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Advanced Internal Combustion Engine Sensor Analysis by Means of Modelling and Real-Time Measurement

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Advanced Internal Combustion Engine Sensor Analysis by Means of Modelling and Real-Time Measurement REPORT ADVANCED INTERNAL COMBUSTION ENGINE SENSOR ANALYSIS BY MEANS OF MODELLING AND REAL-TIME MEASUREMENT Heime Jonkers EWI DATAMANAGEMENT & BIOMETRICS EXAMINATION COMMITTEE Prof.Dr.Ir. R.N.J.Veldhuis, dr. G.G.M. Stoffels, dr. ir. A.J. Annema DOCUMENT NUMBER EWI19/DMB - BA-EE/001/HJ 24-01-2019 Abstract Given modern increased ability to model, measure and process the operation conditions of the internal combustion engine, an opportunity was presented to greatly improve the performance of older combustion engines through the development of a more affordable engine management system. As part of the development of this system, a study into the possible improvements to the usage of common automotive drivetrain sensors was conducted, resulting in a numerical model of the common SI (Spark Ignition) engine, the development of a real time measurement system and a set of real-time measurements on a representative Volvo b230k engine. These real time measurements were combined with the created model to result in the finding of 3 additional uses for the common MAP (Manifold Air Pressure) sensor, namely engine speed determination, crank angle position read out and camshaft profile identification. Additionally, methodologies for the usage of EGT (Exhaust Gas Temperature) sensors for the determination of the AFR (Air Fuel ratio) with provided engine speed were proposed, and the possible relationship between MAT (Manifold Air Temperature) and engine operating friction were discussed. Preface The subject of this research was based in my personal interest in the motorcycle and car hobby, and my future ambitions to start a company specialized in the improvement of the performance of the vehicles commonly used in this hobby. This project has allowed me to gain a lot of knowledge on the topic of engine management, tuning and the creation of engine control systems, which will most definitely be applied in future projects and the development of my company. I would like to thank my examiners and supervisors Prof.Dr.Ir. R.N.J. Veldhuis, dr.ir. A.J. Annema and dr. G.G.M. Stoffels as well as my unofficial supervisor ing. G.J. Laanstra for their much-appreciated help and contribution during the weekly and individual meetings as well as for their helpful suggestions during project roadblocks. I additionally would like to thank my family and friends for their help and understanding during the key moments of this project, and their key advice during the finishing stages of this project. Contents Contents ....................................................................................................................................................................1 Introduction ...............................................................................................................................................................2 The IC Engine: Theory ................................................................................................................................................3 A brief history of the internal combustion engine ..................................................................................................3 Operating principles of the internal combustion engine ........................................................................................3 The Two and Four stroke engine ............................................................................................................................4 The Diesel and Otto cycle.......................................................................................................................................6 Description of proposed test engine ......................................................................................................................8 The IC Engine: Modelling ..........................................................................................................................................10 Modelling research ..............................................................................................................................................10 Model construction .............................................................................................................................................11 Parameters from model .......................................................................................................................................17 The IC Engine: Real-Time Measurement ...................................................................................................................19 Sensors ................................................................................................................................................................19 Sensor placement ................................................................................................................................................20 Measurement ......................................................................................................................................................21 Method................................................................................................................................................................22 Discussion ............................................................................................................................................................22 Operating Conditions: Theory vs Practice .................................................................................................................24 Manifold Air Pressure ..........................................................................................................................................24 Manifold Air Temperature ...................................................................................................................................26 Exhaust Gas Temperature ....................................................................................................................................27 Operating Conditions: Extraction .............................................................................................................................29 Engine speed .......................................................................................................................................................29 Engine rotation ....................................................................................................................................................30 Camshaft profile. .................................................................................................................................................30 Engine fueling and load ........................................................................................................................................31 Concluding ...............................................................................................................................................................32 Achievements ......................................................................................................................................................32 Thesis discussion..................................................................................................................................................32 Suggested additional development ......................................................................................................................32 1 Introduction In the car and motorcycle hobby, wherein the maintenance, driving/riding and improvement of old vehicles is often the motivation, the demand for better fuel economy, control, power and reliability are requested[1.7], [1.8]. A cost- effective solution to these demands is often found in an electronic fuel injection (EFI) and electronic ignition (EI) conversion, which replaces the often dated original and often mechanical fuel and ignition system by a more precisely controllable electronic system[1.9], [1.10]. The added control offered by these systems also allows for improved emission performance at the cost of system simplicity[1.11],[1.12]. Great opportunity Given modern improvements in the ability to process[1.1], model[1.2] and measure[1.3],[1.4] the operating conditions of the internal combustion engine, an opportunity is presented to greatly improve the performance of older combustion engine powered hobbyist cars and motorcycles. Which is of the essence amongst ever more stringent emission demands[1.5] to allow for the longer survival of the hobby, amongst a world switching to the electric motor vehicle[1.6]. These conversions are however often found to be inaccessible for most hobbyist due to the complex calibration and often substantial costs of these systems[1.11] in comparison to the original system. An issue which was proposed to be addressed by the development of a more affordable and simple electronic fuel injection and ignition system by retaining only the most necessary of functions and sensors, simplifying calibration and reducing system complexity. Road to progress During this report the initial step towards such a system will be discussed through means of an advanced analysis of the system to be controlled. Starting off with research towards common combustion engine operation principles, from which a numeric combustion engine model in the MATLAB environment will be created. This model will then be used along with the research into common engine operating principles to distill
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