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NI Combustion Analysis System Software for LabVIEW User Manual

1. User s Manual DiAdem VIEW EXAMPLETDV beaks File View Insert Settings Window Help 12 x Ea 09 OMe m EN 4 rire Se Wwe DOD 2 wl HAA ew hy Oe Data Portal Internal Data x NAVIGATOR O KF Er le AAIEN a DRVN_017MAP0201_000 a Bite Cyde oO 2 Time p 12 Speed P2 cycle Gly Volume a 12 Crank Angle P2 volume s 12 avolume 4 li cylinder Area a E fife Synchronous amp 12 Time i 12 MAP 1 1B CylPress1 ol 12 RailPress gt 12 SparkCurl 25 F2 Injectioncurt z4 P2 RailCur 5 a g3 1 knock12 2 12 Knock34 1 12 SparkCoild ot ee ee ae i SparkCoil2 2 7263E 12 2 72632E 12 oe SparkCoil4 12 InjectionVi 12 InjectionV2 EP All Cha A f2 InjectionV3 Name Time Speed Tyde Crank Ange Volume aVolume Cinder Ar P Injections a Number i 2 3 4 5 Je 7 ne p Length 1965 3965 1965 3600 3600 3600 3600 N structure Aust 7 Unit ns RPM caD liter liter m2 Common Properties Channel Contents Name E 2 72144533507 _ 3450 85400390625 17670 360 0 045299993569 2 246350049937 10 0110835 Description 2 2 7214800956E 3452 42016601562 17671 359 799987792 0 4 55789268016 0 0110836 Unit E 2 7215148474 3452 5966796875 17672 359 600006103 0 9 11578536033 0 0110839 Minimum 4 2 72154959182 3453 6748046875 17673 359 399993896 0 1 36755406856 0 0110845 Maximum 5 2 72158432822 3454 52221679687 17674
2. s Knock Settings SE Reference CAD Knock CAD Filter kHz Signals Filter Cutoffs Filter Results Threshold Cylinder 2 Current Fay Cylinder3 Oto 0to0 7 Holdi E Cylinder 4 0to0 0to0 J Hold 2 A Cylinder 5 0to0 0to0 Fl Hold 3 pa Cylinder 6 A 8 g Cylinder 7 v Hold 4 A amp Cynder YiHolds By X F Cylinder 9 0to0 0to0 7 Hold 6 S J a Cylinder10 0tod Oto 5 ae Cylinder11 0to0 0to0 7 Hola7 E E Cylinder12 Oto0 0to0 V Filter ANI _Cylinder13 _ 0to0 0to0 Cylinder 14 Otod e Cylinder15 0to0 10 12 Cylinder 16 0to0 Frequency kHz Reference Start 210 CAD Knock Start 0 CAD v Current Faw Reference End 180 CAD Knock End 30 CAD 7 Hold1 High Cutoff 8 kHz Min Reference 0 r 7 Hold 2 1 Low Cutoff 5 kHz Threshold 0 5 OS j 7 Hold 3 3 a Hold 1 Clear1 7 Hold 4 3 WV A Hold 2 Clear 2 7 Hold 5 E andpass 8 a Hold 3 Clear 3 v Hold 6 e l A Filter Z ae NIV AN Hold 4 Clear4 7 Hold 7 5 Rectify 7 Filter WW Hold 5 Clear 5 Hold 6 Clear 6 gt K Integrate EPEE aas gt Hold 7 Clear 7 10 12 r lt F kH k Compare en reguency Ikik Knock Results Theoretical Knock Freq Gas Temp Calculation must be enabled The next step in calibrating knock is to determine the knocking frequency The frequency magnitude should be reality stable unless knocking Therefore the filter frequencies should include the knocking event but not other events The filte
3. Misfire Settings Lo e x j Misfire Peak Pressure v 1000 Threshold kPa O KJ Misfire Specifies the method to use for Misfire detection Threshold Specifies the threshold used to detect a misfire The use of the value depends on the misfire method used National Instruments All rights reserved 83 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 14 Simulation Settings The simulation settings allow the user to control how simulated waveforms are generated The simulation is enabled on the engine setup page s Simulation Settings X Speed RPM Simulation P t pEPNTererersrreysreyereyt a pares Cam Start Cam Duration Synchronous Pump Start SMUT nT uO 700 2000 3000 4000 5000 6000 Manifold Absolute Pressure 71 32 kPa abs 150 CAD 50 CAD 300 CAD Load 1 RPM Fuel Rail Pressure 10 9168 MPa abs 30 190 50 m 3 a 1 1 Ty Mn TR 25 9874 CAD ne E Exhaust Cam CAD Intake Cam 25 987 CAD Injection Location Injection Duration Spark Location Cid Lookup Tables Synchronous Pump Duration 10 9168 CAD 101 82 CAD 0 2707 ms 96 821 CAD 11 821 0 3053 6 8210 GD RunProfile Spark Dwell 1 ims 1 8210 0 9803 3 17897 3 PWM Frequency 10 kHz PWM Duty Cycle 20 9299 9 Speed Load iA Z S i Qa D eo u x a a 1 I I 1 I I 1 1 1 I 1 1 1 1 1 J i L I i i 1 I m 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
4. Horizontal Cut s Pressure Metrics Settings Standard Peak Pressure 60 Peak Pressure Start CAD 1 60 Peak Pressure End CAD Endpoints Polytropic g 2 Endpoint Window CAD 90 Polytropic Compression Start CAD w 60 Polytropic Compression End CAD 60 Polytropic Expansion Start CAD a 90 Polytropic Expansion End CAD 360 Intake Pressure Start CAD 300 Intake Pressure End CAD 300 Exhaust Pressure Start CAD 360 Exhaust Pressure End CAD L TDC Probe I 300 360 Si l l l l l 360 300 200 100 0 100 200 Crank Angle CAD 1 Detailed settings for the basic calculation group 2 Plot of current signals and windows Endpoint Window Exhaust Pressure End Exhaust Pressure Start Intake Pressure End Intake Pressure Start Peak Pressure Peak Pressure End Peak Pressure Start Polytropic Polytropic Compression End Polytropic Compression Start Polytropic Expansion End Specifies the size of the window used to average the endpoints when calculating the polytropic exponents Specifies the end of the exhaust pressure calculation Specifies the start of the exhaust pressure calculation Specifies the end of the intake pressure calculation Specifies the start of the intake pressure calculation Specifies the method used to calculate the peak pressure Specifies the end of the peak pressure window Specifies the start of the peak pressure window Specifies the method
5. Ca a TN s Analog Output Channels Setup 2 Physical Channel Disabled Type a Peak Pressure kPa abs cCDAQ1 Mod3 aol Maximum Speed RPM eDAQI Mod a02 Average Net Mean Effective Pre cCDAQ1 Mod3 a03 Coefficientof variation Name 50 Mass Fraction Burned CAD 2 Recent Name l Load Recent Name Net Mean Add Insert CEN sf Phsicat Chane COO ii coac Moc 200 Disable Oa S ee Type pop eve up Value Move n 10 Gain po owen es ee O Offset E a es Doo Ooo E e e o ef iai d 1 Summary of all defined outputs 2 Controls for manipulating the list of outputs 3 Detailed setup of the selected outputs AO Type Analog output type associate with the measurement Cylinder Cylinder associated with each measurement Disable Disables data acquisition and calculations associated with each measurement Gain Gain associated with each measurement Max Maximum voltage range associate with the measurement Min Minimum voltage range associate with the measurement Name Name or description associated with each measurement Offset Offset associated with each measurement Physical Channel Physical channel associated with each measurement Type Measurement Type associated with each measurement National Instruments All rights reserved 62 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2
6. Phase Random Z Encoder Setup A Rising Edge Disable FPGA _NoFPGA cDAQ1 Mod4 v Encoder Setup Error Encoder Resolution 360 ppr Random Z Phase 0 CAD Digital Filter 0 5 us Encoder Extrap Level 2 Encoder Divide 4 TDC Offset 0 CAD Max Speed 4500 RPM Actual TDC Offset 0 CAD Sample Resolution 360 ppr Cycle Resolution 720 ppc DIO Module EPT Sim Enable Engine encz DO ENCA TU Check Encoder maw r Measured Sample Resolution 360 Measured Cycle Resolution 720 Check Encoder l sesso sanson O Phase Random Z Encoder Setup A Rising E ews LLT extrap 4 LI Disable FPGA FPGA Actual TDC Offset Check Encoder Cycle Resolution Digital Filter Deployment Indicates the actual top dead center offset used by the engine position tracking system Updates the encoder debug scope Note Encoder must rotate at least 4 times for the scope to update once the button is pressed Indicates the calculated cycle resolution Defines the digital glitch filter used by the engine position tracking system National Instruments All rights reserved 46 Encoder Debug LED Encoder Divide Encoder Setup Error Encoder Extrap Level Encoder Resolution Encoder Setup EPT Sim Enable Max Speed Measured Sample Resolution Measured Cycle Resolution Disable FPGA Phase Random Z Phase Sample Resolution TDC Offset cDAQ DIO Module
7. 1 Plot of current signals and rising and falling edges 2 Selection of cylinder to display 3 Detailed setup of the selected cylinder Exhaust Cam Edge Angles Exhaust Cam Edge Count Exhaust Cam Edge Directions Intake Cam Edge Angles Intake Cam Edge Count Intake Cam Edge Directions Specifies the angle for each exhaust cam pulse of each cylinder Specifies the number of exhaust cam pulses for each cylinder Specifies the direction of exhaust cam pulse for each cylinder Each cylinders data is stored in a bit field corresponding to each pulse Specifies the angle for each input cam pulse of each cylinder Specifies the number of intake cam pulses for each cylinder Specifies the direction of intake cam pulse for each cylinder Each cylinders data is stored in a bit field corresponding to each pulse National Instruments All rights reserved 80 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 11 Injection Settings The injection settings define how injection waveforms are processed The injection calculations measure starting angle duration and fuel flow for each injection Fuel Rail Pressure Fuel Rail Pressure Source Min Injection Signal Type X Fuel Pressure Y Duration Z Fuel Flow s Injection Settings xs Duration ms mg Inj g SM 0 000 1 000 a 0 000 0 000 0 000 1 000 0 000 0 000 m 2 4 a U 3 u
8. User s Manual 4 2 3 Forward and Reverse IIR The Forward and Reverse Infinite Impulse Response IIR filter requires filtering frequency lowpass and filter order inputs The Butterworth filtering method is used with a sampling frequency of 200 Hz The filter order dictates the response of the signal roll off where a higher order has a steeper roll off This filter is passed in both forward and reverse directions to avoid shifting the phase of the waveform National Instruments All rights reserved 116 NI Combustion Analysis System Software for LabVIEW User s Manual 4 2 4 FIR Filter with Rollback The FIR Filter with Rollback requires filtering frequency lowpass and filter order inputs This filter is a backward looking moving average which smoothes a signal by marching through the waveform and averaging N 1 points before each given point including the point itself In this case N is also the filter order This filter method shifts the phase of the waveform N 2 points to the right therefore rollback is necessary to correct the phase of the signal National Instruments All rights reserved 117 NI Combustion Analysis System Software for LabVIEW User s Manual 4 3 Cylinder Pressure Pegging In the case that in cylinder pressure is measured using a dynamic pressure transducer e g piezoelectric the captured waveform must be pegged to an absolute value in order to obtain accurate results U
9. Disable Filter Cutoff Gain Max Min Name Offset Physical Channel Cold junction compensation channel associated with each measurement when using a channel cold junction compensation source Cold junction compensation source associated with each measurement Cold junction compensation value associated with each measurement when using a constant cold junction compensation source Disables data acquisition and calculations associated with each measurement Knock Threshold for Each Cylinder Gain associated with each measurement Maximum voltage current or temperature associated with each measurement Minimum voltage current or temperature associated with each measurement Name or description associated with each measurement Offset associated with each measurement Physical channel associated with each measurement National Instruments All rights reserved 59 NI Combustion Analysis System Software for LabVIEW User s Manual Save Trigger Enables the channel to be used to trigger the start of a file save Each index is associated with each measurement Scaling Scaling method associated with each measurement Terminal Terminal configuration associated with each measurement Configuration Thermocouple Type Thermocouple type associated with each measurement Units Units associated with each measurement National Instruments All rights reserved 60 NI Combustion Analysis System Software for LabVIEW User s Man
10. Filter Cutoffs Filter Results Threshold 03 0 25 o N Integrator Oo BR N Data Set Knock j 0 0 1 2 3 4 5 6 ve Data Set xs Last the filtered window results are integrated and compared The threshold should be set to determine where knock starts The threshold is removed to get the final knock value Any value above zero is considered knock Greater knock values indicate greater levels of knock The threshold page shows the results of the integration and the raw and final results of the comparison National Instruments All rights reserved 79 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 10 Cam Settings The cam settings are used to calculate cam phasing The system should be set up for each cylinder separately The setup button analyzes the cam signal and generates an array of angles for rising and falling edges to compare to calculate the phasing The baseline settings should be set when the phaser control is turned off or disconnected s Cam Settings o 2s Pe Cylinder 1 0 8 5 0 6 K w pw c Falling 245 Falling 145 Care 300 Setup 6 Edge Count Falling 235 200 1 300 30 pps P ae 283 Setup 6 Edge Count Falling 153 Falling 53 I i I l l l epee 135 200 100 0 100 200 300 360 Rising _ Crank Angle CAD Falling 327
11. PXI Chassis Controller FPGA C Series Hardware S Series DAQ M Series DAQ SCXI Modules DAQ Accessories Host System NI PXI 1050 PXI Chassis With Integrated SCXI 8 PXI 4 SCXI Slots NI PXI 8119 RT 2 3 GHz Quad Core PXI Controller With LabVIEW Real Time 80GB or Greater 2 5 in SATA SSD NI PXI 7853R R Series Multifunction RIO With Virtex 5 LX85 FPGA e NI 9151 R Series Expansion Chassis for C Series I O e NI 9411 6 Channel 500ns 5 to 24 V Digital Input Module e NI SHC68 68 RDIO Digital Cable for R Series 2 to 4 NI PXI 6123 16 Bit 500 kS s ch Simultaneous Sampling Multifunction DAQ NI PXI 6251 16 Bit 1 MS s Multichannel 1 25MS s 1 Channel 16 Analog Inputs e 1 or 2 NI SCXI 1102 32 Channel Thermocouple Voltage Input Module e 1 or 2 NI SCXI 1102B 32 Channel Amplifier Module 200Hz Bandwidth 2 to 4 NI BNC 2090A Shielded Rack Mount BNC Connector Block 2 to 4 SH68 68 EP for S Series modules 1 or 2 TC 2095 for NI SCXI 1102 1 or 2 BNC 2095 for NI SCXI 1102B 2 to 4 SH96 96 for SCXI modules Recommended System CPU OS 1 6 GHz Multi Core or faster Microsoft Windows 7 8 National Instruments All rights reserved 12 NI Combustion Analysis System Software for LabVIEW User s Manual RAM 4 GB or more Hard Drive 10 GB or more free space Software NI LabVIEW Professional Development System NI LabVIEW Real Time Module NI LabVIEW FPGA Module NI DAQmx NI RIO NI LabVIE
12. Q get an error message when try to activate the software What do do A Refer to the Software Activation section Q Howdoladd my own calculations or results to the NI CAS Software A NI CAS Software provides the ability to easily integrate user calculations in three areas Processing Heat Release Rate and Calculations 1 Processing All of the results of the processing steps alignment scaling pegging separation are provided to the user calculations which can manipulate the waveform and other information before all of the calculations get the information 2 Heat Release Rate All of the results from the processing steps are provided to the user calculations which need to generate a heat release rate waveform The resulting waveform is then used to calculate mass fraction burned and other heat release related parameters 3 Calculations All of the results from the processing steps and calculation steps are provided to the user calculations The user calculations provide an array of calculated results to the NI CAS Software for display and saving in summary files NI CAS Software applications contain the ability to stream custom data from other parts of the application FPGA Data originates in the FPGA Each parameter needs to be assigned an ID All FPGA data streams to raw data files Only data with ID defined in the FPGA Setup are processed in real time and saved in summary files Slow Speed Data is read no more than
13. 359 200012207 0 1 82334333658 0 0110852 Length 7074000 6 272161907442 3454 1494140625 17675 359 Ji 0 0110862 NoValues No z 2 7216538329E 3452 42529296875 17676 358 799987792 0 010874 Flags No 3 2 72168859475 3452 45751953125 17677 358 600006 103 18754464387 0 011088 Monotony 3 2 72172334987 3452 06762695313 17678 358 399993896 0 64333391189 0 0110904 Status Read X 10 2 72175811047 3452 48486328125 17679 358 200012207 0 4 10247594118 0 0110923 IE e x 11 2 72179288625 3451 03515625 17680 358 n 455845147371 0 0110943 _ Select a channel tross the sniciiire ar fraia fhe Iit lt p ee ie ee ea ee Sree LLN sheets X Cursord 0 Cursord 0 Z Cursorl 0 Converting TDMS Files to Other Formats TDMS files can be converted to other formats and opened in a variety of interfaces Many resources are available on at http Awww ni com The NI CAS Software comes with an application to convert a group or folder of files from the TDMS format to text files Due to the change in how data is being stored text files will take 10 times the disk space as the TDMS files See Batch Processing for more details National Instruments All rights reserved 180 NI Combustion Analysis System Software for LabVIEW 5 5 Batch Processing Batch Process Raw Files to Summary files NI CAS Software contains an application to process raw files to
14. y 1 d d aQn o h A T T where dQ d8 rate of heat release y ratio of specific heats cp cy V cylinder volume dP d8 cylinder pressure derivative w r t crank angle P cylinder pressure dV d8 cylinder volume derivative w r t crank angle dQn d8 heat transfer derivative w r t crank angle h heat transfer coefficient Aw cylinder wall surface area T cylinder global gas temperature Tw cylinder wall temperature 1 Gatowski J A Balles E N Chun K M Nelson F E Ekchian J A Heywood J B 1984 Heat Release Analysis of Engine Pressure Data SAE Technical Paper Series 841359 2 Hayes T K Savage L D Sorenson S C 1986 Cylinder Pressure Data Acquisition and Heat Release Analysis on a Personal Computer SAE Technical Paper Series 860029 National Instruments All rights reserved 140 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 3 Single Zone Dual Transducer dQ 1 Prag dP n Ving a9 7 aaa Ve do Pe Gg er Eme Gg where dQ d8 rate of heat release n polytropic coefficient Vic main chamber volume dPmc d main chamber pressure derivative w r t crank angle Vpc pre chamber volume dPpc d pre chamber pressure derivative w r t crank angle Pmc main chamber pressure dV mc d main chamber volume derivative w r t crank angle 1 Grimm B M Johnson R T 1990 Review
15. 1 NI CAS Software File Structure Groups Channels Volume e Crank Angle e Volume e dVolume e Cylinder Area User Properties File Settings Basic Settings Cam Settings e 0 15 Filter Settings e 0 15 Engine Geometry Setup Synchronous e Time e Al0 15 e TDC e Data e Reduced Resolution e Reserved e DI4 15 e DI Data Heat Release Settings Injection Settings Knock Settings e 0 15 Misfire Settings Pegging Settings Gas Temperature Settings Separate Settings TDC Offset Settings Asynchronous e Time Use R S R S R S R S R S C R S C O R C N O 0 1 Z B BQ Of QO Of A EO Cf A olal ol ofa Q O Description Pre calculated volume related waveforms Cycle crank angle Cycle volume Cycle volume derivative Cycle cylinder area User specified properties File settings Basic settings Cam settings Cam settings for each cylinder Filter settings Filter settings for each filter Engine geometry setup Engine synchronous data Sample timestamp Synchronous channel Digital channel setup Digital channel setup Digital channel setup Digital channel setup Digital channel setup Digital channel data in bit field Heat release Settings Injection Settings Knock Settings Knock settings for each cylinder Misfire settings Pegging settings Gas temperature settings Separate settings TDC offset settings Asynchronous data Sample timestamp National Instruments All rights re
16. 3 IF DCAT is Activated the files may be processed When the Process Files button is pressed all of the selected raw data files will be porcessed The Current File File Porgress and Total Progress may provide feedback on the status of the conversions The porcess may take 1 2 min for each 100MB of raw data There is not way to stop the process after it starts 4 Exits the VI Batch Process TDMS files to Text files User s Manual NI CAS Software contains an application to process TDMS files to text files The application can process up to 8 files in parallel The user selects a source folder and the desired files to process The summary files are placed in the specified folder National Instruments All rights reserved 181 NI Combustion Analysis System Software for LabVIEW User s Manual 4 Batch Process TDMS Files to Text Files ES 1 2 Raw Data Folder Summary File Output Folder C Data C Data Filter Files Selected Keep Directory Structure tdms Refresh 2 Prefix Suffix D DRVN_O18M4P0105_001 tdms D DRYN_022MAP0303_035 tdms D DRYN _O22MA 0_046 tdms Process Files 1 Select the data for conversion Select the Raw Data Folder This is the root folder that contains all the raw data files you wish to convert Edit the File name Filter if needed Its default setting is to find all TDMS files Select the indivigual Files From th
17. All rights reserved 2 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 4 Filter Settings nine ee e aea E ential aie aE E eames tattaast 69 3 2 1 5 Pressure Metrics Settings nosnennseeeeeeeeeeeeeeeeeterrrrnrrrrrrrrrssssssrtttrrrrrnnnrnnnnsnssrennnee tenn 70 3 2 1 6 Unit Conversions Settings 2 550 cet ects lata sc Slickdeals caatesnsy oretett cee reer eeettadatoces 72 3 2 1 7 Temperature Settings wi o2205 sseecceni ceases casts cate ceteacs cacedeuian hedecce ech sed aad eas oc 73 3 2 1 8 Heat Release SOUING S222 cP ccc trees teeth 8 tdeee nenene e tapeintsts aeweesacs Saekte a encen deere rsvetaeweeeees 74 3 2 1 9 Knock Settings scx ccsicies chee oe lta ecece cachet ee Neate ceed cannscaceuedet cine n A EERE REE aa iaee EREE 76 3 26 OAC Amy SRUING Sec Sn Ol Nee heat ae Te A sel ae ee areata mete al Rios 80 3 2 1 11 Injection Settings wesc c 28 eso cetdec ede caaisac acts lectus acedebigncdcdsecendetecengecuaeetaettassdacheevea es 81 3 2112 Spark SeA S ihc as cites Leathe a mutt Lacie eaten dilate PE Ea r neta as 82 3 2 1 43 Misfire SCUINOS 3 2 520522 coon aaaeei enana ne nerenin taba ceteeeab Seo civechaescateiseetecnawscene 83 3 2 1 14 Simulation Settings 4 5662 ak cet eatd ace Sc Gl che es eta acess Ge tett coe are ceeeeete ata tuee 84 O22 FUG AVG cece ee ss E hn ee aay Aa a eee es Sa ee ok kee athe oe ee a 86 DAZ I RAV PIGS SAVES x2 2ecccth iki ite enact hls Bit a E eee aea SEA AEEA teats asd 87 3 2 2 2 S
