DelphiEngine test bench calibration methodology for Delphi Diesel common rail systemWord下载.docx
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DelphiEngine test bench calibration methodology for Delphi Diesel common rail systemWord下载.docx
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BSFC:
BrakeSpecificFuelConsumption
TDC:
TopDeadCenter
PWM:
PulseWidthModulation
I/D:
InnerDiameter
ECU:
ElectronicControlUnit
HP:
HighPressure
I2C:
IndividualInjectorCharacteristic
APC:
Accelerometerpilotcontrol
ERPM:
EngineRevolutionPerMinute
APV:
ApplicationProgrammableVariable
APM:
ApplicationProgrammableMap
4.Testcelldefinitionandenginechecking
4.1.Instrument
Thetestcellshouldincludeallthenecessaryinstrumentsforperformancetest,andemissiontestifneeded.Generallybelowinstrumentsarerequiredinatestcell.
_dynamometerandcontrolunit
_fuelbalancerwithreasonableaccuracy
_fuelcooler
_cylinderpressuremeasurementequipment
_temperaturesensortomeasuretheexhausttemperatureforeachcylinder
_airfilterandflowmeter
_intercooler
_temperaturesensors
temperaturesensorsbeforeandafterintercooler,exhausttemperaturesensor,coolanttemperaturesensor,oiltemperaturesensorarenecessarytomonitortheenginestatusandkeeptheengineruninsafeconditions
Sensorstomonitorthefueltemperaturebeforepumpinlet,fueltemperaturesforinjectorreturnandpumpreturnareoptionalandwhichwillhelptomonitorthelowpressuresystem.
_pressuresensors
exhaustpressuresbeforeandafterturbo,oilpressure,airpressuresbeforeandafterintercooler
_emissioninstrumentifemissionmeasurementisrequired
_SteadyvoltagesupplytopowerECU;
10-16voltageisacceptable
_Atmospheremeterandhumiditymeter
4.2Lowpressuresystem
4.2.1Circuitfortestcell
Thepipeworkandfittingstobeminimum8mmI/D
Thepipeworkthatisincontactwithfuelshouldnotcontaincopperorzinc
Therecommendedgenericconfigurationofthelowpressurecircuitforatestcellisdescribedinthefollowingdiagram:
FUELCOOLER
(IFREQD)
4.2.2.PressureConditions
ThedepressionattheHPpumpinlet(measured50mmfromthepumpinlet)mustbeabove-400mbarinrelationtotheatmosphericpressure.
Ifthislevelisreached,STOPTESTandinvestigatecause.
ThepressureattheHPpumpreturn(measured50mmfromtheventurioutlet)mustbebelow300mbarabovetheatmosphericpressure.
Theselimitationsaregeneric,specificlimitationsforeachapplicationwillbeprovidedinsystemobjectivespecification.
4.2.3TemperatureConditions
Thefueltemperatureshouldbekeptas40-45degreeCatnormalrunningconditions.
Forthehottest,thetemperatureatpumpinletshallremainbelow85°
C(Peaktemperatureof90°
Ccanbeacceptedduring30secondswhenrunning).Thelowpressurecircuitmustallowtheadditionalheatwhichcomesmainlyfromtheleakreturnoftheinjectors,tobedissipated.Thistemperaturecouldbeashighas110DegCathighengineloads.
IfthetemperaturedifferentialacrosstheHPpump,INLETtoRETURNexceeds50degC,STOPTESTandinvestigatecause.
Theselimitationsaregeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.
4.2.4FilterChangeInterval
Thefilterelementshouldbechangedafter200hoursofenginerunning.
Thislimitationisgeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.
Seealsofilterteamrecommendationofthefilteranalysis.
4.2.5Watersedimentor
Checkandemptyifneeded.Sameintervalasfilterchange
4.3Airinletandexhaustsystem
-monitorpressuredropacrossintercoolerifapplicable
-monitorbackpressure
4.4Electricalsystem
4.4.1.BatteryVoltage
ThesystemensuresnormalfunctionforbatteryvoltagesattheECUsupplypinconnectorsbetween10to16V.ThevoltageshouldbekeptsteadytoguaranteetheFIEsystemworkproperly.Ifthevoltageisnotatnormalcondition,somerecoveryactionsneedtobetakenintoaccounttoputbackthevoltagetonormalsteadyvoltagelevel.
Thesystemcanoperateforamaximumof1hourbetween16Vand18VatECUsupplypin,andthefunctionmaybedeteriorated.Duringjumpstart(between18Vand24VatECUsupplypin),thesystemcanmeetatleastthefunctionalrequirementrelevantforthestartofvehicle,theover-voltage(between18Vand24VatECUsupplypin)timeshallbelessthan1minutewithambienttemperaturelessthan20°
C.
