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Engine Measurements & Calibrations

MOT/MBM-E
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Who should attend?

  • This course provides an understanding of the “how” and “why” of measurements, their use for development and calibration of spark ignition and diesel engines.
Audience :
  • Engineers and technical staff making or using measurement equipment for the purposes of tuning in order to better understand the measurement and equipment, the calibration process and the risks of wrong results interpretation.

Level : Advanced

Course Content

  • Introduction to the engine tuning & calibration

      • Different benefits to consider: basic settings, performance, cold operation, depollution/standards to be met, particulate filter regeneration, OBD diagnostics. Impact of drifts and dispersions, ambient conditions. The engine operating points. Main parameters of engine tuning.

  • Stationary engine dyno test bench measurements

      • Tests carried out on stationary engine dyno test benches: reliability tests of engine components or after-treatment systems, architecture development tests (friction, thermal, fluid circuits) or engine control development tests. Driving and monitoring system of an automated test bench.
      • Slow measurements: cooling circuit (temperature, pressure, flow), stability criteria, parts thermo-mechanical resistance tests; oil and fuel circuits (pressure and temperature control, consumption measurement); air circuits (temperature and hygrometry regulation, mass and volume flow meters); load machine, torque and speed measurement.
      • Instantaneous measurements: measurement and acquisition of cylinder pressure, intake and exhaust instantaneous pressures, angular encoding, combustion analysis.
      • Virtual engine test bench tour.

  • Engine test bench measurements analysis

      • Validation process of a test by results analysis, comparison with the expected results.
      • How to determine the reasons of a non-validation.

  • Special vehicle test bench

      • Equipment, instrumentation, measurements goals from the tuning point of view
      • Climatic room.
      • Evaporation room.
      • Altimeter bench.
      • Aero-climate bench.
      • Tests on track, on cycles, in extreme conditions, customer requirements.
      • Virtual bench tour.

  • Measurements of non regulated pollutants & of particles granulometry

      • Measurements of non regulated pollutants (NrP): HC, aldehydes, NH3, HAP.
      • Particles granulometry: electrical low pressure impactor (ELPI), Scanning mobility Particle Sizing (SMPS). Difficulties to interpret the measurements results. Dynamic mass measurements (TEOM, Micro Soot Sensor).

  • Sampling methods at engine dyno & roller test benches

      • Hot or cold samples, wet or dry gas analysis.
      • Constant flow dilution system (Constant Volume Sampling).
      • Full or partial flow systems, advantages and drawbacks.

  • Classical methods of gaseous pollutants & particles measurements

      • Nitrogen monoxide and dioxide measurement with infrared absorbing detector.
      • Nitrogen oxides measurements with chemico-luminescence.
      • Oxygen measurement with paramagnetic detector.
      • Unburnt hydrocarbons measurement with flame ionization detector.
      • Particles measurement with gravimetric method, smoke meter, opacity meter.

  • Gas analysis by fourier transform infrared (FTIR) & ultraviolet (FTUV)

      • Measurement principle, use of spectrometer, analyzed gas.
      • Advantages compared with other methods: response time, wet hot gas sampling, lack of calibration with titer gas, results obtained.

  • Numerical methods for engine tuning & calibrations

      • Definition of the cycle operating points. Engine parameters impact on tuning methodologies and numerical approach. Definition of DoE: choices of operating points, parameters, measures and measuring instruments. Numerical models identification. Optimization of the calibration according to requirements (consumption, emissions, noise, approval, performance). Optimization methodologies.

Learning Objectives

  • Upon completion of the course, participants will be able to:
  • know the fundamentals of engines’ tuning, calibration and associated tests,
  • know the types of measurements and means necessary for engine calibration,
  • know the pattern of an engine development and the associated measurements,
  • know the major types of tests and measurements necessary for engine and vehicle development,
  • understand the tests on track and the customer requirements,
  • understand the structures of the different engine test bench types and how to drive and monitor them,
  • know the measurement methods called “slow” such as speed, torque, temperatures, pressure, flows, gas analysis,
  • know the instantaneous measurement methods such as in-cylinder pressure and how to use them in combustion analyses,
  • use the classical gas sampling and analyses,
  • set the main rules of a test campaign.
  • identify dysfunctions to avoid misinterpretation.