18. Features Development Deployment e Open source example projects for integration with real time control applications eX e Next cycle control capabilities a e FPGA based high speed signal processing ee TF a ea e Low cost feature rich turnkey bundled system License Version Measurement Configuration and Engine Geometry Development Deployment e Individual channel scaling features X e Cylinder Assignment Gain Gain Offset Polynomial Table Lookup e Channels can be assigned to all cylinders as references such as pegging X X e Simultaneous engine synchronous and engine asynchronous X measurements e Medium Speed Data Sampled at a fixed frequency 1kHz or less X X e Thermocouples e Slow Speed Pressures e Other e Supports FPGA Data Sampled based on FPGA setup engine synchronous and or asynchronous e Digital outputs for sample clock and active high during logging X X e Supports multiple S Series devices for simultaneous sampling of signals X in both engine synchronous cylinder pressure etc and engine asynchronous knock etc domains e Supports 1 M Series device for multiplexed sampling of signals engine X synchronously cylinder pressure etc National Instruments All rights reserved 6 NI Combustion Analysis System Software for LabVIEW User s Manual e Supports 1 cDAQ chassis and multiple C Series devices for simultaneous X sampling of signals in both engine synchronous cylinder press
19. File Queve Medium Speed Medium Speed HHHH Write Summary DAQ Buffer Data to Disk Stream Raw Data to Disk National Instruments All rights reserved 97 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 3 6 Loop The loop status display indicates execution status of each NI CAS Software loop FPGA Control Count 0 FPGA Control Period FPGA Control Time 900 0 ms DAQ Count 1566 DAQ Period 100 0 ms DAQ Time 001 8 ms Align Count 157174 Align Period 001 0 ms Align Time 000 0 ms Raw File Count 31513 Raw File Period 005 0 ms Raw File Time 000 1 ms Summary File Count 6266 Summary File Period 002 2 ms Summary File Time 000 0 ms Process Count 6266 Process Period 001 5 ms Process Time 002 2 ms Next Cycle Control Count 0 Next Cycle Control Period 000 0 ms Next Cycle Control Time 000 0 ms Display Count 6266 Display Period 002 2 ms Display Time 000 3 ms 1 2 3 e 1 Loop Count Shows the current iteration of the specified loop 2 Loop Period Shows the current period of the specified loop 3 Loop Time Shows the current execution time of the specified loop National Instruments All rights reserved 98 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 3 7 Error The error status display shows an error and warning message for each loop in the NI CAS Software The errors are accompanied with an error number and an error message An new error state
20. K 6 18 Cige 0 C2ge 273 Wall Temperature BDC K 2 28 Cic 0 C2 273 Wall Temperature TDC K 2 28 Cle 0 00324 Cle Start of Combustion End of Combustion N Above Zero v Boxcar Average Below Zero v 20 Start Angle CAD 60 End Angle CAD 5 N Start 5 N End j Woschni Coefficient 1 for Compression Default 2 28 Woschni Coefficient 1 for Combustion and Expansion Default 2 28 Woschni Coefficient 1 for Gas Exchange Default 6 18 Woschni Coefficient 2 for Compression Default 0 0 Woschni Coefficient 2 for Combustion and Expansion Default 0 00324 Woschni Coefficient 2 for Gas Exchange Default 0 0 Specifies the angle to end looking for the end of combustion Specifies the method used to determine the end of combustion Specifies the method used to calculate heat release Defines the heat transfer when using the constant Heat Transfer Correlation method Specifies the method used to calculate the Heat Transfer Correlation Specifies the number of samples to use when determining the end of combustion Specifies the number of samples to use when determining the start of combustion Specifies the method use to calculate the polytropic exponent Specifies the volume of the prechamber used in dual transducer calculations Pressure waveform smoothing factor as a percent of one engine cycle National Instruments All rights reserved 74 Start Angle Start of Combustion User Heat Release VI Wall Temperatu
21. N Chun K M Nelson F E Ekchian J A Heywood J B 1984 Heat Release Analysis of Engine Pressure Data SAE Technical Paper Series 841359 National Instruments All rights reserved 152 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 3 3 Propane SAE841359 y 1 375 6 99 10 T where y ratio of specific heats T cylinder global gas temperature K 1 Gatowski J A Balles E N Chun K M Nelson F E Ekchian J A Heywood J B 1984 Heat Release Analysis of Engine Pressure Data SAE Technical Paper Series 841359 National Instruments All rights reserved 153 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 3 4 Custom The custom option for the polytropic correlation allows the user to input values for coefficients a and b to be used in the following linear correlation y a T K b where y ratio of specific heats T cylinder global gas temperature K National Instruments All rights reserved 154 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 4 Start and End of Combustion A precise definition of the start of combustion SOC and end of combustion EOC is required for accurate calculation of the mass fraction burned MFB crank angle locations The SOC and EOC are used to define a window over which the cumulative heat release is calculated from the heat release rate HRR waveform The following
22. Next Cycle Calculations iesistie e aerarii 49 3 1 1 6 System Optimiza tioN saien e aT E a id EEDS 50 3 1 2 WO Hardwa e Se UID nsin n a D a a eaa a 51 3 1 21 Sample Rat s Setup sacia a a Sante aaae e a a raa 52 3 1 2 2 Sync Analog Channels Setup s 2c cc h needed Mel eel dened heist eee nnn 53 3 1 2 3 Sync Digital Channels Setup ccsscceieie sce eesicte ence cae aiarecae aielassatin edie eet 55 3 1 2 4 Async Analog Channels Setup 2 c s c cccicct tec enee eee ee eneeeene ese cnee de cenee ee eeennedeeeereeecnene 56 3 1 2 5 Async Digital Channels Setups cssiccesccivccssen cides tcc htins seennty eaneteneie ade eo sane dee eteenetatn keene 58 3 1 2 6 Medium Speed Channels Setup ccccccccccccecccccceeeeeeneeesseesseeeeeeeeeeeeeeeeeeeeeeeeenseaaeeees 59 Obes PP GAUSUGAIM 6 lUD es crt poacsaccatanantatuay a ais as een ieee ealuannanicaialaateel 61 3 1 2 8 Analog Output Channels Setup sc icivcirsccasisi ocd hotoapeaiaies ohelenilassloeaeechscsdcconbetharaiionane 62 3 2 MING aa ace slats ates tie fat hts eM ta ese aa aides oes ioe Rohe fe oe dons oe etna io ees e ied 63 9 2 Al SEUNG S cre he ce oiac ee aa a ett es a a E aetna 64 3 2 1 1 Motoring and TDC Offset Settings ccc ciccccscseeceginteinecene ded nastvecaat nielanoat o sedeeeneteeene eect 65 3 2 1 2 Async Conversion Settings sis cccecdencc neue desi eeeteieniciles ceed 67 3 2 1 3 Pegging SCUIMGS esnai e a seats a ntesede ee E add aa aa aae aaa a 68 National Instruments
23. Online National Instruments All rights reserved 63 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 Settings National Instruments All rights reserved 64 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 1 Motoring and TDC Offset Settings The Motoring TDC Offset window is a tool to assist the user in correctly phasing sampled engine synchronous data with calculated volume data In general this window should only be utilized while the engine is motoring or spinning without firing Several methods for finding the TDC Offset include positioning the peak pressure with the use of a thermodynamic loss angle positioning a TDC probe signal and manual input s Motoring and TDC Offset Settings 28 Reference Cylinder Detailed Py tog _ 1 v Intake lava 10000 1 4 v Compression Peak Pressure Peak Pressure Location j s v Expansion A T 4633 57 kPa 0 41 CAD 2 1000 J Exhaust A 4 TDC Probe Location amp 7 PolyC m D NaN CAD ic 7 PolyE W 5 IMEP COV of IMEP 3 100 37 0461 kPa 0 0044 6 Polytropic Coefficient Thresholds 131 PolyCLow 136 PolyC High aoe 01 0 506334 1 35364 PolyC Out of Range a yo wn Volume liter 1 33 PolyE Low 1 4 PolyE High Cylinder Pressure 1 35099 PolyE yer ee 7 Cylinder1 n 0 5 0 5 i t 0 dPoly Low dPoly High 4700 0 00265 dPoly joo 2 A TDC Offset Reference TDC Fine Adjust
24. P0 2 PFI 2 DI 2b Expected Encoder Signals The Deployment Version of NI CAS Software allows for a variety of encoders and triggering options by using the Engine Position Tracking EPT FPGA cores to synchronize the DAQ sampling The FPGA block accepts only the encoder pattern The encoder pattern consists of evenly spaced A and B pulses combined with a once per revolution Z pulse An additional signal can optionally be used to determine the phase of a 4 stroke engine This can be any signal that has a unique pattern for the complete engine cycle e g a cam pattern cylinder pressure spark injector or similar The Development Version of NI CAS Software also has the ability to extrapolate low resolution encoder signals to increase the sample resolution greater than the encoder resolution Similarly the encoder signal can be divided to reduce the sample resolution Encoder A Encoder B 7 r Encoder National Instruments All rights reserved 18 NI Combustion Analysis System Software for LabVIEW User s Manual 2 2 2 Deployment Version Hardware Setup cDAQ Chassis Configuration NI cDAQ 9139 Stand alone The NI cDAQ 9139 must utilize a NI 9411 recommended NI 9401 or a NI 9402 digital input module for encoder inputs The Deployment Version of NI CAS Software is installed directly on the integrated NI cDAQ 9139 controller Microsoft Windows OS The user interface can be displayed on a monitor attached to the cDAQ
25. PE error Unbundling calculation inputs 3 Create start and end of combustion constants in degrees after top dead center DATDC then convert them to array indices using the Rotations Per Cycle and Sample Resolution inputs National Instruments All rights reserved 168 NI Combustion Analysis System Software for LabVIEW User s Manual SOC DATDC 20 EOC DATDC gt Engine Geometry Setup Rotations Per Cycle gt Samples deg SCORE Sample Resolution ppr Defining and converting SOC and EOC to indices Note Waveform array indices start with 0 at 180 2 stroke or 360 CAD 4 stroke before compression TDC For example with a 3600 pulse per revolution encoder on a 4 stroke engine the indices will range from O to 7200 with 3600 being compression TDC Sample Resolution Index DATDC 180 or 360 360 deg 4 Index an array subset from the heat release rate waveform starting with the SOC and ending at the EOC with duration EOC SOC This array subset corresponds to the period during which combustion is occuring Using a For Loop this discrete subset can be integrated using shift register terminals and an add block The result is the scalar value for cumulative heat release in Joules SOC DATDC 20 EOC DATDC Rotations Per Cycle Samples deg solution ppr Indexing the heat release waveform and calculating the integral 5 Pack the scalar result and value name into a cluster u
26. System Software for LabVIEW User s Manual 100 80 60 40 Injector Voltage V 20 Crank Angle CAD Piezo Voltage National Instruments All rights reserved 135 NI Combustion Analysis System Software for LabVIEW User s Manual A beyo s0 9afu c o fag a Crank Angle CAD 136 National Instruments All rights reserved NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 Heat Release The heat release rate or dQ dt represents the difference between the chemical energy or heat released by combustion of the fuel and the heat transfer from the system 1 The CAS software calculates the heat release rate using several user selectable mathematical models including Single Zone Single Zone Heat Transfer Single Zone Dual Transducer Single Zone Dual Transducer Heat Transfer Modified Rassweiler and Withrow Pressure Ratio For those models including heat transfer the following correlations are available for selection Constant Woschni 1967 Woschni 1990 Hohenberg In the cases where heat transfer is neglected adiabatic the polytropic process is considered reversible and therefore isentropic If an ideal gas is assumed the polytropic coefficient is constant and equal to the ratio of specific heats Y n 2 However when heat transfer is calculated the following polytropic correlations are available for selection Hayes Ind
27. T x aj Fuel Rail Pressure Source DAQ Channel Duration Size 2 Fuel Pressure Size 2 Signal Voltage o Type DI Solenoid Min Injection 0 1 in Injection ms Defines the fuel rail pressure of the injectors Determines the source of the fuel rail pressure used in determining fuel flow Defines the minimum injection width Defines the injector signal type Defines the injector type Defines the X Axis Fuel Pressure of the 2d injector calibration table Defines the Y Axis Duration of the 2d injector calibration table Defines the Z Axis Fuel Flow of the 2d injector calibration table National Instruments All rights reserved 81 dwell for each spark Min Dwell Restrike Delay Signal NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 12 Spark Settings The spark setting determine how spark signals are processed The spark calculations determine the spark angel and x Spark Settings Signal Voltage Min Dwell 0 1 Restrike Delay 1 ms k A ms f J eae j Defines the minimum dwell width Defines the maximum restrike delay Defines the spark signal type National Instruments All rights reserved 82 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 13 Misfire Settings The misfire settings determine how a misfire event is determined
28. THE USER OR APPLICATION DESIGNER IS ULTIMATELY RESPONSIBLE FOR VERIFYING AND VALIDATING THE SUITABILITY OF NATIONAL INSTRUMENTS PRODUCTS WHENEVER NATIONAL INSTRUMENTS PRODUCTS ARE INCORPORATED IN A SYSTEM OR APPLICATION INCLUDING WITHOUT LIMITATION THE APPROPRIATE DESIGN PROCESS AND SAFETY LEVEL OF SUCH SYSTEM OR APPLICATION National Instruments All rights reserved 195 NI Combustion Analysis System Software for LabVIEW User s Manual 9 6 Environmental Management National Instruments is committed to designing and manufacturing products in an environmentally responsible manner NI recognizes that eliminating certain hazardous substances from our products is beneficial not only to the environment but also to NI customers For additional environmental information refer to the NI and the Environment Web page at ni com environment This page contains the environmental regulations and directives with which NI complies as well as other environmental information not included in this document National Instruments All rights reserved 196
29. The user specified position is usually the default cam position or the position where the cam returns without power x Cam Settings Lo bel Cylinder 1 Setup n 6 Edge Count amp 0 6 n Z Falling 233 o Falling 133 Risings 57 I P abe 300 200 100 100 300 a60 Falling 24 Crank a CAD 297 1 Setup 0 8 6 Edge Count 5 0 6 HU Falling 167 x o iasa 27 Falling 67 a l meg IDE l im l 123 360 300 200 100 0 100 200 300 360 Rising Crank Angle CAD Falling 313 National Instruments All rights reserved 159 NI Combustion Analysis System Software for LabVIEW User s Manual 4 13 Synchronous Pump NI CAS Software uses a digital signal with rising and falling edges to determine the start end and duration of multiple pulses over the span of one engine cycle The number of pulses is reported along with the start end and duration for each pulse 7 Cylt Cyl2 Cyl3 Cyl4 Avg Pas s Plot Synchronous Pump Synchronous Pump aa 360 HA I 300 250 1 200 i 150 1 100 j I 1 50 0 50 Crank Angle CAD l i i l i T 100 150 200 250 300 359 National Instruments All rights reserved 160 NI Combustion Analysis System Software for LabVIEW User s Manual 4 14 PWM NI CAS Software uses a digital signal with rising and falling edges to determine the f
30. Tools Data Window Help OBE RBAGORAIYH Xam FI E 2l kli 0 Baa E E About g J333 M fe 1 A B c D E F Root Name Title Author Date Time Groups Description Summary_001 Group Channels Description Cylinder_1 38 Ensemble Average 11 COON kona Cylinder_1 Channel Datatype Unit Length Minimum Maximum Description Coefficient of Variance Mean Ni_ArrayColumn Standard Deviation Start index Peak Pressure kPa abs DT_FLOAT 190 849976 6198 100342 2 641693711 5638 233765 198 5931473 LOC PP CAD OT_FLOAT 15 5 25 28 26742744 1 815000057 0 684071794 PolyC DT_FLOAT 0 985251635 1 079280943 1 076011777 1 037295341 0 014881893 PolyE DT_FLOAT 0884210229 1106829375 2 8040151 1 000904739 0 037420694 Intake Pressure kPa abs DT_FLOAT 40 03009701 109 6497002 9 226884842 75 88676262 9 335978508 Exhaust Pressure kPa abs OT_FLOAT 7 17280006 129 7148895 7 633623362 93 58624649 9525361776 Max Press Rise kPa CAD DT_FLOAT 739 2883301 1264 801025 8 340785265 978 3118286 108 7985229 MPR Location CAD DT_FLOAT 0 75 15 7 425747871 0 757499993 0 075000057 IMEP kPa DT_FLOAT 204 4370499 241 8543091 2 588683426 221 8386841 7 656934977 PMEP kPa DT_FLOAT 26 38108921 13 73475409 8 221258879 20 537148 2 251216114 NMEP kPa DT_FLOAT 186 6294708 219 9280243 2495105982 201 301506 6 696914434 5 MRB CAD DT_FLOAT 0 292098999 0 207183838 63 04363632 0 063247835 0 053164981 10 MFB CAD DT_FLOAT 0 032730103 _0 311576843 22 80360746_ 0 14106125
31. User s Manual 4 9 2 1 Constant This setting uses a constant user input for the heat transfer coefficient in units of Wim K National Instruments All rights reserved 146 4 9 2 2 Woschni 1967 3 26 mas 0 2 0 8 0 55 70 8 Gam PYST W 7 C Sp Co P P wW 1 9p T a Gas Exchange C1 6 18 C2 0 Compression Cy 2 28 C2 0 Combustion and Expansion Cy 2 28 Co 3 24 x 10 where h heat transfer coefficient W m K N engine speed RPM B cylinder bore m P cylinder pressure kPa T cylinder global gas temperature K w mean cylinder gas velocity m s Sp mean piston speed m s Vp displacement per cylinder mS V cylinder volume m Pm motored cylinder pressure kPa n polytropic coefficient NI Combustion Analysis System Software for LabVIEW User s Manual Tic Pive Vivc bulk cylinder temperature cylinder pressure and cylinder volume at intake valve closing respectively 1 Heywood J B Internal Combustion Engine Fundamentals McGraw Hill Inc New York NY 1988 2 Woschni G 1967 A Universally Applicable Equation for the Instantaneous Heat Transfer Coefficient in the Internal Combustion Engine Society of Automotive Engineers Paper 670931 National Instruments All rights reserved 147 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 2 3 Woschni 1990 This modified version of Woschni s corr
32. a 4600 7 o Peak Pressure x 0 CAD 5 m 4 ad 2 4550 Loss Angle Set TDC Offset 7i 4500 0 5 CAD OK Calc TDC Offset TDC Offset Change N j 1 1 1 1 1 1 1 1 L 1 I 1 j 1 1 1 09 CAD 0 09 CAD 5 4 5 4 3 5 3 2 5 2 1 5 1 0 5 0 0 5 1 15 2253354455 5 Actual TDC Offset HEA Crank Angle CAD gt 1 CAD j 1 Selection of the reference cylinder to be used for calculating a TDC Offset 2 Relevant motoring values based on the statistical mean 3 Calculated polytropic coefficients for reference 4 New TDC Offset settings using Peak Pressure or a TDC Probe 5 Current and calculated TDC Offset values 6 Detailed P V diagram including the calculated compression and expansion polytropic coefficient lines 7 Plot of cylinder pressure and TDC probe if selected vs engine position Actual TDC Offset Indicates the actual top dead center offset used by the engine position tracking system Calc TDC Offset Indicates the calculated new TDC offset based on the TDC Offset reference and associated parameters National Instruments All rights reserved 65 COV of IMEP dPoly dPoly High dPoly Low IMEP Loss Angle Out of Range Peak Pressure Peak Pressure Location PolyC PolyC High PolyC Low PolyE PolyE High PolyE Low Reference Cylinder Rolling Stats Size Set TDC Offset TDC Fine Adjust TDC Offset TDC Offset Change TDC Offset Reference NI Combustion Analysis System Software for LabVIEW User s
33. cycle loop from the CAS PXI FPGA to the engine control FPGA target Copy the PXI folder containing TRIGO 7 from the CAS PXI FPGA target to the engine control FPGA target 5 Make sure the encoder signals are connected to the appropriate sources 6 Compile the engine control FPGA VI Real Time Pe Open CAS Target vi under the PXI target Copy the contents of CAS Target vi into your engine control target VI Remove the SCM Init VI and FPGA Open Reference function copied from the CAS example Connect the the SCM Init VI and FPGA Open Reference function from your engine control application to the copied CAS code National Instruments All rights reserved 30 NI Combustion Analysis System Software for LabVIEW User s Manual Note The FPGA reference must be set to Dynamic mode National Instruments All rights reserved 31 NI Combustion Analysis System Software for LabVIEW User s Manual 2 4 Performance National Instruments All rights reserved 32 NI Combustion Analysis System Software for LabVIEW User s Manual 2 4 1 Development Version Performance Overview The performance of the system depends on many factors including PXI Controller Speed Ram amp OS Microsoft Windows or Real Time DAQ Hardware Limitations Sampling Rate Response Times Engine Speed Cylinder Measurement Count Asynchronous Sampling Rate Medium Speed Data Number of Channels and Sample Rate FPGA Data Number of Channels an
34. if currently stopped Displays the state of the file writing process Indicates if a new file will be written or an old file will be overwritten Presses the Start Stop File buttons on Raw File and Sum File dialogs at the same time Current files path and name when saving Location on the target system where data will be saved Name of saved files XXX is replaced by the File Counter and standard data time formats c are applied to the name User comments added to the file Single One file is written and saving stops Continuous A new file is started when the previous one finishes File Part increments by on for each file The saving process must be stopped manually Indicates the current part of a continuous multi part save Enables a size limit on file saving and defines the maximum file size National Instruments All rights reserved 89 NI Combustion Analysis System Software for LabVIEW User s Manual Time Limit Enables a time limit on file saving and defines the maximum time Cycle Limit Enables a cycle limit on file saving and defines the maximum number of cycle File Counter Indicates the current file count Reset Counter Value Desired value to set File Counter to when Reset Counter button is pressed Reset Counter Resets the file counter to the Reset Counter Value File Progress Indicates the approximate status of the file save compared with the file limit conditions Process File Contains a pa