4.4.2.Powersupplyrequirements
ThepowersupplyconnectionsshouldhaveminimumDCresistance,ideally<
40mOhmstotal.
Inthecaseofdynamometerinstallationsthepowersupplyunit(PSU)shouldbechosentomanagethepeakcurrentrequirement,ieaminimumof25A.IdeallythePSUshouldbeoftheswitch-modetypeasthisisbettersuitedtotransientdemandchanges.ThesupplyshouldbelocatedascloseaspossibletotheECU(<
1.5m)tominimisevoltdrop.
4.5Enginecheckingbeforefirststart
Anenginestartattemptshouldonlybemadewith:
_anadequatefuelsupplysystem.
_afullyassembledhighpressurefuelsystem
_allthesensorsconnected
_thekeyswitchONtomaketheECUpoweron,butnostart
_allinjectorcorrectiondata(C2I)enteredintotheECU.
_faultlistbecheckedandallfaultsbeclearedbeforestartingtheengine.
Afterthefirststartoftheengine,(eitheranewengineorafterdismantlingofthefuelsystem),theengineshouldbestoppedafteraperiodofbetween1and5minutesrunningatidletocheckforfuelleaks.AvisualONLYinspectionshouldbemadeofthelowandhighpressuresystem.
5Softwarerelease
Delphiwillreleasethesoftwareatthebeginningofanewapplication.
ThelevelofthissoftwarewillbedefinedbytheEMSteamandwilldependonthesystemfunctiondefinition.
6Systemlimitsdefinition
Beforeanyfullloadtests,enginelimitsandthesystemlimitsshouldbedefinedtoguaranteesafeoperation.
6.1.Purpose
Thissubjectdescribesthesystemlimitsthatshouldbetakenintoaccountwhenanapplicationiscarriedout.
6.2.Enginelimits
Theenginelimitsmustbeknownbeforestartinganengineonatestbench.
Themostimportantvaluestoknoware:
_themaximalcylinderpressure,
_themaximalenginespeed,
_themaximaltemperaturebeforeturbine,
_themaximalintakeairtemperatureaftertheturbocharger.
Note:
alltheseitemsarecustomer’sresponsibilities.Inordertomonitorthecylinderpressure,customerneedstomachineaspecificcylinderheadtoinstallthecylinderpressuregauge.
Exceedingtheselimitscoulddamagetheengine.Someautomatedtestsbenchesareabletolookafteruser-definedlimits.
Themaximalfueldemandshouldbedefinedbeforerunningtheengineonatestbench,topreventbringatoobiginjection,whichcouldmaketheengineexceedthemaxexhausttemperatureandcylinderpressurelimitsanddamagetheengine.Thetimingsshouldalsobeconsidered:
it'
simportanttoestimatethetimingslimitsforthemultipleinjections,whichcouldcausethemaxexhausttemperatureandcylinderpressure.
6.3.FuelSystemLimits
Toguaranteethesystemoperation,somelimitsmustbetakenintoaccount.
6.3.1.Fuelcharacteristics/customer’sresponsibility
ThecommonrailsystemistobeusedwithEN590fuels,orEMC5(ie:
EN590+5%ofester).Ifothersfuels,orpoorqualityfuels,areusedthenthedurabilityofthesystemcannotbeguaranteedwithoutspecificmeasurestobedefinedwiththecustomer.
Delphireservestherighttorequestthecustomertoprovidethefuelspecification.
6.3.2.Railpressurelimits/Delphi’sresponsibility
Thedemandedpressuremustbewithinminimalandmaximallimitsthatvaryagainstspeed.Thislimitationisgeneric,specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecification.
Belowisagenericexample:
6.3.3.Fuellinglimits/Delphi’sresponsibility
Theminimumfueldemandforpilotinjectionisafunctionofrailpressure.Itisintendedtobeabletoguaranteethatatleast0.5mm³
/shotisinjectedintotheenginetakingintoaccountshot-to-shotandvariationofmeandelivery,ascontrolledbyAPC.
Belowisagenericexampleshowstheminimumdeliverylimit:
6.3.4.Pilotandmaininjectionsseparationlimits/Delphi’sresponsibility:
TakingintoaccounttheI2CandtheAPCstrategiesandlowbatteryoperation,theminimumuseableelectricseparationshouldbesetatthebeginningat1000µ
s(starttostart).
Theshownexampleisgeneric.Specificlimitationforeachapplicationwillbeprovidedinsystemobjectivespecificationtoallowmorecalibrationpossibilities.
7Nozzledefinition/customer’sresponsibility
Oncetheenginelimitsandsystemlimitsarecreated,thenextstepinthedevelopmentprocessistochoosethehydrauliccomponentswhichwillallowtheperformancetargets.
7.1.Purpose
Thefirstpurposeoftheenginebenchdevelopment
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