................. 1-4 Construction of piezoelectric pressure transducers...........................2-12 Contamination .......................... 10-5, 10-6 Contamination resistance..................9-10 Cooling water crosstalk........................ 3-7 Crank angle encoder ..................9-1, 10-8 Crank angle encoder with integrated sensor ................................... 9-6 Crank angle error.................................9-17 Crank angle errors...............................9-11 Crank angle resolution ......................... 9-9 Crankshaft torsion ...............................9-13 Cut-off frequency.................................3-19 Cyclic heating.......................................3-10 Cyclic temperature drift .. 3-8, 3-12, 4-14 Data acquisition...........................2-2, 10-8 Dead volume............................. 4-13, 4-15 Dead weight tester......................6-3, 10-8 Deformation impact ...........................3-16 Deposits .................................3-16, 5-4, 8-3 Descaling .......................................8-2, 10-5 Design ......................................... 4-20, 4-22 Diaphragm ............................................ 2-12 Digital signal recording ........................ 9-1 Discharge .............................................. 2-18 Drift compensation........ 2-21, 10-5, 10-7 Duration of combustion .............. 1-5, 7-5 Electrical drift..............................2-17, 2-20 Electrical filter ....................................... 2-22 Electrodes................................................ 2-4 Electromagnetic compatibility.......... 9-10 Electromagnetic fields ..............2-25, 10-6 Electrometer amplifier .......................... 3-7 Energy conversion points .................... 4-5 Evaluation........................... 4-5, 9-17, 10-8 Flow recess ........................................... 4-13 Forced zero point ...................................3-4 Friction analysis...................................... 4-5 Friction mean effective pressure .........................................................4-4, 9-17 Front-sealing............................................ 5-5 Gallium orthophosphate.............. 2-9, 5-2 Gas exchange analysis ......... 1-6, 1-7, 4-5 Gas oscillations ...................................... 4-9 Glow plug adaptator .......................... 4-14 Ground loop...............................2-24, 10-6 Heat flow......................................... 3-1, 3-7 Heat range .............................................. 5-4 Helmholtz resonator........................... 4-16 High pass filter ..................................... 2-22 High pressure indicating...................... 1-3 Hydrothermal synthesis ....................... 2-8 IMEP stability ........................................ 3-17 Indicated mean effective pressure.. 9-17 Indicating channel....................................... .................................4-13, 4-15, 4-18, 4-23 Indicating equipment .................2-2, 10-8 Indicating parameters... 1-3, 1-4, 4-3, 4-5 indicator chart ........................................ 1-1 Influence of measuring position ........ 4-7 Input offset............................................ 2-18 Input voltage ........................................ 2-17 Installation bore ..................................... 4-8 Installation error................................... 9-11 Installation position............................... 5-5
15
Index
15-1
Insulation resistance........... 2-23, 3-6, 8-1 Interference signals .....................2-24, 7-5 Knock detection..................................... 4-5 Leakproofness.................... 4-19, 5-8, 9-10 Lifetime.................................. 3-4, 4-23, 9-9 Linearity............................................ 2-7, 3-5 Linearity deviation ......................... 3-4, 3-5 Load change drift...................... 3-13, 10-4 LONG.....................................................2-20 Longitudinal effect.......................2-5, 2-12 Low pass filter.......................................2-22 Low pressure indicating ....................... 1-6 Machining the mounting bore ........... 5-9 Maintenance........................................... 8-1 marker disk.............................................. 9-7 Marker disk....................................9-6, 9-12 Measurement cabling...... 2-1, 2-23, 10-6 Measurement range....................3-3, 4-23 Measurement task .......................4-3, 4-23 Measuring element ............ 2-4, 2-12, 3-9 Measuring point...................................4-19 Measuring position........... 4-8, 4-13, 4-18 Mechanical engine load....................... 4-5 Miniature pressure transducer.................. ..................................... 2-14, 3-8, 4-24, 5-3 Misfire detection.................................... 4-5 Monitoring............................................... 4-5 Motion noise.........................................2-23 Mounting principle................... 4-20, 4-22 Multi-point-calibration........................... 6-2 Natural frequency........................3-5, 4-21 Noise.......................................................3-20 Noise analysis ......................................... 4-4 Noise charge.........................................3-21 Operating conditions............................ 4-3 Operating temperature range ............ 3-4 Output signal ..................................2-7, 3-4 Overload range ...................................... 3-3 Parameters............................................... 3-3 Peak pressure....................... 4-5, 7-5, 10-2 Permanent zero-line deviation .........3-14 Piezo material...............................2-7, 2-11 Piezoelectric effect................................ 2-3 Piezoelectric pressure transducer......................................2-1, 2-12 Piezoelectricity ....................................... 2-3 Pipe oscillations......................... 4-15, 10-5 Plug-in transducer ................................4-22
Polarity ...................................................3-18 Polytropic exponent ............................. 7-2 Potential difference.............................10-6 Prechamber................................ 4-12, 10-3 Pressure indicating ................................... 1-1, 3-8, 4-1, 5-1, 5-5 Pressure jump...............................2-19, 6-6 Pressure measuring probe.........4-24, 5-2 Pressure rise............................................ 1-4 Pressure transducer cooling .. 2-14, 10-4 Pressure transducer selection................... ..................................................... 4-20, 4-24 Pyroelectric effect ................................. 2-8 Quartz ...............2-3, 2-8, 2-12, 2-14, 4-21 Reference transducer .........................3-12 Repair ....................................................... 8-1 Representative pressure....................... 4-7 RESET..............................................6-6, 10-7 Resistor for negative feedback.........2-20 Resonance frequency.................3-6, 3-19 Ripple .....................................................3-20 Sampling rate.......................................... 9-2 Screening...............................................2-23 Sensitivity.................................... 3-18, 4-23 Shock resistance ..................................4-23 SHORT ........................................ 2-20, 10-7 Short term drift....................................... 7-5 Shoulder-sealing..................................... 5-5 Signal discretization .............................. 9-1 Signal-to-noise ratio.............................4-21 Similar-to-static measuring.................2-18 Single-point calibration......................... 6-2 Sooting ........................................ 3-16, 10-5 Spark plug adaptator ............................ 4-8 spark plug adaptor ................................ 5-3 Spark position......................................... 5-4 Speed of the pressure rise................... 4-9 Speed range............................................ 9-9 Squish-induced flow................. 10-3, 10-5 Stabilising support .................... 9-14, 9-16 Stability............................................. 2-7, 4-6 Start of combustion ...................... 1-4, 1-5 Step ........................................................... 6-1 Structure-borne noise ...... 2-22, 3-15, 7-3 Supporting arm ....................................9-14 Swirl chamber..................4-12, 9-21, 10-3 TDC determination .............................9-20 TDC Determination ................. 9-19, 9-24
15-2
Engine Indicating
TDC sensor ................................ 9-22, 9-23 Temperature ................................... 2-8, 3-1 Temperature calibration....................... 6-5 Temperature drift................................... 3-8 Temperature resistance......................4-23 Test engine....................................4-3, 4-24 Thermodynamic analysis ..................... 1-5 Thermodynamic loss angle ...............9-20 Time constant.......................................2-18 Transmission behaviour ....................... 3-4
Transversal effect.........................2-6, 2-13 Triboelectrical effect ........................... 10-6 Twin formation....................................... 2-9 Uncooled pressure transducer......... 4-22 Vibration resistance ............................ 9-10 Water slap ............................................... 5-9 Water-cooled pressure transducer.. 2-12 Zero-line detection ....................... 7-1, 7-5 Zero-line gradient................................ 3-14
15
Index
15-3