35. it on the second computer You are not prohibited from transferring your software from one computer to another and you do not need to contact or inform NI of the transfer Because activation codes are unique to each computer you will need a new activation code Refer to How Do Activate My Software to acquire a new activation code and reactivate your software Deactivating a Product To deactivate a product and return the product to the state it was in before you activated it right click the product in the NI License Manager tree and select Deactivate If the product was in evaluation mode before youactivated it the properties of the evaluation mode may not be restored Using Microsoft Windows Guest Accounts NI License Manager does not support Microsoft Windows Guest accounts You must log in to a non Guest account to run licensed NI application software National Instruments All rights reserved 25 NI Combustion Analysis System Software for LabVIEW User s Manual 2 3 2 MAX Hardware Configuration National Instruments All rights reserved 26 NI Combustion Analysis System Software for LabVIEW User s Manual 2 2 2 1 Development Version MAX Hardware Configuration Using NI Measurement and Automation Explorer MAX configure the PXI chassis and real time controller Set the IP address to a desired static value Install the current versions of NI LabVIEW Real Time Module and the NI DAQmx Drivers along with any other desired
36. low side of primary ignition coil to measure the spark event and spark dwell Spark Current To measure the current drawn by the spark module attach a current probe to the low side of the primary ignition coil park Driver o D O fe a lt The signal should be similar to the following National Instruments All rights reserved 163 NI Combustion Analysis System Software for LabVIEW User s Manual Spark Current A Crank Angle CAD Spark Voltage The low side of the primary ignition coil can reach 400V Therefore a protective circuit is needed to prevent the high voltage from reaching the DAQ device A zener diode with a breakdown voltage of 1 2 the maximum analog input voltage is required 10V ADC 5V zener diode A resistor rated above 400V is also required It should be sized to limit the current flow to the zener diode 100 kQ and 1 4 W Please note Most DAQ devices and accessories have maximum voltage limits that should be followed Please refer to your hardware documentation for details IE the SCB 68 has a maximum voltage of 48V listed in the user s manual National Instruments All rights reserved 164 NI Combustion Analysis System Software for LabVIEW User s Manual park Driver Asepuooes The signal should be similar to the following National Instruments All rights reserved 165 NI Combustion Analysis System Software for LabVIEW User s Manual 300 200 1
37. methods are used to define these locations Start of combustion SOC Constant Defines a constant crank angle DATDC as the SOC N Below Zero Sets a crank angle DATDC to begin looking for a negative zero crossing in the HRR waveform After N points are found past the negative zero crossing the crossing is confirmed to be the SOC Boxcar N Below Zero Same definition of N Below Zero except that a Boxcar filter of window N is applied to the HRR waveform Also rather than using N points to confirm the crossing the first negative zero crossing is taken as the SOC N Above Zero Sets a crank angle DATDC to begin looking for the last positive zero crossing in the HRR waveform After N points are found past the positive zero crossing the crossing is confirmed to be the SOC Boxcar N Above Zero Same definition of N Above Zero except that a Boxcar filter of window N is applied to the HRR waveform Also rather than using N points to confirm the crossing the first positive zero crossing is taken as the SOC The following figure represents both the N Below Zero and N Above Zero conditions for calculating the SOC where 1 lt N lt 6 Heat Release Rate J CAD HRR jad A N m j co N Above Zero N not satisfied N Below Zero 20 18 16 14 12 10 8 6 4 2 0 Engine Position after TDC CAD End of combustion EOC National Instruments All right
38. of Simple Heat Release Computations SAE Technical Paper Series 900445 National Instruments All rights reserved 141 d y 1 d8 de y 1 d8 dQn e h A T T where dQ d8 rate of heat release n polytropic coefficient V me main chamber volume dPmc d main chamber pressure derivative w r t crank angle Vpc pre chamber volume dPpc d pre chamber pressure derivative w r t crank angle Pmc main chamber pressure dV mc d8 main chamber volume derivative w r t crank angle dQni d8 heat transfer derivative w r t crank angle h heat transfer coefficient Aw cylinder wall surface area T cylinder global gas temperature Tw cylinder wall temperature d 1 dP dP dV R e re TE Ve a d Bae n GQne a NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 4 Single Zone Dual Transducer Heat Transfer 1 Grimm B M Johnson R T 1990 Review of Simple Heat Release Computations SAE Technical Paper Series 900445 2 Gatowski J A Balles E N Chun K M Nelson F E Ekchian J A Heywood J B 1984 Heat Release Analysis of Engine Pressure Data SAE Technical Paper Series 841359 National Instruments All rights reserved 142 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 5 Modified Rassweiler and Withrow Jev n i d dP Ka ag R Par where dQ d8 rat
39. once per cycle and is saved in raw and summary data files The top level NI CAS Software example contains a template showing how to write the data The data enters NI CAS Software through a global variable where the user defines the name units and value for each item User Properties can be added to raw and summary files This data is captured at the beginning of a file and only written once NI CAS Software example applications write all CalPoints to the properties by default Q How do l add a miscellaneous sensor waveform to my display A To display and save any signal simply add it to the measurement setup and associate it with the appropriate cylinder It will be displayed with all the Al or DI data for that cylinder When do I need to align the TDC offset A The TDC offset must be aligned any time the encoder position is modified This includes changing the encoder A The TDC offset will change as a result of changing the encoder setup parameters These parameters may have a small effect on the relation of TDC to the encoder Z pulse Please see the section above for more details A The TDC offset will change as a result of changing the encoder resolution even if the Z pulse remains constant National Instruments All rights reserved 183 NI Combustion Analysis System Software for LabVIEW User s Manual Q How do l save the current configuration A To save the current NI CAS Software settings use the NI SCM Save Current
40. summary files The application can process up to 8 files in parallel The user selects a source folder and the desired files to process The summary files are placed in the specified folder r 4 Batch Process Raw Files PA Raw Data Folder C Data Filter tens Files Files Selected 2 O DRVN_018M4P0105_001 tdms D DRYN_022MAP0303_035 tdms D DRYN_022MAP0310_046 tdms Select All Deselect All al Summary File Output Folder C Data Keep Directory Structure Array Data Prefix Suffix Process Files Exit 1 Select the data for conversion Select the Raw Data Folder This is the root folder that contains all the raw data files you wish to convert Edit the File name Filter if needed Its default setting is to Find all TDMS files Select the indivigual Files From the list of Files using the standard windows selection method Hold Ctrl to select multiple items and Shift to select a range of items You may also Select All and Deselect All 2 Set the Summary File Output Folder You have the option to Keep Directory Structure of the Raw Data Folder You may also turn on the options to convert the summary files to Text Files or create Array Files containing all the processed array data for all the cycles The Prefix and Suffix are appended to the name of hte raw data file to create the name of the summary data file
41. using a separate or combined Y axis ARONS Only available with the Development License National Instruments All rights reserved 103 NI Combustion Analysis System Software for LabVIEW User s Manual s Plot Volume 0 6 S pes l Volume liter i o 1 360 I i 50 50 100 Crank Angle CAD j I j 300 250 200 150 100 2 o 0 006 dVolume liter I I I I 250 200 150 50 100 l 300 I 150 ay E lt as gt 9 0 01 SH I I 1 I I I 1 1 1 I EPI 360 300 250 200 150 100 50 0 50 100 150 200 250 300 360 Crank Angle CAD FeR l 250 I 150 200 This plot displays the results of the volume calculations or loading a volume file 1 Volume Cylinder volume as a function of crank angle 2 dVolume Differential cylinder volume as a function of crank angle 3 Cylinder Area Cylinder head and piston area as a function of crank angle National Instruments All rights reserved 104 NI Combustion Analysis System Software for LabVIEW User s Manual s Plot Pressure Pressure kPa abs I I 1 I j I I 360 300 250 200 150 100 50 0 50 Crank Angle CAD I I I I 11 100 150 200 250 300 360 This type of plot displays the results of a specific type of signal for all the cylinders and engine average for a single cycle 1 Plo
42. will cause the window to open lo 53 s Error Align Error DAQ Error Display Error FPGA Error i OOOO I OOOO 0 0 0 0 Next Cycle Error Process Error Raw Error Summary Error i o o 0 0 0 0 Display On Error National Instruments All rights reserved 99 NI Combustion Analysis System Software for LabVIEW User s Manual 3 3 Results National Instruments All rights reserved 100 NI Combustion Analysis System Software for LabVIEW User s Manual 3 3 1 X Axis All plots using Crank Angle as the X axis can be modified collectively by using the plot scaling tool at the top of the Plots tab The plot scaling tool contains several preset values that are commonly used to look at data as well as a custom setting which can be used to enter values not included in the presets s CAS Run Time Host File Seme E Calibration Snapshot INSTRUMENTS E Erer Medium Speed Data wooo S Spark Command Fuel Rail Pressure Injector Command Intake Cam Exhaust Cam PWM PE O National Instruments All rights reserved 101 NI Combustion Analysis System Software for LabVIEW User s Manual 3 3 2 Plots Plots display data in array form The NI CAS Software contains several different typed of plots that are used for different kinds of data Plots using Crank Angle as the x axis have global settings using the X Axis controls Most plots are resizable by dragging the corner or side of t
43. window The pegging window is centered about the pegging location National Instruments All rights reserved 120 NI Combustion Analysis System Software for LabVIEW User s Manual 4 3 3 Polytropic The Polytropic pegging setting requires a pegging location a pegging window and a constant polytropic coefficient to define the pegging reference The pegging location window should be positioned during the compression stroke after the intake valve is closed e g from 90 to 60 DATDC The following calculations are used to define the pegging reference P P 2new v n 1 2 Prep P2 Pr new Where location 1 and 2 are the average values at the respective endpoints of the pegging window specified P is pressure V is volume and n is the desired polytropic coefficient At each endpoint a smaller window is specified of which the average value is taken as the endpoint value 2 CAD means 2 CAD before and after a given point Finally the cylinder pressure is pegged by adding Pref to the original unpegged pressure waveform s National Instruments All rights reserved 121 NI Combustion Analysis System Software for LabVIEW User s Manual 4 4 Pressure Metrics Several important results are derived from the pressure waveform including peak pressure peak pressure location peak pressure rise rate peak pressure rise rate location polytropic coefficient of compression and polytropic coefficient of e
44. 0 18000 20000 Calculation Time Calculation time for each processing or calculation step Name and Color Name and color of the processing or calculation step Calculation Time Graphical representation of calculation time The plot maximum is the maximum allotted time available to finish the calculations NI Combustion Analysis System Software for LabVIEW User s Manual National Instruments All rights reserved 95 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 3 5 Buffer The buffer status display indicates the state of the NI CAS Software buffers The NI CAS Software buffers should not overflow under normal operation Each buffer is used in a different part of the system s Buffer x Alignment Queue MM 121072 Sync Size 2 Raw Fie Queue M 0 r Sync Process Use l a lll 15840 _ Sync Raw Process Use Feedback Queue g z 32768 Async Ind Size Display Queue a Daa i Summary Fie Queue en Saca eae 3960 Async Ind Raw Process Use l Next Cycle Ready CAD 524288 Async Size 2 24000 Async Process Use 132000 sync Raw Process Use 0 FPGA Size 0 FPGA Process Use 0 FPGA Raw Process Use 1 Medium Speed Size 0 Medium Speed Process Use J 0 Medium Speed Raw Process Use 1 Buffer Summary Each buffer holds and delivers data to a different part of the NI CAS Software 2 Alignme
45. 0 042889405 50 MFB CAD DT_FLOAT 0 538764954 1 210098267 13 27857399 0 74751547 0 132345859 75 MFB CAD DT_FLOAT 0 852653503 _2 903182983 26 02818775 1 385801017 0 480931833 90 MFB CAD DT_FLOAT 1 112411499 19 8550415 75 08928108 2 982174933 5 2 985724926 Max HRR CAD OT_FLOAT 63 28506088 126 4829178 9 724574804 9142874336 11 85474157 LOC Max HRR CAD OT_FLOAT 268 875 254 625 1 882509649 263 4000092 6 61137414 Misfire DT_FLOAT 0 0 0 0 0 Cycle Number DT_FLOAT 33352 5 33426 75 0 048874358 33389 625 21 75861883 Speed DT_FLOAT 1124 898102 1127 586456 0 038156094 1126 359283 0 57303299 Message DT_STRING Error DT_STRING Ensemble Average Channel Datatype Unit Length Minimum Maximum Description N _ArrayColumn Start Index Pcyl kPa _1 DT_FLOAT 7 Inject_Current A _1 DT_FLOAT 720 Rail_Pressure bar _1 OT_FLOAT 720 Temperature K _1 DT_FLOAT 720 41 Heat Release J CAD 1 DT_FLOAT 720 42 MFB Fraction 1 OT_FLOAT 720 43 M 4 mN Summary_001 root Cyinder_1 Ensemble Average Ready Opening TDMS Files in DIAdem DlAdem is a power full tool for viewing analyzing and presenting data When DIAdem is installed double clicking on a tdms file will open it in DIAdem National Instruments All rights reserved 179 NI Combustion Analysis System Software for LabVIEW
46. 00 100 200 300 Crank Angle CAD 166 National Instruments All rights reserved NI Combustion Analysis System Software for LabVIEW User s Manual 4 17 Custom User VIs While NI CAS Software incorporates many well known calculations and processing operations useful for combustion analysis inevitably each project is different and may require calculations not included in NI CAS Software by default To accommodate this NI CAS Software has the ability to execute custom user programmed VIs in three different locations processing heat release and calculations Processing algorithms are intended to manipulate waveforms e g cylinder pressure pegging before other calculations are performed Custom heat release allows the user to designate a non standard model for heat release Finally the outputs of user calculations are scalar values for which statistics are automatically calculated User Templates In order to ensure successful integration of a custom user VI user VI templates must be used as a starting point for all custom user VIs User VI templates are included with the installation of NI CAS Software in the example project as well as the following location in the LabVIEW directory examples Combustion Analysis Note The LabVIEW development environment is required to create a custom user VI Custom Application Cumulative Heat Release In this application the user desires to calculate the cumulative heat releas
47. 2 1 N19411 cDAQ2Mod1 2 N19215 BNC cDAQ2Mod2 3 N19215 BNC cDAQ2Mod3 4 NI9201 cDAQ2Mod4 Network Devices PX PXI System Unidentified Y Serial amp Parallel 44 Scales E Software M Drivers Q Remote Systems National Instruments Measurement amp Automation Explorer Measurement amp Automation Explorer MAX provides access to your National Instruments products What do you want to do Manage my devices and interfaces amp manage my installed National Instruments software manage virtual channels or tasks for my devices 44 Create scales for my virtual instruments ED Configure my IVI instrument drivers amp Imporvexport my device configuration file B Note Some categories are device specific For example the IVI category appears only if you have IVI installed National Instruments All rights reserved 29 NI Combustion Analysis System Software for LabVIEW User s Manual 2 3 3 Development Version Example Project and System Integration The Development Version of NI CAS Software can be run as a stand alone application using the NI CAS Software example application The following steps are required to run the NI CAS Software example Open the CAS example project From LabVIEW select Help gt Find Examples Search for Combustion Analysis Update the PXI target IP address for the user s PXI target Right click on the PXI icon in the project and sel
48. 42 44 46 48 50 52 54 56 58 60 f Time s J Speed and load settings N pre defined profile o Pre defined profile Cam Start Exhaust Cam Fuel Rail Pressure Injection Duration Injection Location Intake Cam Manifold Absolute Pressure PWM Duty Cycle Detailed simulation settings Specifies the simu Specifies the simu Specifies the simu Specifies the simu Specifies the simu Specifies the simu lated cam start lated exhaust cam offset lated fuel rail pressure lated injection duration lated injection locations lated intake cam offset Simulated settings mode Lookup tables adjust detailed settings based on speed and load Specifies the simulated manifold absolute pressure Run profile runs the Specifies the simulated pulse width width measurement duty cycle National Instruments All rights reserved 84 NI Combustion Analysis System Software for LabVIEW User s Manual PWM Frequency Specifies the simulated pulse width width measurement frequency Spark Dwell Specifies the simulated spark dwell Spark Location Specifies the simulated spark location Speed Specifies the simulated engine speed Synchronous Pump Duration Specifies the simulated synchronous pump duration Synchronous Pump Start Specifies the simulated synchronous pump start National Instruments All rights reserved 85 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 2 File
49. CANT INJURY TO A HUMAN 2 IN ANY APPLICATION INCLUDING THE ABOVE RELIABILITY OF OPERATION OF THE SOFTWARE PRODUCTS CAN BE IMPAIRED BY ADVERSE FACTORS INCLUDING BUT NOT LIMITED TO FLUCTUATIONS IN ELECTRICAL POWER SUPPLY COMPUTER HARDWARE MALFUNCTIONS COMPUTER OPERATING SYSTEM SOFTWARE FITNESS FITNESS OF COMPILERS AND DEVELOPMENT SOFTWARE USED TO DEVELOP AN APPLICATION INSTALLATION ERRORS SOFTWARE AND HARDWARE COMPATIBILITY PROBLEMS MALFUNCTIONS OR FAILURES OF ELECTRONIC MONITORING OR CONTROL DEVICES TRANSIENT FAILURES OF ELECTRONIC SYSTEMS HARDWARE AND OR SOFTWARE UNANTICIPATED USES OR MISUSES OR ERRORS ON THE PART OF THE USER OR APPLICATIONS DESIGNER ADVERSE FACTORS SUCH AS THESE ARE HEREAFTER COLLECTIVELY TERMED SYSTEM FAILURES ANY APPLICATION WHERE A SYSTEM FAILURE WOULD CREATE A RISK OF HARM TO PROPERTY OR PERSONS INCLUDING THE RISK OF BODILY INJURY AND DEATH SHOULD NOT BE RELIANT SOLELY UPON ONE FORM OF ELECTRONIC SYSTEM DUE TO THE RISK OF SYSTEM FAILURE TO AVOID DAMAGE INJURY OR DEATH THE USER OR APPLICATION DESIGNER MUST TAKE REASONABLY PRUDENT STEPS TO PROTECT AGAINST SYSTEM FAILURES INCLUDING BUT NOT LIMITED TO BACK UP OR SHUT DOWN MECHANISMS BECAUSE EACH END USER SYSTEM IS CUSTOMIZED AND DIFFERS FROM NATIONAL INSTRUMENTS TESTING PLATFORMS AND BECAUSE A USER OR APPLICATION DESIGNER MAY USE NATIONAL INSTRUMENTS PRODUCTS IN COMBINATION WITH OTHER PRODUCTS IN A MANNER NOT EVALUATED OR CONTEMPLATED BY NATIONAL INSTRUMENTS
50. Calibration as Default purple or the Save Calibration As blue buttons on the SCM interface This saves a file to the LabVIEW default data directory This is typically under My Documents LabVIEW Data for Microsoft Windows and C ni rt LabVIEW Data for Real Time Calibration files have a cdl extension These options can be found under the Calibration menu Q How dol load a saved configuration A To load a previous NI CAS Software calibration copy the desired calibration file into the LabVIEW default data directory This is typically under My Documents LabVIEW Data for Microsoft Windows and C ni rt LabVIEW Data for Real Time Use the Calibration gt Load Calibration if live loading is enabled Use the Calibration gt Set Calibration and restart the NI CAS Software target if live loading is disabled Restart the NI CAS Software target application and select the appropriate file is the calibration selector is enabled See the NI SCM User s Manual for more details Q Why does Microsoft Excel fail to open a TDMS files A The TDMS Microsoft Excel plug in opens each property in a new column across the top of the spreadsheet Property fields are used to store all gt 255 of the configuration parameters However Microsoft Excel 2003 is limited to 255 columns Open the TDMS plug in properties and turn off custom property imports Q How do I customize the user interface A The user interface is a stand
51. M 1645 05 MB Free Disk Space Free Space on the C Drive Core CPU use for each CPU core RT only CPU Average system CPU use RT only RAM Available system RAM RT only Only available with the Development License National Instruments All rights reserved 93 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 3 3 EPT The EPT engine position tracking status display indicates the state of the encoder tracking This function is only available when using an FPGA A B Crank Count Crank Count Max Crank Count Min Crank Position Cycle Cycle Period FPGA Time Gate Reset Max CAT Overspeed Stalled Start Time Sync Z s EPT us WDA Crank Count 339 Be Crank Count Max 720 3 Crank Count Min 720 p eee Crank Position 1355 CAT e Overspeed Cycle 0 Stalled sync Cycle Period 4799489 Ticks FPGA Time 1548964546 ns Max CAT 2880 CAT Start Time 0 ns Indicates the state of the encoder A signal Indicates the state of the encoder B signal Indicates the current crank count of the engine position tracking system Indicates the maximum crank count observed after starting the engine position tracking system Indicates the minimum crank count observed after starting the engine position tracking system Indicates the current position of the engine position tracking system Indicates the current cycle after starting the engine position t
