Engine Test System
Project details
Modern internal combustion engines employ complex electronic systems equipped with a wide variety of sensors which co-ordinate the actions of engine components such as valves, fuel injectors and spark plugs, to achieve optimal efficiency, performance, and emissions reduction. Our customer is engaged in pioneering engine research into zero-carbon, high-efficiency propulsion systems to improve the impacts on air quality and climate for the transport sector. Their research necessitates the ability to precisely vary engine parameters while simultaneously performing cutting-edge optical diagnostic techniques and high-speed logging of sensor data, requirements that cannot be met by off-the-shelf engine control units. This case study showcases how we were able to transform their engine research by providing a customised software solution that not only met but exceeded their expectations.
Project challenge
The challenge lay in developing a custom software solution to interface with the existing engine hardware, providing full control overfuel injection and ignition timing while also co-ordinating the optical experiment timings and data logging. Previously, they were using two outdated software tools—one for control and another for data recording—which led to numerous issues. These included difficulty in editing and maintaining the software, loss of live parameter control during data logging, inflexibility in manipulating and displaying acquired data, and a complicated manual setup process increasing the chances of generating invalid data. To overcome these challenges, they required an entirely new software solution that offered the same functions but without any of the drawbacks and that also provided a flexible environment for displaying multiple live data channels to inform the operator and improve the success rate of experiments. We successfully addressed these needs and delivered a solution that enhanced the efficiency and effectiveness of their engine research.
Project solution
We supplied new software that retained the same look and feel as the old software, ensuring a minimal transition period. However, it came with a vast range of new features, making it highly useful and user-friendly: The software allows users to create virtual channels, reading data from physical channels, and apply real-time scaling and calculations on data straight from the engine. This feature provides greater flexibility and efficiency in data processing. Custom data displays have been added, enabling users to create various combinations of graphs, charts, and indicators, allowing real-time data acquisition from the engine in customisable ways for rapid performance analysis. An invaluable addition is the ability to load and save experiment profiles. Once users have set up the software to their preferences, they can easily retrieve and continue from where they left off without wasting time on reconfiguration between each user or experiment. Users can now set alarms to trigger when any data channel or calculated value goes beyond pre-selected limits. These alarms can be soft, alerting users to abnormal readings, or hard, stopping operations to prevent engine damage. Moreover, the software now performs complex calculations using the engine data, such as the Indicated Mean Effective Pressure (IMEP) and Mass Fraction Burned (MFB) directly. Previously, these calculations were done externally after conducting experiments. Additionally, an optional PID controller has been incorporated to maintain a chosen air-fuel-ratio value via control of the injection duration. When enabled, this feature frees the user to focus on other aspects of their experiments. The software solution comprehensively met the customer’s needs and implemented a framework which enables straightforward editing of the software to address future needs as they arise.