52. Manual Indicates the statistical coefficient of variation of the indicated mean effective pressure net of the reference cylinder Indicates the difference between the statistical mean of calculated compression and expansion polytropic coefficients Specifies the maximum threshold for the difference between compression and expansion polytropic coefficients Specifies the minimum threshold for the difference between compression and expansion polytropic coefficients Indicates the statistical mean of indicated mean effective pressure net of the reference cylinder Specifies the difference between peak cylinder pressure and cylinder TDC due to heat transfer losses commonly referred to as the thermodynamic loss angle Indicates whether the associated polytropic coefficient is within the stated maximum and minimum threshold values Indicates the statistical mean of peak pressure of the reference cylinder Indicates the statistical mean of location of peak pressure of the reference cylinder Indicates the statistical mean of calculated polytropic coefficient of the compression stroke based on the logarithmic P V diagram Specifies the maximum threshold for the calculated polytropic coefficient of the compression stroke Specifies the minimum threshold for the calculated polytropic coefficient of the compression stroke Indicates the statistical mean of calculated polytropic coefficient of the expansion stroke based on the logari
53. NI Combustion Analysis System Software for LabVIEW D NATIONAL INSTRUMENTS User s Manual NI CAS NI Combustion Analysis System Software for LabVIEW User s Manual Web http www ni com powertrain controls E mail powertraincontrolsinfo ni com National Instruments All rights reserved 1 NI Combustion Analysis System Software for LabVIEW User s Manual Table of Contents 1s PrOGUCt INMOGUCIORN 3 sesen icbiclaeeed tet cane ee ete a iaatgin hans es ee aheate hb Je seats nei as E iA 5 1 1 Features By License Versi n cick snecs oni ean Mel bie ccc ee iaa 6 ee eet FOW annee a ios oer a a aie ant esetst ia ven tac 10 2 Getting Stale sencera a e a elias ane nether teen aa ee aaa 11 2 1 Recommended System Requirements 2 c 2 2 c ccceeeeeeeeeeeneeeeeessceccceeeedeeeeeeeeeneeseesenesengeeeeneeeee 12 2 1 f S upported C Series Mod le Seienn A a E sa a E 15 2 2 Matdware COnmngurationy seresa a a ia TE E Se ease 16 2 2 1 Development Version Hardware Setup cs csessssssseeeeeeeeeeeeeeeeeeeeeeeeceeseeeeeaeaneaaesseesseesees 17 2 2 2 Deployment Version Hardware Setup sscsec stescacces sesasnashee aageads Giantncalaadssencternla iahetatin Ba venleus 19 2 3 Software CoOmiguration iineicsrcce cee estes Laake cc Rees 23 2 9 1 Activating YOUR SOMWANG sss cesses sees ecostecater a pees cadre aT a E Ea ace 24 2 3 2 MAX Hardware Configuration soc cenncieds denen denen de heeled 26 2 2 2 1 Devel
54. NI Combustion Analysis System Software for LabVIEW User s Manual Indicates whether the Measured Sample Resolution and Measure Cycle Resolution values match the Sample Resolution and Cycle Resolution values respectively Specifies the level to divide the extrapolated resolution by in order to determine the final sample resolution Not all combinations of encoder resolution extrapolation level and encoder divide are valid Indicates an error in the engine position tracking configuration Specifies the level of encoder extrapolation used in the engine position tracking system 2 valid Specifies the encoder resolution as it is seen by the engine position tracking Determines which encoder events are used by the engine position tracking system Enables EPT simulation of the engine encoder signals for offline testing Specifies the maximum speed of the engine Displays the number of edges counted for one encoder rotation Displays the number of edges counted for one engine cycle Specifies if the system is configured for acquiring data without an FPGA engine position tracking system Determines the method of preprocessing the encoder signal to pass only a single index pulse per cycle to the engine position tracking system Defines which cycle to use when using a random z Indicates the calculated sample resolution based on the encoder settings Specifies the global TDC offset It is commonly used to easily adjust for c
55. NY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE CUSTOMER S RIGHT TO RECOVER DAMAGES CAUSED BY FAULT OR NEGLIGENCE ON THE PART OF NATIONAL INSTRUMENTS SHALL BE LIMITED TO THE AMOUNT THERETOFORE PAID BY THE CUSTOMER NATIONAL INSTRUMENTS WILL NOT BE LIABLE FOR DAMAGES RESULTING FROM LOSS OF DATA PROFITS USE OF PRODUCTS OR INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF ADVISED OF THE POSSIBILITY THEREOF This limitation of the liability of National Instruments will apply regardless of the form of action whether in contract or tort including negligence Any action against National Instruments must be brought within one year after the cause of action accrues National Instruments shall not be liable for any delay in performance due to causes beyond its reasonable control The warranty provided herein does not cover damages defects malfunctions or service failures caused by owner s failure to follow the National Instruments installation operation or maintenance instructions owner s modification of the product owner s abuse misuse or negligent acts and power failure or surges fire flood accident actions of third parties or other events outside reasonable control National Instruments All rights reserved 191 NI Combustion Analysis System Software for LabVIEW User s Manual 9 2 Copyright Under the copyright laws this publication may not be reproduced or transmitted in any form electronic or mechanical including pho
56. RE eae ceca a 115 4 2 3 Forward and Reverse WR ccc lt cnechwectect eh ida bedees deve cecwestatethde nd leens lp tarere rerer erreen mennene 116 4 2 4 FIR Filter with ROMDACK ss cec ceuc ev eeccercese ce igecaceasauc Sucetecstceecaaesde cd tess sous ete etka ces aeenesseeueadieawskne 117 4 3 Cylinder Pressure Pegging cn 20 0 os ee eta sc eles eel ens tule cat etonele 118 ASSi1 COMSIAIN saccades Satine eae eae ls a ae TE 119 43 2 S yN Nr NOUS MAP Scz toacct alsin weal steele ett sweatin nett ae a E Tea aAA halide 120 ASS POI UODIC ses cke estates na cicea beatae ees Sietansnee SE E dtu at amon aeiceece ue seengs clad 121 4 A Pressure MGUICS lt 5 20s A a adler ii S aan leachate net a Ss ald 122 4 4 1 Pressure and Pressure Rise Rate ceeee cece eeeeeeeeee eee ee eee e eee e eee eeeeeeeeeaaaaaaeeeeeeeeeeeeeeeeeeeeeea 123 4 4 2 Polytropic Coefficients itz ct cusses ines he eeteset eetere rrna nkone niania nannat tend rtiri rtan 124 AAS TDC Probe ai araa a EAE ce EBEDE A EELE naet esos eee Se teas de Aat see aus 126 4 5 Mean Effective Pressure c nants te retake Gehrels el ens tubal ie eee edin eenaa 127 4 6 M toring Pressure aea arae iaaa aa eet acacia al cs cate oS ca hs ed cee eh cae a ea ee ca 128 4 7 Global Gas Temperature vccncisssthahsas coatings aeewa dscns ovoodane na udats duvaewestaassweshivdcacdant ath aarcu lanes desea tied iweneeld 129 cio Ba Lal O a ere EE T re Pr Pr ere Tne RE Perea 130 National Instruments All rig
57. Save National Instruments All rights reserved 86 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 2 1 Raw File Save NI CAS Software raw files contain all of the data as it comes from the DAQ system and all of the settings entered by the user This data can be used to generate summary data Because all of the data is saved in a raw format calibrations and other settings can be modified and applied the calculations when reprocessing However the data in the file need some processing before it is useful in most user applications NI CAS Software contains several applications examples and an API for using raw data files s Raw File Save File Path Path C Data File Name Raw_XXX Comments Single File Part 0 File Counter 0 Size Limit Size Limit 300 MB Reset Counter Value 0 ceeTiime Limits Time Limit 60 s Reset Counter _ Cycle Limit Cycle Limit 1000 Manual Trigger Process File 4 File Start Stop File Starts saving a file if currently stopped or stops saving a file if currently stopped Standby Writing Displays the state of the file writing process New File Overwrite Indicates if a new file will be written or an old file will be overwritten Sum Raw Presses the Start Stop File buttons on Raw File and Sum File dialogs at the same time File Path Current files path and name when saving Path Location on the target
58. W FPGA Module Xilinx Tools NI Software Calibration Management Toolkit for LabVIEW Display resolution 21920x1080 National Instruments All rights reserved 13 NI Combustion Analysis System Software for LabVIEW User s Manual Deployment Version of NI CAS Software Target System Recommended cDAQ System cDAQ Chassis e NI cDAQ 9139 NI CompactDAQ Stand Alone Chassis Core i7 1 33 GHz 8 slot NI cDAQ 9174 NI CompactDAQ 4 Slot USB Chassis NI cDAQ 9178 NI CompactDAQ 8 Slot USB Chassis NI cDAQ 9184 NI CompactDAQ 4 Slot Ethernet Chassis NI cDAQ 9188 NI CompactDAQ 8 Slot Ethernet Chassis C Series Modules See Supported C Series Modules Host System for USB and Ethernet cDAQ Targets Recommended System CPU 1 6 GHz Multi core or faster OS Microsoft Windows 7 8 RAM 4 GB or more Hard Drive 10 GB or more free space USB 2 0 for USB devices Software e LabVIEW Runtime Engine e NI DAQmx e NI Software Calibration Management Toolkit for LabVIEW Display resolution 21920x1080 National Instruments All rights reserved 14 NI Combustion Analysis System Software for LabVIEW User s Manual 2 1 1 Supported C Series Modules Supported Modules NI 9401 8 Ch 5 V TTL High Speed Bidirectional Digital I O Module NI 9411 6 Channel 500 ns 5 to 24 V Digital Input Module Recommended High speed Engine NI 9215 4 Channel 100 kS s ch 16 bit 10 V Analog Input Module synchronous NI 9220 16 Channel 100 kS s
59. W VIs and examples have been provided to allow easy access to the cycle by cycle data without any need to know the specifics of the encoded data Please note that the data in the files is stored as voltages and must be scaled and pegged when appropriate to be useful Stream Data Units Opening Raw Data Files 1 Determine the file version and if it is a raw or summary file 2 Read configuration data a General settings are found at the group level b Channel settings are found at the channel level 3 Determine the TDC offsets a Use the first bit of DI Data TDC to get the global TDC offset b Use Engine Geometry Setup properties to determine resolution and cylinder TDC offsets c Use the third bit of DI Data Reduced Resolution to reconstruct asynchronous data 4 Decode Data to determine cycle speed time and cycle number 5 Use engine synchronous or asynchronous timestamps to reconstruct FPGA and medium speed data 6 Separate different types of data for each cylinder 7 Apply channel gains and offsets to get to engineering units 8 Apply calculations to get results Raw File Viewer National Instruments All rights reserved 177 1 Make sure the Activation indicator is green 2 Select a raw file to open 3 Slide the cycle selector to the desired cycle 4 Select a cylinder to display 5 Select the appropriate tab to view and change settings 4 DCAT Post Process Raw Fi
60. able on National Instruments website and listed at the beginning of this manual A Verify that NI SCM is installed and activated Please see the NI SCM user s manual for details on installation and activation of NI SCM A Verify that NI CAS Software for Deployment is activated Check the Deployment Target Program front panel to verify that it is activated correctly A Manually start the application Please see the SCM user s manual for more details 1 Launch the NI CAS Software for Deployment Target Program It cam be started from LabVIEW select Help gt Find Examples Search for CAS 2 Open NI SCM 3 Within NI SCM define the Target IP address as 127 0 01 or your computer IP address 4 Within NI SCM set the Host VI to lt Program Files gt National Instruments CAS 2014 Host CAS Runtime vi 5 Within NI SCM set the pairing file to lt Program Files gt National Instruments CAS 2014 Host CAS Runtime par 6 Within NI SCM start the Host VI Q Why does the real time controller crashed without warning A Reboot the controller and try running the application again A It may be possible to exceed the total physical memory of real time system In this case the real time controller will most likely crash real time systems do not have virtual memory The memory should be monitored using one of National Instruments All rights reserved 185 NI Combustion Analysis System Software for LabVIEW User s Manual the t
61. ail to execute programming instructions due to defects in materials and workmanship for a period of 90 days from date of shipment as evidenced by receipts or other documentation National Instruments will at its option repair or replace software media that do not execute programming instructions if National Instruments receives notice of such defects during the warranty period National Instruments does not warrant that the operation of the software shall be uninterrupted or error free A Return Material Authorization RMA number must be obtained from the factory and clearly marked on the outside of the package before any equipment will be accepted for warranty work National Instruments will pay the shipping costs of returning to the owner parts which are covered by warranty National Instruments believes that the information in this document is accurate The document has been carefully reviewed for technical accuracy In the event that technical or typographical errors exist National Instruments reserves the right to make changes to subsequent editions of this document without prior notice to holders of this edition The reader should consult National Instruments if errors are suspected In no event shall National Instruments be liable for any damages arising out of or related to this document or the information contained in it EXCEPT AS SPECIFIED HEREIN NATIONAL INSTRUMENTS MAKES NO WARRANTIES EXPRESS OR IMPLIED AND SPECIFICALLY DISCLAIMS A
62. ard LabVIEW VI It may be modified with LabVIEW development tools to meet user requirements The file should be saved in a new location so that updating NI CAS Software installation does not overwrite the changes A See the NI SCM User s Manual Q What font is used in the example applications A The example applications use Segoe UI size 15 pt as the default font In some circumstances a different size is used Q Why am getting DAQ errors A Make sure that the hardware is set up properly in the Measurements and Automation Explorer and that the Measurement Setup tab has the proper physical channel names A Verify that the device is not being used for other DAQ tasks A Verify that a single DAQ device in not used for synchronous and asynchronous measurements Q Why is the top of the pressure signal clipped flat A The signals will appear flat when the charge amplifier is outputting a value greater than the DAQ device or the charge amplifier output is at its maximum A Reset the charge amplifier to set the zero offset pressure A Adjust the output gain of the charge amplifier Q What do do if am having trouble obtaining encoder sync National Instruments All rights reserved 184 NI Combustion Analysis System Software for LabVIEW User s Manual A Verify that the Cam Crank TDC signals are set up correctly polarity offsets etc A The TDC signal and the crank signals should not have rising edges at the same tim
63. as an executable it can be deployed to portable low cost cDAQ hardware NI CAS Software allows streaming of raw data to file continuously by cycle count time or file size Raw data files are stored in National Instrument s popular TDMS format and include all channel configurations engine geometry and custom test data to allow complete reconstruction of the test environment at a later date Cycle by cycle summaries of analysis parameters can also be logged to TDMS files for later review The TDMS file format is an open format allowing these files to be post processed with a variety of tools including the NI CAS Software Post Processing tools NI DIAdem or Microsoft Excel License Versions Development License The Development License of NI CAS Software enables a LabVIEW toolkit for users to integrate sophisticated combustion analysis and data logging with engine control applications The toolkit includes many analysis functions front panel controls and utilities including data streaming to disk pre processing heat release pressure metrics knock analysis noise analysis raw data logging summary data reporting and post processing The NI CAS Software for Development leverages R Series FPGA S Series simultaneous analog sampling and M Series Multiplexed analog sampling PXI devices from National Instruments to supervise engine position tracking and synchronization of data collection and processing SCXI hardware can be leveraged for
64. ast enough to keep up with the data waiting to write to it Disk access is typically between 10MB s and 70MB s However due to seek times and writing header information the actual speed at which the system can stream data to disk may be slower The throughput of a specific HDD is dependent on many factors including the type of hard drive and the system that it is installed in The NI CAS Software will buffer data in the RAM if the disk is not fast enough to stream all the data to disk However the buffers have limited space and cannot sustain continuous streaming if the disk is not fast enough 50000 5 a 10 MB s A3090 30 MB s a 40000 50 MB s gt 35000 70 MB s 2 30000 25000 E 20000 15000 J amp 10000 5000 0 T T T T T 1 0 10000 20000 30000 40000 50000 60000 Samples per Rotation The data above was calculated using the following equation MS 60 000 000 DS SR 32 8 Where MS Maximum Speed RPM SR Sample per Rotation DS Disk Speed MB s National Instruments All rights reserved 35 NI Combustion Analysis System Software for LabVIEW User s Manual 2 4 2 Deployment Version Performance Overview The performance of the system depends on many factors including CPU speed RAM size and speed Hard drive speed Operating system and additional running applications DAQ hardware limitations sampling rate r
65. aw Hill Inc New York NY 1988 2 Stone R Introduction to Internal Combustion Engines 3rd Edition Copyright Richard Stone 1999 National Instruments All rights reserved 112 NI Combustion Analysis System Software for LabVIEW User s Manual 4 2 Waveform Filters Four different filter types with customizable parameters can be used to remove unwanted noise from the synchronous and asynchronous signals Boxcar Rolling N Cycles Forward and Reverse IIR and FIR Filter with Rollback National Instruments All rights reserved 113 NI Combustion Analysis System Software for LabVIEW User s Manual 4 2 1 Boxcar The Boxcar filter requires N points for input This filter also known as a moving average is a very simple FIR filter which smoothes a signal by marching through the waveform and averaging N points before and after each given point including the point itself National Instruments All rights reserved 114 NI Combustion Analysis System Software for LabVIEW User s Manual 4 2 2 Rolling N Cycles The Rolling N Cycles filter requires N cycles for input This filter is an ensemble average of the last N consecutive cycles as shown in the following equation N 2a l Bay DF i Note The Rolling N Cycles filter tends to be resource intensive scaling with the number of cycles used National Instruments All rights reserved 115 NI Combustion Analysis System Software for LabVIEW
66. ble Y array associated with each measurement when using the table scaling method National Instruments All rights reserved 56 NI Combustion Analysis System Software for LabVIEW User s Manual Terminal Configuration Terminal Configuration array associated with each measurement Type Measurement Type associated with each measurement Units Units associated with each measurement National Instruments All rights reserved 57 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 5 Async Digital Channels Setup The time based asynchronous digital measurement setup is used to define hardware timed digital IO associated with the asynchronous analog inputs These measurements are sampled at a fixed frequency s Async Digital Channels Setup x Name TDC Data Reserved DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14 DI15 Reduce Resolution Undefined Type Undefined Undefined Name DI4 Type Undefined Undefined Undefined Undefined Undefined Undefined Undefined Undefined Undefined Undefined Undefined Undefined Cylinder Undefined 01 02 1 Summary of all defined measurements 2 Detailed setup of the selected measurement Cylinder Inverted Name Type Cylinders associated with each measurement in a bitfield Invert the digital signals associated with each measurement Name associated with each measurement Measure
67. ch 16 Bit 10 V Analog Input Module NI 9222 4 Channel 500 kS s 16 Bit Simultaneous Analog Input Module Recommended NI 9223 4 Channel 1 MS s 16 Bit Simultaneous Analog Input Module High speed Engine NI 9215 4 Channel 100 kS s ch 16 bit 10 V Analog Input Module asynchronous NI 9220 16 Channel 100 kS s ch 16 Bit 10 V Analog Input Module NI 9222 4 Channel 500 kS s 16 Bit Simultaneous Analog Input Module Recommended NI 9223 4 Channel 1 MS s 16 Bit Simultaneous Analog Input Module Medium Speed NI 9201 8 Ch 10 V 500 kS s 12 Bit Analog Input Module NI 9203 8 Ch 20 mA 200 kS s 16 Bit Analog Current Input Module Recommended NI 9205 32 Ch 200 mV to 10 V 16 Bit 250 kS s Analog Input Module Recommended NI 9211 4 Channel 14 S s 24 Bit 80 mV Thermocouple Input Module NI 9213 16 Channel Thermocouple Input Module Recommended NI 9215 4 Channel 100 kS s ch 16 bit 10 V Analog Input Module NI 9220 16 Channel 100 kS s ch 16 Bit 10 V Analog Input Module NI 9222 4 Channel 500 kS s 16 Bit Simultaneous Analog Input Module NI 9223 4 Channel 1 MS s 16 Bit Simultaneous Analog Input Module NI 9401 8 Ch 5 V TTL High Speed Bidirectional Digital I O Module NI 9402 4 Ch LVTTL High Speed Digital I O Module NI 9411 6 Channel 500 ns 5 to 24 V Digital Input Module Output NI 9263 4 Channel 100 kS s 16 bit 10 V Analog Output Module NI 9264 16 Channel Analog Output Module NI 9265 4 Channel 100 kS s 16 Bit 0
68. cified for PolyC and PolyE As our function P can be rearranged to match the form Y 4 be used to solve for PolyC and PolyE B the following system of equations can y Ax b nfi nx Iny SL nx XL An ya n Xh nx XL ny a Xi n y b Xi In x n where National Instruments All rights reserved 124 NI Combustion Analysis System Software for LabVIEW User s Manual National Instruments All rights reserved 125 NI Combustion Analysis System Software for LabVIEW User s Manual 4 4 3 TDC Probe The TDC probe location is a calculation taken from the waveform generated by a TDC probe sensor used during engine setup The TDC probe location can be used to correctly phase the acquired engine data with engine position and calculated volume data The first step in calculating the TDC probe location is determining which TDC peak in the waveform is the relevant compression TDC peak In the case of a two stroke engine there is only one peak The compression firing TDC peak is typically the lowest of the peaks due to increased pressure in the cylinder Based on the selected peak a window of the TDC probe signal surrounding the peak is selected and analyzed using one of the following methods 1 The standard method of calculating the peak TDC probe location involves simply using the built in LabVIEW array functions to search the pre defined window of the TDC probe array for the maximum valu
69. d RPM V cylinder volume m P cylinder pressure kPa T cylinder global gas temperature K Sp mean piston speed m s 1 Hohenberg G F 1979 Advanced Approaches for Heat Transfer Calculations Society of Automotive Engineers Inc Paper 790825 National Instruments All rights reserved 149 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 3 Polytropic Correlation National Instruments All rights reserved 150 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 3 1 Hayes SAE860029 an C R T lt 1000K E 3 6359 1 33735 107 T 3 29421 1076 T 1 9112 107 9 T 0 275462 1071 T R T gt 1000K Cp 3 04473 1 33805 1073 T 0 488256 1076 x T 0 0855475 107 T3 0 005701327 10 12 T R where y ratio of specific heats T cylinder global gas temperature K Cp specific heat for constant pressure R the universal gas constant 1 Hayes T K Savage L D Sorenson S C 1986 Cylinder Pressure Data Acquisition and Heat Release Analysis on a Personal Computer SAE Technical Paper Series 860029 National Instruments All rights reserved 151 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 3 2 Indolene SAE841359 y 1392 813 105 T where y ratio of specific heats T cylinder global gas temperature K 1 Gatowski J A Balles E
70. d Sample Rate Encoder Resolution Calculation Parameters HDD Throughput User Calculations National Instruments All rights reserved 33 NI Combustion Analysis System Software for LabVIEW 2 4 1 1 S Series Hardware One of the key items limiting the maximum engine speed is the DAQ hardware There are two cases where the DAQ hardware may limit the maximum engine speed The first is the case where the DAQ equipment has a large sample rate but the encoder resolution is high For example a 500kS s ch DAQ device is limited to 8333RPM with a 3600ppr encoder The second case is where the DAQ hardware has a small sample rate For example a multiplexed sampling device at 1MS s divided among 16 channels has a 62 5kS s ch sampling rate 50000 penis 1000 kS s ch 500 kS s ch 40000 a 250 kS s ch 5 35000 100 kS s ch 30000 50 kS s ch 25000 E 20000 15000 amp 10000 5000 0 T T T T T T T X 1 0 500 1000 1500 2000 2500 3000 3500 4000 Encoder Resolution ppr The data above was calculated using the following equation _ 60 000 SR ER MS Where MS Maximum Speed RPM SR Sample Rate kS s ch ER Encoder Resolution ppr National Instruments All rights reserved 34 NI Combustion Analysis System Software for LabVIEW 2 4 1 2 HDD Streaming data to the disk requires that the speed of the hard drive is f
71. e This condition can cause a situation where the TDC signal and the crank signals toggle position and cause an error One signal may be read as true before the other A Verify that the proper signals are connected to the FPGA It may be helpful to pass the encoder signals through the FPGA and read them use an oscilloscope if available A The encoder synchronization is controlled by the engine tracking VIs Please refer to the EPT documentation for details on the specific flags and inputs Q Why are the buffers or queues overflowing A The buffers fill when the computer system hardware is not able to keep up with the program demands A combination of faster CPU faster hard drive or additional RAM will alleviate the problem A The performance of the system depends on many variables including user defined functions It may be necessary to remove some real time processing to achieve the desired performance Q Why are the speed and the timer not working correctly A Check the PFI to PO jumpers described in the hardware setup information That data is transferred over these jumpers Q Why is the NI CAS Software running but are doing nothing A Please verify that you have activated the NI CAS Software Please see Installation and Activation for details Q Why doesn t the Deployment Version of NI CAS Software start correctly A Verify that the appropriate version of DAQmx and LabVIEW Runtime are installed The installers are avail
72. e a start file event Determines the number of cycles to save to a raw file at a time to improve disk performance Configures the maximum update rate of plot data Configures the maximum update rate of statistical data Delays the start of Host VI execution to allow initialization Determines the maximum update rate of plot Determines the maximum update rate of tables Determines the maximum update rate of trends Determines the maximum update rate of the knock configuration display National Instruments All rights reserved 50 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 IO Hardware Setup National Instruments All rights reserved 51 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 1 Sample Rates Setup The sample rates setup must be configured in the offline mode Information entered should be specific to the data acquisition hardware used as invalid inputs will cause DAQ errors s Sample Rates Setup _ R Max Sync Rate 500 kS s Async Rate 100 kS s Medium Speed Rate 10 S s Async Rate Specifies the sample rate of the asynchronous data Max Sync Rate Specifies the maximum sample rate of the synchronous measurement DAQ device Medium Speed Rate Specifies the sample rate of the medium speed DAQ National Instruments All rights reserved 52 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 2 Sync Ana
73. e in Joules for one cycle of combustion Mathematically this is done by integrating calculated heat release rate dQ d8 between the defined start of combustion SOC and end of combustion EOC as in the following equation soc d The following steps were accomplished to achieve this goal 1 Open the template for custom user calculations in the Combustion Analysis examples folder The block diagram should appear as follows National Instruments All rights reserved 167 NI Combustion Analysis System Software for LabVIEW User s Manual 44 CAS Calculations User Template vi Block Diagram File Edit View Project Operate Tools Window Help Engine Geometry Results C5 All Setup 75528 Initialize E4 Volume Results All Results 75s Cycle Waveforms L Cycle Data error E Pezz error W 4 m User Calculations Template 2 Use the Unbundle by Name function from the Cluster Class amp Variant function palette to unpack the following inputs e Cycle Waveforms Heat Release Rate J CAD e All Setup Engine Geometry Setup Rotations Per Cycle e Engine Geometry Results Sample Resolution ppr Cycle Waveforms KEST Heat Release Rate J CAD All Setup Engine Geometry Setup Rotations Per Cycle Engine Geometry Results Sample Resolution ppr Initialize LTE Volume Results 8 All Results 75 28 KPS gt User Results Cycle Data errorj Ei
74. e list of Files using the standard windows selection method Hold Ctrl to select multiple items and Shift to select a range of items You may also Select All and Deselect All 2 Set the Summary File Output Folder You have the option to Keep Directory Structure of the Raw Data Folder You may also turn on the options to convert the summary files to Text Files or create Array Files containing all the processed array data for all the cycles The Prefix and Suffix are appended to the name of hte raw data File to create the name of the summary data file 3 IF DCAT is Activated the files may be processed When the Process Files button is pressed all of the selected raw data files will be porcessed The Current File File Porgress and Total Progress may provide feedback on the status of the conversions The porcess may take 1 2 min for each 100MB of raw data There is not way to stop the process after it starts 4 Exits the VI Select All Deselect All National Instruments All rights reserved 182 NI Combustion Analysis System Software for LabVIEW User s Manual 6 Troubleshooting A Microsoft Windows Help file chm for NI CAS Software is provided with the software download Each window within the user interface contains a Help button in the bottom right corner Pressing this button will open the Help file to the associated help topic page Frequently Asked Questions FAQs
75. e location 2 The spline method of calculating the peak TDC probe location involves creating a splined waveform for the array that has ten times the resolution of the TDC probe array The splined waveform array is searched for peak value location using the built in LabVIEW array functions 3 The final method of calculating the TDC probe location the Horizontal Cut assumes a symmetrical profile of the TDC probe signal A horizontal window below the peak is selected in which numerous horizontal cuts are taken For each cut the crank angle or x axis values at each point intercepting the waveform are taken and the midpoint is found The collection of midpoints for each horizontal cut are averaged resulting in the TDC probe location Horizontal Cut Method TDC Probe Signal TDC Probe Location Horizontal Cut Window s Horizontal Cuts Intercepts A Midpoints 15 10 5 0 S 10 15 20 25 Engine Position CAD National Instruments All rights reserved 126 NI Combustion Analysis System Software for LabVIEW User s Manual 4 5 Mean Effective Pressure Mean effective pressure MEP is a value commonly used to quantify engine load or work output independently of engine size All MEPs in this software are indicated values as the calculations are based on cylinder pressure The following equation is used to calculate the various MEPs MEP W l y where W indicated work for a given engine r
76. e of heat release n polytropic coefficient V cylinder volume dP d8 cylinder pressure change due to piston motion and heat release w r t crank angle P cylinder pressure 1 Grimm B M Johnson R T 1990 Review of Simple Heat Release Computations SAE Technical Paper Series 900445 2 Rassweiler G M Withrow L 1938 Motion Pictures of Engine Flames Correlated with Pressure Cards Society of Automotive Engineers Paper 380139 National Instruments All rights reserved 143 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 6 Pressure Ratio dQ P NMEP V a e S M d P d AP oa Pms Prii 7 i where dQ d8 rate of heat release P cylinder pressure Pm motored cylinder pressure NMEP net indicated mean effective pressure Va displaced cylinder volume d8 crank angle differential V cylinder volume n polytropic coefficient 1 Sellnau M C Matekunas F A Battiston P A Chang C F Lancaster D R 2000 Cylinder Pressure Based engine Control Using Pressure Ratio Management and Low Cost Non Intrusive Cylinder Pressure Sensors SAE Technical Paper Series 2000 01 0932 National Instruments All rights reserved 144 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 2 Heat Transfer Correlations National Instruments All rights reserved 145 NI Combustion Analysis System Software for LabVIEW
77. ect Properties Confirm or update the expansion chassis C Series modules and FPGA I O in CAS FPGA vi to match the user s hardware Open and compile CAS FPGA vi in the FPGA target Open CAS Target vi in the PXI target Run SCM Init by double clicking on the icon on the block diagram of CAS Target vi It is the right most block diagram item Run CAS Target vi Launch NI SCM Console and point it to the PXI target IP address CAS Host vi and CAS Host par The host files are located with the project in the examples folder For more information on the SCM Console please see the SCM user s manual Integrating Development Version Into An Engine Control Application The Development Version of NI CAS Software can run as a stand alone application or as part of a larger project A single PXI chassis can run both an engine controller and combustion analysis Integrating the two systems into a single platform allows lowered equipment costs in addition to providing closed loop feedback to the engine controller The following steps are required to integrate the Development Version of NI CAS Software into an engine control application First open the CAS example project From LabVIEW select Help gt Find Examples Search for CAS FPGA 4 1 Open CAS FPGA vi under the CAS PXI FPGA target 2 3 Copy CAS Data and CAS Encoder Debug FIFOs from the CAS PXI FPGA target to the engine control FPGA Copy the single
78. elation 1 takes part load operating conditions into account w C S5p 2 i imEp Vive when Vp Tive tl 3s gt 0 2 C2 are P P gt 2 C Sp Ve IMEP where w mean cylinder gas velocity m s Sp mean piston speed m s Vtpc cylinder clearance squish volume m Tivc Pive Vivc cylinder global gas temperature cylinder pressure and cylinder volume at intake valve closing respectively IMEP indicated mean effective pressure kPa Vp displacement per cylinder m P cylinder pressure kPa Pm motored cylinder pressure kPa 1 Woschni G 1967 A Universally Applicable Equation for the Instantaneous Heat Transfer Coefficient in the Internal Combustion Engine Society of Automotive Engineers Paper 670931 2 Sihling K Woschni G 1979 Experimental Investigation of the Instantaneous Heat Transfer in the Cylinder of a High Speed Diesel Engine Society of Automotive Engineers Inc Paper 790833 3 Huber K Woschni G and Zeilinger K 1990 Investigations on Heat Transfer in Internal Combustion Engines Under Low Load and Motoring Conditions Society of Automotive Engineers Inc Paper 905018 National Instruments All rights reserved 148 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 2 4 Hohenberg _ 494 6 N x V 70 06 y ps 7 04 y Sp 1 4 02 where h heat transfer coefficient W m K N engine spee
79. er 3 0to0 0to0 0tod v Hold1 A Cylinder4 Oto0 Oto0 0to0 7 Hold2 5000 Cylinder 5 0to0 0to0 Otod 7 Hold 3 e Cylinder6 0tod 0tod ods HM 4000 Cylinder 0to0 Dtod Dto0 7 Holds BY amp Cylinder8 0tod 0tod Oto YHolds Ry 3000 g Cylinder 9 0to0 0to0 0tod 7 Hold6 i 5 Cylinder10 0to0 0to0 0to0 o 2000 Cylinder11 0to0 tod 0too 7 Hold7 id a Cylinder12 0to0 0to0 0to0 1000 Cylinder13 0to0 0to0 0to0 Cylinder14 0to0 Oto0 Oto0 3 mar Cylinder15 0to0 0to0 Oto0 6 100 200 300 360 Cylinder 16 Otod Otod Otod Crank Angle CAD Reference Start 210 CAD Knock Start 9 CAD v Current Fay 15 Reference End 180 CAD Knock End 30 CAD J Hold1 A 2 High Cutoff 8 kHz Min Reference 0 f 7 Hold 2 A Low Cutoff 5 kHz Threshold 0 5 J 7 Hold 3 Mi med Kno Hold 1 Clear1 7 Holds By T i NAAA AI NAAA Hold 2 Clear 2 7 Holds E Bandpass 7 Hois BW Filter Hold 3 Clear 3 o q ied Hold 4 Clear 4 7 Hold7 E Hold 5 Clear 5 1 Hold 6 Clear 6 EH A w 1 5 1 I 1 1 i 1 1 1 1 Hold 7 Clear 7 4 360 300 200 100 0 100 200 300 360 r Crank Angle CAD Compare y Knock Results Summary of settings for each cylinder Detailed setup of the selected measurement Calibration setup displays Hold and clear for up to 7 cycles Pressing the buttons captures the current waveforms for comparison ce cae ae High Cutoff Frequency Specifies the High Cutoff Frequency of the knock filter for each cylinde
80. er may be optionally powered by the module If the encoder is powered from the module power 5 to 30 VDC must be supplied to the Vsup and COM screw terminals of the module Vsup is internally reduced to 5V and available from the DSUB connector The encoder should be connected to the NI 9411 module according to the table below Please note that the NI 9411 module inputs are optionally single ended or differential pairs Some optical encoders provide complimentary differential signal outputs which enable greater noise immunity when connected with differential digital inputs The table below shows the connections to be made for single ended or differential operation If single ended operation is required then the b pin of each input should be left unconnected Shielded cabling is recommended Encoder Signal NI 9411 DB15 Connector Pin Encoder 5V optional Externally Supplied or NI 9411 Pin 4 5Vout Encoder Ground optional Externally Supplied or NI 9411 Pin 12 COM Encoder Z required NI 9411 Pin 2 P0 1 PFI 1 DI 1a Encoder Z Compliment optional NI 9411 Pin 10 P0 1 PFI 1 DI 1b National Instruments All rights reserved 17 NI Combustion Analysis System Software for LabVIEW User s Manual Encoder A required NI 9411 Pin 1 P0 0 PFI O DI Oa Encoder A Compliment optional NI 9411 Pin 9 P0 0 PFI O DI Ob Encoder B optional NI 9411 Pin 3 P0 2 PFI 2 DI 2a Encoder B Compliment optional NI 9411 Pin 11
81. er on the product packing slip or on the shipping label If you have installed a previous version using your serial number you can find the serial number by selecting the Help About menu item within the application or by selecting your product within NI License Manager Start All Programs National Instruments NI License Manager You can also contact your local National Instruments branch National Instruments All rights reserved 24 NI Combustion Analysis System Software for LabVIEW User s Manual What is a Computer ID The computer ID contains unique information about your computer National Instruments requires this information to enable your software You can find your computer ID through the NI Activation Wizard or by using NI License Manager as follows 1 Launch NI License Manager by selecting Start All Programs National Instruments NI License Manager 2 Click the Display Computer Information button in the toolbar For more information about product activation and licensing refer to ni com activate How Can Evaluate NI Software You can install and run most NI application software in evaluation mode This mode lets you use a product with certain limitations such as reduced functionality or limited execution time Refer to your product documentation for specific information on the product s evaluation mode Moving Software After Activation To transfer your software to another computer install and activate
82. er s Manual X NI PXI 6123 Dev1 Measurement amp Automation Explorer SF Properties X Delete Name E Serial Number E socket Number E Bus Number E Memory Range 1 E Memory Range 2 EIRG Level EEJ Pxt Slot Number E PII Chassis Number PXI PXI System NI PXI 8106 amp E RIO Devices a Y serial 4M Scales amp 6 Software Chassis 1 PXI 1031 Measurement amp Automation Explorer E Q Remote Systems GaP RETOO3 ll Data Neighborhood Sg Devices and Interfaces E NI DAQmx Devices S PXI PXI System NI PXI 8106 2p amp E RIO Devices PXI Trigger Reservation options National Instruments All rights reserved 28 NI Combustion Analysis System Software for LabVIEW User s Manual 2 2 2 2 Deployment Version MAX Hardware Configuration The user must take note of a few configuration settings in NI Measurement and Automation Explorer MAX in order to work with the NI CAS Software The DAQ device aliases as shown below are used to identify the physical channels in the NI CAS Software measurement setup The DAQ device can be renamed by right clicking on the device and selecting the rename option s E My System GJ Data Neighborhood a Devices and Interfaces a amp NicDAQ 9172 cDAQL _ 1 N19268 lt DAQIModi 9 2 NI9401 CDAQTMod2 3 NI9263 cDAQ1Mod3 4 NI9215 BNC cDAQIMod4 5 NI9411 cDAQIModS a NI cDAQ 9174 cDAQ
83. esponse times Medium Speed Data Number of Channels and Sample Rate Engine speed Encoder resolution Cylinder and measurement channel count Calculation configurations National Instruments All rights reserved 36 NI Combustion Analysis System Software for LabVIEW User s Manual 2 4 2 1 cDAQ Hardware The figure below shows the cDAQ hardware limitations The cDAQ system uses simultaneous sampling device Therefore the DAQ hardware limitations are constant for any number of cylinders 20000 18000 16000 14000 12000 10000 8000 6000 4000 2000 J 100KS s 500 kS s 1 MS s Maximum Speed rpm SSO T E 0 1000 2000 3000 4000 5000 6000 7000 Encoder Resolution ppr The following formula can be used to estimate the performance of a simultaneous DAQ hardware device _ 60 000 MSR Speed ER Where Speed Maximum Engine Speed rpm MSR Maximum Sample Rate of DAQ device kS s ER Encoder Resolution ppr National Instruments All rights reserved 37 NI Combustion Analysis System Software for LabVIEW User s Manual 2 4 2 2 NI cDAQ 1939 Benchmark The NI cDAQ 1939 was tested under a variety of conditions in order to demonstrate the capabilities of the system while running Each test condition was evaluated on the maximum engine speed where the system could calculate all the results without loosing data for the real time calculati
84. evolution Vg displaced cylinder volume The indicated work Wj is calculated using the following equation W gt av rev where p cylinder pressure dV change in cylinder volume Gross IMEP Gross IMEP IMEPg is calculated for each non pumping engine revolution A six stroke engine therefore will have two independent IMEPg values Pumping MEP Pumping MEP PMEP is calculated for the pumping stroke except in the case of a two stroke engine Net IMEP Net IMEP IMEP is calculated by summing the IMEPg value s and the PMEP 1 Heywood J B Internal Combustion Engine Fundamentals McGraw Hill Inc New York NY 1988 National Instruments All rights reserved 127 NI Combustion Analysis System Software for LabVIEW User s Manual 4 6 Motoring Pressure The motoring pressure is modeled based on cylinder pressure volume valve timing and either a constant or calculated polytropic coefficient The pressure is modeled assuming a polytropic pressure as in the following equation V S a Pmi Praia V starting at the point Pm i 1 Pive where Pm motored cylinder pressure kPa V volume mS n polytropic coefficient Pivc cylinder pressure at intake valve closing kPa National Instruments All rights reserved 128 NI Combustion Analysis System Software for LabVIEW User s Manual 4 7 Global Gas Temperature The global bulk gas temperature is modeled based on cy
85. figurable I O National Instruments All rights reserved 187 RT SCM TDC Sum Sync VI Real Time Software Calbiration Management Toolkit Top Dead Center Summary Synchronous sampled at specific CAD Volume Virtual Instrument NI Combustion Analysis System Software for LabVIEW User s Manual National Instruments All rights reserved 188 NI Combustion Analysis System Software for LabVIEW User s Manual 8 Additional Support Feedback Contact your local NI branch office for support details or visit http www ni com support For additional help with getting your NI hardware and software installed and configured visit http www ni com gettingstarted National Instruments All rights reserved 189 NI Combustion Analysis System Software for LabVIEW User s Manual 9 Important Information National Instruments All rights reserved 190 NI Combustion Analysis System Software for LabVIEW User s Manual 9 1 Warranty Remove the following paragraph for software products NI CAS Software is warranted against defects in materials and workmanship for a period of one year from the date of shipment as evidenced by receipts or other documentation National Instruments will at its option repair or replace equipment that proves to be defective during the warranty period This warranty includes parts and labor The media on which you receive National Instruments software are warranted not to f
86. gine synchronous analog inputs These measurements are sampled at even crank angle increments with respect s Sync Digital Channels Setup a z Undefined Name Type TDC Undefined Data Reduce Resolution Undefined Reserved Undefined DI5 Undefined DI6 Undefined DI7 Undefined DI8 Undefined DI9 Undefined DI10 Undefined DI11 Undefined DI12 Undefined DI13 Undefined DI14 Undefined DI15 Undefined 1 Summary of all defined measurements 2 Detailed setup of the selected measurement Cylinder Inverted Name Type Name DI4 Type Undefined Cylinders associated with each measurement in a bitfield Invert the digital signals associated with each measurement Name associated with each measurement Measurement Type associated with each measurement Only available with the Development License National Instruments All rights reserved 55 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 4 Async Analog Channels Setup The time based asynchronous measurement setup is used to define all the physical channels These measurements are sampled at a fixed frequency s Async Analog Channels Setup lo xs Name Physical Channel Disabled Type a Name Knock Sensor 2 cDAQ1 Mod7 ail Acoustic Knock Sensor 1 Physical Channel o1 v02 03 104 cDAQ1 Mod7 ai0 X Disable 05 06 Type 0 None n a 07 2 Acoustic Fil
87. hanges in the encoder without needing to change each cylinder TDC Specifies the encoder index signal name when using the Deployment Version of NI CAS Software and a cDAQ chassis National Instruments All rights reserved 47 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 4 Calculations In setup mode the user can enable or disable different groups of calculations to perform real time calculations on the target Each group of calculations has its own settings and results Enabling calculation groups will increase the processor usage depending on the complexity of the calculations Note Some calculations require results from another calculation group in order to work i e heat release models including heat transfer simulation require the Gas Temp calculation to be enabled s Calculations X User Process National Instruments All rights reserved 48 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 5 Next Cycle Calculations In setup mode the user can enable or disable different groups of calculations to perform next cycle calculations on the target Each group of calculations has its own settings and results Enabling calculation groups will increase the processor usage depending on the complexity of the calculations and increase the time required to provide next cycle results Note Some calculations require results from another calculation group
88. he window s Plot Sync AI Data c es v Cylinder Pressurel kPa PAA 1 10 II I 1 I I I I I I I I I I 360 300 250 200 150 100 50 0 50 100 150 200 250 300 360 Crank Angle 3 maw 4 5 Note Cylinder pressures are not pegged Cylinder 1 Range This type of plot displays analog results for a single cylinder and a single cycle of data at a time 1 Plot Legend Displays plot names and units with the ability to turn off a plot 2 Plot Data Data display area 3 Plot Controls Controls for controlling zoom and cursors 4 Cylinder Selection Select the cylinder to display 5 Y Axis mode Select between using absolute units or of range for the Y axis National Instruments All rights reserved 102 NI Combustion Analysis System Software for LabVIEW User s Manual s Plot Sync DI Data e 2 v TDC 4 v Data A v Reduce Resolution A v Reserved A al I I I I I I 1 I 360 300 250 200 150 100 50 0 50 100 150 200 250 300 360 Crank Angle 3 MAN 4 5 Cylinder 1 Stack Plots Il This type of plot displays digital results for a single cylinder of data at a time Plot Legend Displays plot names with the ability to turn off a plot Plot Data Data display area Plot Controls Controls for controlling zoom and cursors Cylinder Selection Select the cylinder to display Y Axis mode Select between
89. hts reserved 130 NI Combustion Analysis System Software for LabVIEW User s Manual Duration y quauing s0yalu Q 1 9 a D S lt at c fisi fe oO DI Current 131 National Instruments All rights reserved NI Combustion Analysis System Software for LabVIEW User s Manual 1 5 0 5 oO y ueung 10 23fu 0 5 Crank Angle CAD Piezo Current 132 National Instruments All rights reserved NI Combustion Analysis System Software for LabVIEW User s Manual Injector Current A 10 Crank Angle CAD Injector Voltage Injector voltages vary from battery voltage to several hundred volts Therefore a protective circuit is needed to prevent the high voltage from reaching the DAQ device The operating voltage of the injectors should be verified before connecting the injector to the DAQ device Resistor rated above the maximum operating voltage are also required Please note Most DAQ devicess and accessories have maximum voltage limits that should be followed Please refer to your hardware documentation for details IE the SCB 68 has a maximum voltage of 48V listed in the user s manual National Instruments All rights reserved 133 NI Combustion Analysis System Software for LabVIEW User s Manual Injector Driver PFI Voltage Injector Current A Crank Angle CAD DI Voltage National Instruments All rights reserved 134 NI Combustion Analysis
90. hts reserved 3 4 9 Heat Release 4 9 1 Heat Release Models 4 9 1 1 Single Zone 4 9 1 2 Single Zone Heat Transfer 4 9 1 3 Single Zone Dual Transducer 4 9 1 4 Single Zone Dual Transducer Heat Transfer 4 9 1 5 Modified Rassweiler and Withrow 4 9 1 6 Pressure Ratio 4 9 2 Heat Transfer Correlations 4 9 2 1 Constant 4 9 2 2 Woschni 1967 4 9 2 3 Woschni 1990 4 9 2 4 Hohenberg 4 9 3 Polytropic Correlation 4 9 3 1 Hayes SAE860029 4 9 3 2 Indolene SAE841359 4 9 3 3 Propane SAE841359 4 9 3 4 Custom 4 17 Custom User VIs 5 Post Processing 5 1 NI CAS Software File Structure 5 2 Summary Files 5 3 Raw Files 5 4 TDMS Files 5 5 Batch Processing 6 Troubleshooting 7 Abbreviations 8 Additional Support Feedback 9 Important Information 9 3 Trademarks 9 5 Warning Regarding Use of NI Products 9 6 Environmental Management NI Combustion Analysis System Software for LabVIEW User s Manual National Instruments All rights reserved 4 NI Combustion Analysis System Software for LabVIEW User s Manual 1 Product Introduction The NI Combustion Analysis System Software for LabVIEW NI CAS is a unique LabVIEW plug in for performing sophisticated in cylinder combustion analysis and data logging for engine research and development targeted to a wide variety of NI Hardware When licensed as a toolkit it can be used to develop sophisticated PXl based combustion analysis applications with real time feedback control capabilities Licensed
91. i J Wikstrom A Jonsson O Glav R Handel P and Hjalmarsson H 2007 Predication of Engine Noise using Parameterized Combustion Pressure Curves SAE Technical Paper Series 2007 01 2373 International Electrotechnical Commission Electroacoustics Sound level meters IEC 61672 2003 Herbert A and Russell M 1982 Measurement of Combustion Noise in Diesel Engines Mechanical Engineering Technology Reinhart T 1987 An Evaluation of the Lucas Combustion Noise Meter on Cummins B Series Engines SAE Technical Paper Series 870952 National Instruments All rights reserved 157 NI Combustion Analysis System Software for LabVIEW User s Manual 4 11 Misfire The misfire calculation returns a Boolean output 0 or 1 The calculation is based on one of the following misfire threshold kPa comparisons 1 Peak Pressure lt Misfire Threshold 2 Net Mean Effective Pressure NMEP lt Misfire Threshold 3 Combustion Pressure Cylinder Pressure Motored Cylinder Pressure lt Misfire Threshold National Instruments All rights reserved 158 NI Combustion Analysis System Software for LabVIEW User s Manual 4 12 Cam NI CAS Software uses a digital signal with rising and falling edges to determine the cam phasing The user must specify the edge count location CAD and whether each edge is rising or falling The user specified pattern is compared with the actual pattern to determine the cam advance or retard
92. igured to a filter resource The filter resources can be attached to a one or more measurements sos Filter Settings ID Filter Frequency N Order Ferd 1 Forward and Reverse IR 25 0 2 4 Filter ID 3 Pressure L Signal Filtered as 2 Rolling N Cycles 0 10 0 3 None et 0 0 4 None wlio 0 0 5 None 0 0 0 6 None 1 m10 0 0 7 None 10 0 0 3500 8 None 0 0 0 i 3000 9 None 0 0 0 10 None 0 0 0 11 None li o0 0 0 12 None x 0 0 0 13 None m10 0 0 14 None z 0 0 0 Ti 1 1 1 1 i 1 I i 1 I 1 1 i I I I 15 f None Iho o 0 400 350 300 250 200 150 100 50 0 50 100 150 200 250 300 350 400 16 None 0 0 0 ai HA w 1 Detailed settings for each filter resource 2 Plot of current signals and windows 3 Selection of filter resource and signal to plot Filter Defines the type of filter used Frequency Defines the filter frequency as a percent of the nyquist frequency This value is only valid when using FIR and IIR filters N Defines the number of cycles to include in the rolling average or the number of samples to include in the boxcar average Order Defines the order of the filter when using the FIR and IIR filters National Instruments All rights reserved 69 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 5 Pressure Metrics Settings The pressure metrics settings define parameters for the pressure metrics calculation group
93. in order to work i e heat release models including heat transfer simulation require the Gas Temp calculation to be enabled s Next Cycle Calculations oo 8 Enabiea_ Next Cycle Enable Next Cycle Cutoff 60 CAD User Process Disabled Injector Heat Release Disabled Noise Misfire Disabled Knock Disabled FPGA O Disabled User Calculations Only available with the Development License National Instruments All rights reserved 49 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 6 System Optimization The performance dialog allow users to tune some of the NI CAS Software behavior with their system and setup The current settings should work well for most configurations Target Rolling Stats Size Buffer Size Pre Triggered Size Trigger Size Waveform Refresh Rate Statistics Refresh Rate Host Start Delay Plot Period Table Period Trend Period Knock Period s System Optimization S Target Rolling Stats Size 100 Buffer Size 1 s Pre Triggered Size 10 Cycles Trigger Size 10 Cycles Waveform Refresh Rate 100 ms Statistics Refresh Rate 100 ms Start Delay 1000 Plot Period 100 Table Period 100 Trend Period 1000 Knock Period 1000 Configures the rolling statistics buffers used in trends and tables Determines the desired length of the alignment and raw file buffers Determines the number of cycles the raw system will maintain befor
94. inder Top Dead Center offsets relative to the absolute encoder offset National Instruments All rights reserved 44 Displacement Volume Exhaust Valve Close Exhaust Valve Open Head Area Intake Valve Close Intake Valve Open Pin Offset Rotations Per Cycle Stroke Volume File Enable Volume File Path NI Combustion Analysis System Software for LabVIEW User s Manual Indicates the calculated displacement volume Compression Ratio Displacement Volume Clearance Volume Clearance Volume Specifies the nominal exhaust valve closing angle Specifies the nominal exhaust valve opening angle Specifies the cylinder head surface area relative to the bore area Specifies the nominal intake valve closing angle Specifies the nominal intake valve opening angle Specifies the pin offset Defines the number of rotations per cycle 2 Stroke 1 4 Stroke 2 Specifies the piston stroke Stroke 2 Crank Radius Enables use of use of a volume file instead of using the volume calculations Specifies the volume file to use instead of the calculations National Instruments All rights reserved 45 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 3 Encoder Setup The encoder setup must be configured in the offline mode Information entered should be specific to the engine and test setup as it affects all of the calculations results f s Encoder Setup Ls Gil ss s Encoder Setup
95. is processing and any files waiting to be processed Indicates any error associated with file processing H hour 24 hour clock l hour 12 hour clock M minute S second lt digit gt u fractional seconds with lt digit gt precision p a m p m flag x locale specific date y year within century Y year including century m month number b abbreviated month name d day of month a abbreviated weekday name National Instruments All rights reserved 88 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 2 2 Summary File Save NI CAS Software summary files contain all of the calculated results all of the settings entered by the user The file also contains statistics on all the results Ensemble averages are included for user reference s Summary File Save Start Stop File Standby Writing New File Overwrite Sum Raw File Path Path File Name Comments Single Continuous File Part Size Limit File Path Path C Data File Name Sum_XXX Comments File Progress Process File 4 File Start Stop File astana New Filey Single File Part 0 Selim Soe Lint 300 ME File Counter 0 Reset Counter Value 0 Time Limit Time Limit 60 E Reset Counter hs Cycle imitis Cycle Limit 1000 Manual Trigger Starts saving a file if currently stopped or stops saving a file
96. ition and calculations associated with each measurement Filter resource number associated with each measurement 0 No Filter Gain associated with each measurement when using the gain only or gain and offset scaling methods Maximum channel voltage range associated with each measurement Minimum channel voltage range associated with each measurement Name or description associated with each measurement Offset associated with each measurement when using the gain and offset scaling method Physical channel associated with each measurement Polynomial Coefficients associated with each measurement when using the polynomial scaling method Scaling method associated with each measurement Table X array associated with each measurement when using the table scaling method Table Y array associated with each measurement when using the table scaling method National Instruments All rights reserved 53 NI Combustion Analysis System Software for LabVIEW User s Manual Terminal Configuration Terminal Configuration array associated with each measurement Type Measurement Type associated with each measurement Units Units associated with each measurement National Instruments All rights reserved 54 to the engine NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 3 Sync Digital Channels Setup The engine synchronous digital measurement setup is used to define hardware timed digital IO associated with the en
97. ld 4 Hold 5 Hold 6 Hold 7 2 Reference Window z 6 3 i vy 3 S z XS Filter Results Threshold Filter Cutoffs 120 100 Frequency kHz Frequency kHz Next the filter results for the knock and reference window are displayed on the filter results page National Instruments All rights reserved 78 NI Combustion Analysis System Software for LabVIEW User s Manual s Knock Settings Reference CAD Knock CAD Filter kHz Cylinder 2 Cylinder 3 0to0 0to0 0to0 Cylinder 4 0to0 0to0 0to0 Cylinder5S Oto 0to0 0tod Cylinder6 0tod 0tod Oto Cylinder 7 Cylinder 8 Cylinder 9 Cylinder 10 Cylinder 11 Cylinder 12 0to0 0to0 0to0 Cylinder13 0to0 0to0 0to0 Cylinder14 0to0 Oto0 tod Cylinder15 0tod Oto0 0to0 Cylinder16 0to0 Oto0 Oto Reference Start 210 CAD Knock Start 9 CAD Reference End 180 CAD Knock End 30 CAD High Cutoff 8 kHz Min Reference 0 r Low Cutoff 5 kHz Threshold 0 5 l j Knock Hold 1 Clear 1 TIN TN VAS Hold 2 Clear 2 Bandpass Filter Hold 3 Clear 3 Hold 4 Clear 4 Hold 5 Clear 5 Hold 6 Clear 6 Hold 7 Clear 7 ck Compare Knock Results Signals v Knock 7 v Reference a a 2 w V Raw so v Final a CEE
98. le Viewer vi NI Combustion Analysis System Software for LabVIEW User s Manual Setup Synchronous Asynchronous Medium Speed FPGA Settings AI Data 7 MAP kPa A F CylPress1 kPa A J RailPress MPa F SparkCur1 A iW F InjectionCurl A iW F RailCur A A F Knock12 V A F SparkCoill V AM F InjectionV1 V A Crank Angle CAD 4 Range HAW E Cycle Open File C Data DRVN_022MAP0303_035 tdms Exit 21016 21250 21500 21750 22000 22250 22500 22750 22940 21270 Calculations Trends DI Data X 2472 58 Speed RPM 284142009179025 Time ns Cylinder 1 National Instruments All rights reserved 178 NI Combustion Analysis System Software for LabVIEW User s Manual 5 4 TDMS Files Opening TDMS Files in Microsoft Excel National Instruments provides a free Microsoft Excel plug in that imports TDMS files Importing a file creates a multi page spreadsheet with all the data stored in the file The first page contains a summary of all the groups and channels Each group has a page where each column is a channel of data Please note that Microsoft Excel 2003 is limited to 256 columns and 65536 rows Therefore the custom properties displayed in the first 2 rows on the main page which contain all the calculation configuration information may need to be turned off Raw data channels may also be too long and will be truncated E Microsoft Excel Book3 GB ge Edit yew Insert Format
99. linder pressure volume valve timing intake temperature and pressure exhaust temperature and pressure residual gas fraction and either a constant or calculated polytropic coefficient T T s Pev rc Vive n i Tyc T 1 f 1 39 T P B n f where T global gas temperature Tive Pive Vivc bulk cylinder temperature cylinder pressure and cylinder volume at intake valve closing respectively P cylinder pressure V cylinder volume Tj intake temperature f residual fraction Te exhaust temperature Pj intake pressure Pe exhaust pressure n polytropic coefficient 1 Gatowski J A Balles E N Chun K M Nelson F E Ekchian J A Heywood J B 1984 Heat Release Analysis of Engine Pressure Data SAE Technical Paper Series 841359 2 Sharief A Chandrashekar T K Antony A J Samaga B S 2008 Study on Heat Transfer Correlation in IC Engines SAE Technical Paper Series 2008 01 1816 National Instruments All rights reserved 129 NI Combustion Analysis System Software for LabVIEW User s Manual 4 8 Injector NI CAS Software uses a current or voltage measurement to determine the injection events The user must specify the type of injector used PFI DI or Piezo Injector Current To measure the current drawn by the injector module attach a current probe to the to the injector wiring Injector Driver PFI Current National Instruments All rig
100. log Channels Setup The engine synchronous measurement setup is used to define all the physical channels These measurements are sampled at even crank angle increments with respect to the engine s Sync Analog Channels Setup i z Name Physical Channel Disabled Type a Name CyIP 2 cDAQ1 Mod5 ail Cylinder Pressure kPa CyIP 1 Vlo CylP 3 cDAQ1 Mod5 ai2 Cylinder Pressure kPa 102 CylP 4 cDAQ1 Mod5 ai3 Cylinder Pressure kPa Physical Channel ww bes MAP cDAQ1 Mod6 ai0 Manifold Absolute Pressure kP cDAQ1 Mod5 ai0 M Disable _ 05 Rail Pressure cDAQ1 Mod6 ail Fuel Rail Pressure MPa Pi Type 0 None iS ul Spark 1 cDAQ1 Mod6 ai2 Spark Cylinder Pressure kPa FilterID 1 Settings 2 los Injector 1 cDAQ1 Mod6 ai3 Injector i SSS 5 J09 Add Insert Units Terminal Configuration 10 m11 Delete kPa default a2 a 13 Scaling Raw Hardware Input Limitations p14 Gain Only z lo Min 10 Max rise Move Up Move Down 2000 Gain 1 Summary of all defined measurements 2 Controls for manipulating the list of measurements 3 Detailed setup of the selected measurement Cylinder Disable Filter Gain Max Min Name Offset Physical Channel Polynomial Coefficients Scaling Table X Table Y Cylinders associated with each measurement in a bitfield Disables data acquis
101. medium speed data collection which is subsequently aligned with engine synchronous data This software can be targeted to a wide variety of PXI real time controllers depending on the application performance requirements The Development Version of NI CAS Software example application may be used stand alone or integrated with an engine control application Deployment License The Deployment License enables deployment to low cost easy to use portable engine combustion analysis hardware bundles NI CAS Software for Deployment is a pre built NI LabVIEW Runtime executable for Microsoft Windows targeting cDAQ hardware over USB and Ethernet or Stand Alone cDAQ chassis Over fifty NI C Series I O modules can be added to any available slot of an NI cDAQ chassis to meet a variety of application needs The Deployment Version of NI CAS Software supports three time bases high speed engine synchronous high speed angular window time domain and medium speed time domain The Deployment License includes all of the analysis functions included in the Development Version of NI CAS Software toolkit except for Next Cycle control and FPGA based Engine Position Tracking EPT functions Engine synchronous data sampling must take place using optical shaft encoders mounted to the crankshaft National Instruments All rights reserved 5 NI Combustion Analysis System Software for LabVIEW User s Manual 1 1 Features By License Version License Version Highlighted
102. ment Type associated with each measurement Only available with the Development License National Instruments All rights reserved 58 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 6 Medium Speed Channels Setup The time based medium speed measurement setup is used to define all the physical channels Medium speed are intended for sampling test cell and other auxiliary signals These measurements are sampled at a fixed frequency s Medium Speed Channels Setup Lo a Name Physical Channel Dyno Load cDAQ1 Mod8 ail V Gain amp Offset Cycle Average Dyno Speed Disabled Type Name Intake Temperature cDAQ1 Mod8 ai2 Thermocouple and Stats cDAQ1 Mod8 ai0 4 2 Physical Channel Disable Filter Cutoff O Hz Units CEKR Terminal Configuration RPM F K Rare 2 Add Insert aki Differential Delete thermocouples Scaling Raw Hardware Input Limitations Pre V Gain amp Offset 0 Min 10 Max Move Down 1000 Gain 0 Offset 3 File Save Trigger Save Trigger Threshold 1 Save Trigger Direction Rising X N calculations Summary of all defined measurements Controls for manipulating the list of measurements Enable Disable engine cycle averages and statistic 3 Detailed setup of the selected measurement CJC Channel CJC Source CJC Value
103. n Max Pressure Rise Rate kPa CAD Max Max Pressure Rise Rate kPa CAD Min Max Pressure Rise Rate kPa CAD SD Max Pressure Rise Rate kPa CAD COV me 1 Show Statistics Turns on or off rows of statistics 2 Parameter A list of parameters calculated by the specific calculation group 3 Values Calculation results for each cylinder and the engine average for multi cylinder engines National Instruments All rights reserved 108 NI Combustion Analysis System Software for LabVIEW User s Manual 3 3 4 Trend Charts Trend charts contain a history of all the calculated values and rolling statistics The trend chart captures the current values at a fixed rate Therefore they are good for looking at global trends and not for individual cycle events The results are grouped by calculation group that can be turned on or off See Calculations vi to turn or off the calculation groups s Trend Pressure Metrics 1 Error Code 5850 v 1 Peak Pressure kPa abs A 4 1 Peak Pressure kPa abs Mean p 1 Peak Pressure kPa abs Max owe 1 Peak Pressure kPa abs Min 1 Peak Pressure kPa abs SD 1 1 Peak Pressure kPa abs COV Fain 1 Peak Pressure Location CAD ENF 5600 1 Peak Pressure Location CAD Mean 5550 1 Peak Pressure Location CAD Max 1 Peak Pressure Location CAD Min 5500 1 Peak Pressure Location CAD SD AN 5450 1 Peak Pressure Location CAD COV NY 1 Max Press
104. nal Instruments All rights reserved 22 NI Combustion Analysis System Software for LabVIEW User s Manual 2 3 Software Configuration For more information on the NI Combustion Analysis System Software for NI LabVIEW please visit http www ni com powertrain controls To download the NI Combustion Analysis System Software for LabVIEW visit http Awww ni com info and enter the Info Code CASSoftware After installing NI CAS Software it will run for a 7 day full evaluation period Any time during or after the evaluation period NI CAS Software may be activated using the NI License Manager found in the start menu National Instruments All rights reserved 23 NI Combustion Analysis System Software for LabVIEW User s Manual 2 3 1 Activating Your Software Activating Your Software This section describes how to use the NI Activation Wizard to activate your software How Do Activate My Software Use the NI Activation Wizard to obtain an activation code for your software You can launch the NI Activation Wizard two ways e Launch the product and choose to activate your software from the list of options presented e Launch NI License Manager by selecting Start All Programs National Instruments NI License Manager Click the Activate button in the toolbar Notes e If your software is a part of a Volume License Agreement VLA contact your VLA administrator for installation and activation instructions e NI software f
105. ncoder may be optionally powered by the module If the encoder is powered from the module power 5 to 30 VDC must be supplied to the Vsup and COM screw terminals of the module Vsup is internally reduced to 5V and available from the DSUB connector The encoder should be connected to the NI 9411 module according to the table below Please note that the NI 9411 module inputs are optionally single ended or differential pairs Some optical encoders provide complimentary differential signal outputs which enable greater noise immunity when connected with differential digital inputs The table below shows the connections to be made for single ended or differential operation If single ended operation is required then the b pin of each input should be left unconnected Shielded cabling is recommended Encoder Signal NI 9411 DB15 Connector Pin Encoder 5V optional Externally Supplied or NI 9411 Pin 4 5Vout Encoder Ground optional Externally Supplied or NI 9411 Pin 12 COM Encoder Z required NI 9411 Pin 2 P0 1 PFI 1 DI 1a Encoder Z Compliment NI 9411 Pin 10 P0 1 PFI 1 DI 1b optional Encoder A required NI 9411 Pin 1 P0 0 PFI O DI 0a Encoder A Compliment NI 9411 Pin 9 P0 0 PFI O DI Ob optional National Instruments All rights reserved 20 NI Combustion Analysis System Software for LabVIEW User s Manual NI 9401 Digital Input Module When using the NI 9401 digital I O module the crankshaft op
106. nt and Raw Summary The alignment and raw file buffers are many smaller buffers to hold data from different sources 3 Next Cycle Control Data Ready Angle The estimated angle where next cycle results are available The Alignment and Raw buffers gather and hold data from the DAQ system and waits for the desired number of cycles or data to become available The data is then distributed to other functions waiting on it Each source of data writes the data to its own smaller buffer The sizes of these buffers is determined by the maximum sample rate calculated from the engine speed and sample resolution or the sample frequency Next Cycle control data is handed off to the user program where it can be used for whatever control strategy needs it Data for processing real time results is passed to the processing code where it performs all the required calculations and hands the results to the display and summary file functions The raw data streaming has direct access to the alignment buffers and and pulls the buffers directly to disk National Instruments All rights reserved 96 NI Combustion Analysis System Software for LabVIEW User s Manual Alignment amp Raw File Buffers Other DAQ Other Buffers Sync DAQ Syne Buffer Next Cycle Queue User Code ULLAL Next Cycle Control Display Queue i alculate Statistics Async DAQ Async Buffer Processing HHHH for Display Data Queue HHHH Process Data amp Calculate Results Summary
107. olene Propane Custom Note Whenever heat transfer is being calculated the Gas Temp calculations must be enabled in the Calculations subhost 1 Heywood J B Internal Combustion Engine Fundamentals McGraw Hill Inc New York NY 1988 2 Russel L D and Adebiyi G A Classical Thermodynamics Saunders College Publishing Fort Worth TX 1993 National Instruments All rights reserved 137 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 Heat Release Models National Instruments All rights reserved 138 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 1 Single Zone dQ 2 y T n P aV y e n 1 d n 1 d where dQ d8 rate of heat release n polytropic coefficient V cylinder volume dP d8 cylinder pressure derivative with respect to w r t crank angle P cylinder pressure dV d8 cylinder volume derivative w r t crank angle 1 Grimm B M Johnson R T 1990 Review of Simple Heat Release Computations SAE Technical Paper Series 900445 2 Cheung H M Heywood J B 1993 Evaluation of a One Zone Burn Rate Analysis Procedure Using Production SI Engine Pressure Data SAE Technical Paper Series 932749 National Instruments All rights reserved 139 NI Combustion Analysis System Software for LabVIEW User s Manual 4 9 1 2 Single Zone Heat Transfer R E oS d y 1 d
108. on 0 01 Intake Temperature 298 K Intake Pressure 101 kPa abs Exhaust Temperature 298 K Exhaust Pressure 101 kPa abs Window 5 Exhaust Pressure Pressure of the intake gas at the intake valve Exhaust Temperature Temperature of the exhaust gas at the exhaust valve Intake Pressure Pressure of the exhaust gas at the exhaust valve Intake Temperature Temperature of the intake gas at the intake valve Residual Fraction Fraction of exhaust gas remaining in the combustion chamber after the exhaust event Window The crank angle window size used to average noise in synchronous waveform measurements National Instruments All rights reserved 73 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 8 Heat Release Settings The heat release settings define what settings are used for the various methods of calculating heat release Cic Cle Cige C2c C2e C2ge End Angle End of Combustion Heat Release Heat Transfer Heat Transfer Correlation N End N Start Polytropic Correlation PreChamber Volume Smoothing s Heat Release Settings Heat Release Model ser Heat Release VI User Defined v 1 Smoothing P lt 0 PreChamber Volume liter Polytropic Correlation Hayes SAE860029 0 a 0 b Heat Transfer Correlation Wall Temperature Profile Hohenberg w Constant v 0 Heat Transfer W m2 K 480 Wall Temperature
109. on and where the system could no longer write all incoming data to disk The maximum speed of the test engine was 8000 RPM Therefore the test results showing an 8000 RPM limit will probably be able to reach higher engine speeds 5 A ee Ase a a RESES fe ef NI cDAQ 1939 a ec o f eo f eoo f i 2500 2500 Tape pee roses Seca dE Se ee E eae l a kosmoso o of 0 4 ere ee ee Performance Optimization Settings Adjusted National Instruments All rights reserved 38 NI Combustion Analysis System Software for LabVIEW User s Manual 3 NI CAS Software Interface The NI CAS Software Host VI is the top level VI It contains links to all of the NI CAS Software built in screens and provides the user with a starting place This host always remains on top of other NI CAS Software hosts File Operate Calibration Snapshot T Engine Geometry Engine Geometry Calculations Next Cycle Calculations System Optimization Calculations System Optimization Sample Rates Sync Analog Channels Async Analog Channels Medium Speed Channels Analog Output Channels Sample Rates Sync Analog Channels Sync Digital Channels Async Analog Channels Async Digital Channels Medium Speed Channels FPGA Stream Analog Output Channels Deployment Development 1 Information and controls that are always available The user can switch between the setup and running modes open this help documentation or see if any error conditions exis
110. ools available with LabVIEW Remove some of the memory use or add more memory to the system to prevent the crashes Please check with National Instruments for details on upgrading memory in a real time system National Instruments All rights reserved 186 API Async ATDC BRIC BTDC CAD CAS cDAQ CPU DAQ DI dV EPT FFT FPGA HRR Hz GMEP IMEP kB kHz MAX MEP MFB MB MHz NI NMEP OS PFI PFI PMEP PR PCI PXI RIO NI Combustion Analysis System Software for LabVIEW User s Manual 7 Abbreviations Application Interface Asynchronous sampled at specific time intervals Crank Angle Degrees After Top Dead Center Bandpass Rectify Integrate and Compare Crank Angle Degrees Before Top Dead Center Crank Angle Degrees Combustion Analysis System Compact DAQ device Central Processing Unit Data Acquisition Direct Injection Differential Volume Engine Position Tracking Fast Fourier Transform Field Programmable Gate Array Heat Release Rate Hertz sec Gross Mean Effective Pressure Gross Mean Effective Pressure Kilobyte Kilohertz 10 sec Measurements and Automation Explorer Mean Effective Pressure Mass Fraction Burned Megabyte Megahertz 10 sec National Instruments Net Mean Effective Pressure Operating System Peripheral Input DAQ Port Fuel Injector Pumping Mean Effective Pressure Pressure Ratio Peripheral Component Interconnect PCI eXtensions for Instrumentation Recon
111. opment Version MAX Hardware Configuration eeeeeeeeeeeeeeeeeeeeeteeeeeeeneee 27 2 2 2 2 Deployment Version MAX Hardware Configuration eeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeee 29 2 3 3 Development Version Example Project and System Integration cc cceeeeceeeeeeeeeeeeeeeeeees 30 ZA Performante e ees ia sos eat a a nord each esi adhd aI Laclede ree 32 2 4 1 Development Version Performance Overview ssceseeeeeeeeeeeceeeeeeeeceeeeaneaesseesseeseess 33 ZAAA S Series Hardware s ccce a e e E eee 34 BN 2D ee ceceane te ea eter a ts oe neat aint aad sae alae ota i neat als casas 35 2 4 2 Deployment Version Performance Overview ceccecccceeeeeeeee eee eeeeeeeeaaaaaeeeeeeeeeeeeeeeeeeeeeeeea 36 24 2 4 CDAG Hardware siena aeea eea Tecate e aE E a aa ianereiie tal alate 37 2 4 2 2 NI cDAQ 1939 Benchmark sesser a a eee eee 38 3 NI GAS Softwares IntermaCe aen ee a aie thesis ET Er enti 39 Ro Pat Mis Ue ere ere ae eee ei eee a ee eR eR eee ee eee 41 Oo lal MSGR ST al T iis tata ee E E E E fois ashi eat Sit EtG te onde al idn totale taints 42 3 1 1 4 Project SOUP socked spose ieee e ee eon rete Cee 43 3 1 1 2 Enging Geometry Setups sirere ie seme ee a a aie again seek anata 44 Sse Me S Encoder lt 5 S LUD iaehiestas5ics can eauctbacaapednainseiecaneeueighordatmnnpimalos a a 46 oe Pt AIC UIAUOIS srne stesso fara cies oats ee a a cca E i colar te et tata ts 48 3 1 1 5
112. or Mac OS X and Linux operating systems does not require activation What is Activation Activation is the process of obtaining an activation code to enable your software to run on your computer An activation code is an alphanumeric string that verifies the software version and computer ID to enable features on your computer Activation codes are unique and are valid on only one computer What is the NI Activation Wizard The NI Activation Wizard is a part of NI License Manager that steps you through the process of enabling software to run on your machine What Information Do I Need to Activate You need your product serial number user name and organization The NI Activation Wizard determines the rest of the information Certain activation methods may require additional information for delivery This information is used only to activate your product Complete disclosure of the National Instruments software licensing information privacy policy is available at ni com activate privacy If you optionally choose to register your software your information is protected under the National Instruments privacy policy available at ni com privacy How Do Find My Product Serial Number Your serial number uniquely identifies your purchase of NI software You can find your serial number on the Certificate of Ownership included in your software kit If your software kit does not include a Certificate of Ownership you can find your serial numb
113. or via remote desktop over the network ccccccaee NI cDAQ 9174 NI cDAQ 9178 USB The NI cDAQ 9174 must have a NI 9411 recommended NI 9401 or a NI 9402 digital input module for encoder inputs The NI cCDAQ 9178 may use the chassis trigger lines a NI 9411 recommended a NI 9401 or a NI 9402 digital input module NI cDAQ 9184 NI cDAQ 9188 Ethernet The NI cDAQ 9184 must have a NI 9411 recommended NI 9401 or a NI 9402 digital input module for encoder inputs The NI cDAQ 9188 may use the chassis trigger lines a NI 9411 recommended a NI 9402 or a NI 9411 digital input module National Instruments All rights reserved 19 NI Combustion Analysis System Software for LabVIEW User s Manual C Series Hardware The Deployment Version of NI CAS Software requires a 4 slot or greater USB Ethernet or stand alone cDAQ chassis an NI 9411 digital input module and one or more analog input modules The compatible C Series I O modules are listed in the Support C Series Modules page Connect and install the cDAQ hardware according the recommendations found at http www ni com gettingstarted Encoder Connections NI 9411 Differential Digital Input Module recommended For optimum signal integrity NI recommends using the NI 9411 Differential Digital Input Module connected to an optical encoder supporting complimentary outputs When using the NI 9411 digital input module the crankshaft optical e
114. r Knock End Specifies the crank angle to end the knock window for each cylinder Knock Start Specifies the crank angle to start the knock window for each cylinder Low Cutoff Frequency Specifies the Low Cutoff Frequency of the knock filter for each cylinder Minimum Reference Specifies the Minimum Reference Value used to remove noise for each cylinder Reference End Specifies the crank angle to end the reference window for each cylinder Reference Start Specifies the crank angle to start the reference window for each cylinder Threshold Specifies the knock threshold for each cylinder National Instruments All rights reserved 76 NI Combustion Analysis System Software for LabVIEW User s Manual Calibrating knock is a delicate process of capturing various degrees of knock and comparing them to determine where the unacceptable level of knock occurs Changing settings will reprocess all the held data so the new settings can be evaluated over the range of operating conditions The process of calibrating knock starts with setting up windows for checking for knock and reference noise The Signal page shows the current cycle of pressure data and the acoustic waveform The knock window should be located around TDC The reference window should be located away from noise caused by valve closings and other noisy events
115. r cutoffs page displays the FFT of the for the knock and reference windows The first three theoretical fundamental frequencies based on cylinder bore are calculated and displayed for reference National Instruments All rights reserved 77 NI Combustion Analysis System Software for LabVIEW User s Manual s Knock Settings Compare Reference CAD Knock CAD Filter kHz Cylinder 2 O0tod 0tod Otod Cylinder 3 0to0 0to0 0to0 Cylinder 4 0to0 0to0 0to0 Cylinder 5 0to0 0to0 0to0 Cylinder 6 0to0 0to0 0to0 Cylinder Oto0 0to0 Oto0 Cylinder 8 0to0 0to0 0to0 Cylinder 9 0to0 0to0 0to0 Cylinder10 0to0 0to0 0to0 Cylinder 11 0to0 0to0 0to0 Cylinder12 0toO 0tod Otod Cylinder13 0tod 0tod Otod Cylinder14 0too 0to0 tod Cylinder15 0tod 0tod Otod Cylinder16 0tod 0to0 0to0 Reference Start 210 CAD Knock Start 0 CAD Reference End 180 CAD Knock End 30 CAD High Cutoff 8 kHz Min Reference 0 f Low Cutoff 5 kHz Threshold 0 5 J Hold 1 Clear 1 f NIV fV Bandpass Hold 2 Clear 2 ha Filter Hold 3 Clear 3 WIA Hold 4 Clear 4 W Pees Hold 5 Clear 5 Hold 6 Clear 6 Integrate Hold 7 Clear 7 e Knock Results Ss ss S S S S ss ssi S S S S Signals Current Hold 1 Hold 2 Hold 3 Hold 4 Hold 5 Hold 6 Hold 7 Current Hold 1 Hold 2 Hold 3 Ho
116. racking system Indicates the current cycle period measured by the engine position tracking system Indicates the current FPGA timestamp Indicates the state of the encoder Gate Reset signal Indicates the maximum crank angle ticks of the engine position tracking system Indicates an overspeed state of the engine position tracking system Indicates a stalled state of the engine position tracking system Indicates the start time of the current DAQ sampling task according to the FPGA timestamp Indicates a synchronized state of the engine position tracking system Indicates the state of the encoder Z signal Only available with the Development License National Instruments All rights reserved 94 3 2 0 4 Execution The execution status display indicates execution time of each processing and calculation step The calculations can be enabled or disabled using Calculations vi s Execution 41 us 161 us 1265 us 60 us 290 us 1 us 0 us 22 us 4 us 47 us 6 us 11 us 0 us 38 us 29 us 0 us 0 us 0 us 0 us 30 us 0 us 1 us 0 us Calibrate Scale TDC Offset Filter Separate Pegging User Process Basic MEP Motoring Gas Temp Injector Spark Heat Release Noise Misfire Cam Pump PWM Knock Pa PA A EA PA PA PAPA EA EA PA PA PA EA P PA PA PA EA EA PA D 2 E 3 un 5 m a User Calculations am Calculation Time us 12000 14000 1600
117. re Wall Temperature BDC Wall Temperature Profile Wall Temperature TDC NI Combustion Analysis System Software for LabVIEW User s Manual Specifies the angle to start looking for the start of combustion Specifies the method used to determine the start of combustion Specifies the file location of the user heat release VI if used Specifies the Wall Temperature when using the constant Wall Temperature Profile Specifies the Bottom Dead Center Wall Temperature when using the linear Wall Temperature Profile Specifies the method used to calculate the cylinder Wall Temperature Profile Specifies the Top Dead Center Wall Temperature when using the linear Wall Temperature Profile Defines the Polytropic Exponent Correlation a Value when using custom Polytropic Correlation Defines the Polytropic Exponent Correlation b Value when using custom Polytropic Correlation National Instruments All rights reserved 75 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 9 Knock Settings The knock settings determine how knock is detected The knock settings dialog provides information and displays that are helpful for calibrating the knock settings s Knock Settings x Reference CAD Knock CAD Filter kHz Signals Filter Cutoffs Filter Results Threshold Cylinder2 0to0 tod 0to0 Zi Current Za 6000 Cylind
118. requency and duty cycle of a PWM signal The frequency is calculated using the rising edges of the signal The duty cycle is calculated using the ratio of signal high time compared to the time between rising edges The cycle results are averaged over the entire cycle Note The sample rate of the system must be much greater than the PWM frequency to get accurate results sot Plot PWM Sto J PWM WL 1 1 I I I I I I 174 641 160 140 120 100 80 60 43 5026 Crank Angle CAD HEJ Cylinder 1 National Instruments All rights reserved 161 NI Combustion Analysis System Software for LabVIEW User s Manual 4 15 Knock NI CAS Software uses the Bandpass Rectify Integrate Compare BRIC knock detection method This method requires the user to define calibration windows where there is little electrical and mechanical noise The user also must provide cutoff frequencies for the bandpass filter 2nd order Butterworth IIR which allow the fundamental frequencies of knock to pass but not background noise The last required user input is the threshold where the raw knock intensity is considered to be knock Reference Knock Bandpass Filter R Rectify l R kK Integrate IK C Threshold Knock Compare R National Instruments All rights reserved 162 NI Combustion Analysis System Software for LabVIEW User s Manual 4 16 Spark NI CAS Software uses a current or voltage on the
119. respective companies For patents covering National Instruments products technology refer to the appropriate location Help Patents in your software the patents txt file on your media or the National Instruments Patent Notice at ni com patents You can find information about end user license agreements EULAs and third party legal notices in the readme file for your NI product Refer to the Export Compliance Information at ni com legal export compliance for the National Instruments global trade compliance policy and how to obtain relevant HTS codes ECCNs and other import export data National Instruments All rights reserved 193 NI Combustion Analysis System Software for LabVIEW User s Manual 9 4 Patents For patents covering the National Instruments products technology refer to the appropriate location Help Patents in your software the patents txt file on your media or the National Instruments Patent Notice at ni com patents National Instruments All rights reserved 194 NI Combustion Analysis System Software for LabVIEW User s Manual 9 5 Warning Regarding Use of NI Products WARNING REGARDING USE OF NATIONAL INSTRUMENTS PRODUCTS 1 NATIONAL INSTRUMENTS PRODUCTS ARE NOT DESIGNED WITH COMPONENTS AND TESTING FOR A LEVEL OF RELIABILITY SUITABLE FOR USE IN OR IN CONNECTION WITH SURGICAL IMPLANTS OR AS CRITICAL COMPONENTS IN ANY LIFE SUPPORT SYSTEMS WHOSE FAILURE TO PERFORM CAN REASONABLY BE EXPECTED TO CAUSE SIGNIFI
120. ring options a ee e Cylinder pressure pegging options e Optional user developed LabVIEW VI License Version PressureMetrics Metrics Development Deployment Bo aaa e Polytropic coefficients of compression and expansion O ed e Maximum Rate of Pressure Rise and Location e Gross IMEP Pumping MEP PMEP Net IMEP License Version Heat Release Analysis Deployment e Methods include X e Single Zone Single Zone Dual Transducer for pre chamber engines Single Zone Heat Transfer Single Zone Dual Transducer Heat Transfer Modified Rassweiler and Withrow Pressure Ratio User developed LabVIEW VI e Locations of Mass Fraction Burned 5 MFB 25 MFB 50 MFB X X 75 MFB 90 MFB Custom e Maximum heat release rate and location 2 X e Variety of heat transfer correction methods X National Instruments All rights reserved 8 NI Combustion Analysis System Software for LabVIEW User s Manual e In cylinder temperature estimation License Version Engine Noise and Knock Analysis Development Deployment e Raw time domain filtered and angle domain filtered noise indication e Bandpass Rectify Integrate Compare BRIC algorithm for knock X X signal processing e Visual FFT analysis of knock signals for calibration of BRIC License Version Additional Calculations and Analysis Development Deployment e Injection parameters of timing duration and quantity mg injection e Cycle to cycle injection quantit
121. s The analog instrumentation signals should be connected to the NI 9215 NI 9222 or NI 9223 analog inputs The BNC version of the NI 9215 is recommended for ease of connection Shielded BNC cables are recommended Configuring cDAQ Chassis with NI Measurement and Automation Explorer NI Measurements and Automation Explorer MAX should be used to discover or change the name of the DAQ device and its physical channels The names of the device and physical channels will be used on the measurement configuration tab of the user interface National Instruments All rights reserved 21 NI Combustion Analysis System Software for LabVIEW User s Manual Ethernet cDAQ devices must be registered and reserved in MAX before they can be used with the Deployment Version of NI CAS Software To add a cDAQ chassis to a system right click on My System gt Devices and Interfaces gt Network Devices and select Find Network NI DAQmx Device To reserve the cDAQ chassis on a system right click on the discovered cDAQ chassis and select Reserve Chassis When using the DAQ device with the Deployment Version of NI CAS Software only the terminals described above should be used In order to take full advantage of certain hardware features the Deployment Version of NI CAS Software makes programmatic internal connections Connecting signals to other terminals or running other programs which interact with the DAQ device may cause unexpected behavior Natio
122. s System Software for LabVIEW User s Manual 3 2 1 3 Pegging Settings ed for in cylinder applications are relative or dynamic measurements They are accurate in representing the change in pressure over a short period but do not represent an absolute vale To compensate pegging calculating a dynamic offset is used s Pegging Settings Pressure rave Manifold Absolute Pressure A Pegging Synchronous x Location 300 CAD 1 Window 5 CAD I 100 0 100 200 Crank Angle CAD 3 Cylinder 1 l 300 360 1 200 E wm 7 1 Detailed setup of the selected measurement 2 Plot of current sign als and windows 3 Selection of cylinder to display Location Pegging Pegging Pressure Polytropic Exponent Window Specifies the location used to peg cylinder pressure when using constant and synchronous MAP pegging Specifies the method used to peg cylinder pressure Specifies the pressure used to peg cylinder pressure when using constant pegging Specifies the polytropic exponent used for polytropic pegging The crank angle window size used to average noise in synchronous waveform measurements National Instruments All rights reserved 68 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 4 Filter Settings The filter settings define all the filters for engine synchronous and time based asynchronous measurements Each measurement can be conf
123. s reserved 155 NI Combustion Analysis System Software for LabVIEW User s Manual 1 Constant Defines a constant crank angle DATDC as the EOC 2 N Below Zero Sets a crank angle DATDC to end looking for the first negative zero crossing in the HRR waveform After N points are found past the negative zero crossing the crossing is confirmed to be the EOC If a negative zero crossing is not found the End Angle will be used as the EOC 3 Boxcar N Below Zero Same definition of N Below Zero except that a Boxcar filter of window N is applied to the HRR waveform Also rather than using N points to confirm the crossing the first negative zero crossing is taken as the SOC National Instruments All rights reserved 156 NI Combustion Analysis System Software for LabVIEW User s Manual 4 10 Combustion Noise Combustion noise is calculated based on the power level dB from the cylinder pressure waveform using the following steps Converting the cylinder pressure waveform from the engine position domain to the time domain Converting the cylinder pressure signal from the time domain to the frequency domain using Fast Fourier Transform FFT Converting the cylinder pressure frequency domain into a third octave spectrum to simulate analog devices Filter the spectrum for human auditory attenuation using the A weighting curve and for engine structure attenuation using the SA1 7dB curve Lucas plot Scarpat
124. served 173 e Al0 15 TDC e Data e Reduced Resolution e Reserved e DI4 15 DI Data Medium Speed e Time e Alo FPGA e Time ID e Data AIO User Setup Cycle e Time Speed e Cycle Slow Speed e Time Alo Array Data 1 e Crank Angle e Ald 0 Synchronous Waveforms 1 e Crank Angle e Alo Asynchronous Waveforms 1 e Crank Angle e AIO Calculation Waveforms 1 R C N S O NI Combustion Analysis System Software for LabVIEW User s Manual Synchronous channel Digital channel setup Digital channel setup Digital channel setup Digital channel setup Digital channel setup Digital channel data in bit field Medium speed data Sample timestamp Medium speed channel FPGA data Sample timestamp Sample ID Sample Data FPGA channels User defined calculation setup Cycle properties Cycle start timestamp Previous cycle speed Cycle number Slow speed data Sample timestamp Slow speed channel Post process cycle by cycle waveforms for each cylinder Cycle crank angle Cycle by cycle data Engine synchronous ensemble averages for each cylinder Cycle crank angle Ensemble average waveform Asynchronous ensemble averages for each cylinder Cycle crank angle Ensemble average waveform Calculated ensemble averages for each cylinder National Instruments All rights reserved 174 e Crank Angle S e AIO S N Calculation Res
125. sing the Bundle by Name function block and typedef provided Convert the bundle to an array of bundles and connect this to the User Results indicator User Results National Instruments All rights reserved 169 NI Combustion Analysis System Software for LabVIEW Packing outputs into an array of bundles User s Manual 6 Use the Save As function to save your VI as a copy renaming the new variant so that the template is not overwritten Finally select your VI in the Calculations subhost of NI CAS Software and view the result in the User table s Calculations a isbed_ Use Proces i FPGA Enabled User Calculations C CAS Calculations User g Cumulative Heat Release vi Selecting and enabling User Calculations National Instruments All rights reserved 170 NI Combustion Analysis System Software for LabVIEW User s Manual Cumulative Heat Release J Mean Cumulative Heat Release J Max Cumulative Heat Release J Min 309 Cumulative Heat Release J Min Cumulative Heat Release J SD 3 0359 3 0969 2 6701 3 0543 2 9643 Cumulative Heat Release J COV Viewing User results National Instruments All rights reserved 171 NI Combustion Analysis System Software for LabVIEW User s Manual 5 Post Processing National Instruments All rights reserved 172 NI Combustion Analysis System Software for LabVIEW User s Manual 5
126. sing this software cylinder pressure can be pegged using a constant value synchronous manifold absolute pressure MAP signal or a polytropic coefficient Note If a pre chamber pressure is used it will be pegged in the same manner as the primary cylinder pressure National Instruments All rights reserved 118 NI Combustion Analysis System Software for LabVIEW User s Manual 4 3 1 Constant The Constant pegging setting requires a constant scalar value as the pegging reference a pegging location and a pegging window The pegging location typically near a relatively quiescent period within the cycle and while the intake valve s are open specifies the crank angle at which the pegging reference will exactly equal the average of the cylinder pressure waveform over a given pegging window The pegging window is centered about the pegging location National Instruments All rights reserved 119 NI Combustion Analysis System Software for LabVIEW User s Manual 4 3 2 Synchronous MAP The Synchronous MAP pegging setting requires a configured sync analog channel Manifold Absolute Pressure kPa as the pegging reference a pegging location and a pegging window The pegging location typically near a relatively quiescent period within the cycle and while the intake valve s are open specifies the crank angle at which the pegging reference will exactly equal the average of the cylinder pressure waveform over a given pegging
127. software Finally make sure the PXI system controller and PXI chassis are defined correctly in MAX as shown in figures below MAX can also change the aliases names and basic configurations of the DAQ devices if desired The user must take note of a few configuration settings in MAX in order to work with NI CAS Software The DAQ device aliases as shown in the figures below are used to identify the physical channels in the NI CAS Software measurement setup The DAQ device can be renamed by right clicking on the device and selecting the rename option Finally the user must confirm that the PXI Trigger Lines are not reserved for other functions in MAX as shown in the figures below They are automatically reserved as a part of the channel configuration within the NI CAS Software X Chassis 1 PXI 1031 Measurement amp Automation Explorer File Edit View Tools Help Configuration l H Save Eh Open VISA Test Panel 9 My System 9 Remote Systems 3 i RETOO3 a Chassis 1 PXI 1031 Dats Neighborhood i Devices and Interfaces Chassis Status Ga NI DAQmx Devices This chassis is properly configured PXI PXI System NI PXI 8106 SCE E RIO Devices J Serial 4M Scales 6 Software assis Identification Chassis Number 1 General Slot View Triggers PXI Chassis Identification configuration in MAX National Instruments All rights reserved 27 NI Combustion Analysis System Software for LabVIEW Us
128. system where data will be saved File Name Name of saved files XXX is replaced by the File Counter and standard data time formats c are applied to the name Comments User comments added to the file Single Continuous Single One file is written and saving stops Continuous A new file is started when the previous one finishes File Part increments by on for each file The saving process must be stopped manually National Instruments All rights reserved 87 File Part Size Limit Time Limit Cycle Limit File Counter Reset Counter Value Reset Counter File Progress Process File File Error Data Time Format X locale specific time NI Combustion Analysis System Software for LabVIEW User s Manual Indicates the current part of a continuous multi part save Enables a size limit on file saving and defines the maximum file size Enables a time limit on file saving and defines the maximum time Enables a cycle limit on file saving and defines the maximum number of cycle Indicates the current file count Desired value to set File Counter to when Reset Counter button is pressed Resets the file counter to the Reset Counter Value Indicates the approximate status of the file save compared with the file limit conditions Contains a path to a VI on the target system that will be used to process the files after a save operation Leave it blank to disable file processing Indicates the current file that
129. t There may also be menu items available for saving and loading calibrations and other useful functions 2 Selection of different configurations and results groups National Instruments All rights reserved 39 NI Combustion Analysis System Software for LabVIEW User s Manual 3 SubHost list containing all the available NI CAS Software sub hosts Double clicking a name opens it if it is closed normal or closes it if open bold A single click on an open bold name brings it to the front National Instruments All rights reserved 40 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 Offline National Instruments All rights reserved 41 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 General Setup National Instruments All rights reserved 42 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 1 Project Setup The project setup options must be configured in the offline mode Information entered here will help identify calibration files once loaded Internal software simulation is also enabled in this window s Project Setup Engine GM 1 9L Diesel Project Demo Operator NI Simulation Disabled Settings lt Engine Specifies the name or description of the engine Operator Specifies the engine operator Project Specifies the current test project Simulation Enables a simulation that doesn t req
130. t Legend Displays plot names and units with the ability to turn off a plot 2 Plot Data Data display area 3 Plot Controls Controls for controlling Zoom and cursors National Instruments All rights reserved 105 NI Combustion Analysis System Software for LabVIEW User s Manual E 2s s Plot PV v Cyll Avg 1 Pressure kPa abs I 0 0 1 0 2 03 04 05 0 6 Volume liter Thi AON s plot displays the pressure vs volume for all the cylinders and engine average for a single cycle Plot Legend Displays plot names and units with the ability to turn off a plot Plot Data Data display area Plot Controls Controls for controlling zoom and cursors Axis Changes the axis to a log or linear scale National Instruments All rights reserved 106 NI Combustion Analysis System Software for LabVIEW User s Manual s Plot Detailed PV E XG v Intake of J Compression AA A Av v Expansion J Exhaust 1 Pressure kPa abs 0 0 1 0 2 0 3 0 4 0 5 0 6 Volume liter 4 5 Cylinder 1 3 2 This plot displays the pressure vs volume for a single cylinder and a single cycle Plot Legend Displays the name and color for each stroke Plot Data Data display area Plot Controls Controls for controlling Zoom and cursors Cylinder Selection Select the cylinder to display Axis Changes
131. terID 0 Settings p 08 Sete si fall Add Insert Units Terminal Configuration E H default H12 l Delete a l m3 Raw Hardware Input Limitations Gain Only be Jo Min 10 Max F16 l Move Up Move Down 1 Gain 3 Saling 1 Summary of all defined measurements 2 Controls for manipulating the list of measurements 3 Detailed setup of the selected measurement Cylinder Disable Filter Gain Max Min Name Offset Physical Channel Polynomial Coefficients Scaling Table X Table Y Cylinders associated with each measurement in a bitfield Disables data acquisition and calculations associated with each measurement Filter resource number associated with each measurement 0 No Filter Gain associated with each measurement when using the gain only or gain and offset scaling methods Maximum channel voltage range associated with each measurement Minimum channel voltage range associated with each measurement Name or description associated with each measurement Offset associated with each measurement when using the gain and offset scaling method Physical channel associated with each measurement Polynomial Coefficients associated with each measurement when using the polynomial scaling method Scaling method associated with each measurement Table X array associated with each measurement when using the table scaling method Ta
132. th to a VI on the target system that will be used to process the files after a save operation Leave it blank to disable file processing File Indicates the current file that is processing and any files waiting to be processed Error Indicates any error associated with file processing Data Time Format X locale specific time H hour 24 hour clock l hour 12 hour clock M minute S second lt digit gt u fractional seconds with lt digit gt precision p a m p m flag x locale specific date y year within century Y year including century m month number b abbreviated month name d day of month a abbreviated weekday name National Instruments All rights reserved 90 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 3 Status National Instruments All rights reserved 91 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 3 1 Engine The engine status display shows the current speed of the engine It also shows the running time and engine cycle so x 1000 Time 3980654080 ns Cycle 749 X National Instruments All rights reserved 92 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 0 2 Resources The resources display shows the status of the system hardware resources s Resources lol Sm Free Disk Space 129865 MB 24 Core 19 9 cpuji5 Ji RA
133. the axis to a log or linear scale Ee NS National Instruments All rights reserved 107 NI Combustion Analysis System Software for LabVIEW User s Manual 3 3 3 Tables Tables contain all of the calculated values and rolling statistics for each result The results are grouped by calculation group that can be turned on or off See Calculations vi to turn or off the calculation groups Peak Pressure kPa abs Mean Peak Pressure kPa abs Max Peak Pressure kPa abs Min Peak Pressure kPa abs SD Peak Pressure kPa abs COV Peak Pressure Location CAD Peak Pressure Location CAD Mean Peak Pressure Location CAD Max Peak Pressure Location CAD Min Peak Pressure Location CAD SD Peak Pressure Location CAD COV Max Pressure Rise Rate kPa CAD Max Pressure Rise Rate kPa CAD Mean Max Pressure Rise Rate kPa CAD Max Max Pressure Rise Rate kPa CAD Min Max Pressure Rise Rate kPa CAD SD Max Pressure Rise Rate kPa CAD COV me 3 k D iw k i 8 oO Peak Pressure kPa abs Mean Peak Pressure kPa abs Max Peak Pressure kPa abs Min m Peak Pressure kPa abs SD 2 Peak Pressure kPa abs COV Peak Pressure Location CAD Peak Pressure Location CAD Mean Peak Pressure Location CAD Ma Peak Pressure Location CAD Min Peak Pressure Location CAD SD Peak Pressure Location CAD COV Max Pressure Rise Rate kPa CAD Max Pressure Rise Rate kPa CAD Mea
134. thmic P V diagram Specifies the maximum threshold for the calculated polytropic coefficient of the expansion stroke Specifies the minimum threshold for the calculated polytropic coefficient of the expansion stroke Specifies the cylinder used as a reference for TDC offset settings Specifies the size of rolling statistics buffers Sets a new TDC Offset value indicated by the Calc TDC Offset Because the TDC Offset must be configured in the Offline mode the DAQ software must be reinitialized Specifies the TDC fine adjustment A TDC offset may force resampling data which can be slow Specifies the global TDC Offset It is commonly used to easily adjust for changes in the encoder without needing to change each cylinder TDC Indicates the difference between the current TDC offset and the new Calc TDC Offset Specifies the method used to calculate a new TDC Offset National Instruments All rights reserved 66 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 2 Async Conversion Settings The async conversion settings define the method of converting signals to synchronous or asynchronous types depending on what types of signals are available s Async Conversion Settings aja Conversion Fast v Conversion Specifies the method used to convert synchronous data to asynchronous data National Instruments All rights reserved 67 Many of the sensors us NI Combustion Analysi
135. tical encoder must be powered externally and a ground reference from the encoder must be connected to a COM pin of the NI 9401 module The encoder should be connected to the NI 9401 module according to the table below Shielded cabling is recommended Crankshaft optical encoder connections to the NI 9401 module Encoder Signal NI 9401 DB25 Connector Pin Encoder Ground required NI 9401 Pin 1 COM Encoder Z required NI 9401 Pin 16 PO 1 PFI 1 Encoder A required NI 9401 Pin 14 PO 0 PFI 0 NI 9402 Digital Input Module When using the NI 9402 digital I O module the crankshaft optical encoder must be powered externally The NI 9402 should be used when BNC connectors are desired The encoder should be connected to the NI 9402 module according to the table below Crankshaft optical encoder connections to the NI 9402 module Encoder Signal NI 9402 BNC Encoder Z required NI 9402 BNC2 P0 1 PFI 1 Encoder A required NI 9402 BNC1 P0 0 PFI 0 NI cDAQ 9178 Chassis When using the NI cDAQ 9178 chassis external triggers the crankshaft optical encoder must be externally powered The encoder should be connected to the NI cDAQ 9178 chassis according to the table below Shielded cabling is recommended Crankshaft optical encoder connections to the cDAQ 9178 chassis Encoder Signal NI cDAQ 9178 Chassis BNC Connector Encoder Z required cDAQ 9178 Trig 1 Encoder A required cDAQ 9178 Trig 0 Analog Input Module Connection
136. to 20 mA Analog Output Module Recommended NI 9269 Channel to Channel Isolated 10 V Analog Output Module Recommended If BNC connectivity is required we recommend using L com Item BC55 or L com Item BC25 National Instruments All rights reserved 15 NI Combustion Analysis System Software for LabVIEW User s Manual 2 2 Hardware Configuration National Instruments All rights reserved 16 NI Combustion Analysis System Software for LabVIEW User s Manual 2 2 1 Development Version Hardware Setup PXI Chassis Configuration The PXI chassis should contain an NI PXI 785xR FPGA and one or more NI PXI 6123 S Series devices The R Series devices must be inserted into PXI slot number 2 adjacent to the controller The FPGA is used to track the engine position and generate sample clocks The FPGA should connect to a NI 9151 expansion chassis with a NI 9411 DI module for the encoder inputs S Series Accessory Configuration The NI PXI 6123 S Series devices requires four wiring jumpers applied at each NI BNC 2090A accessory as shown in the diagrams below For the NI BNC 2090A accessory NI recommends that 3 of 2OAWG wire with ends stripped by 0 25 should be used for each jumper NI PXI 6123 Accessory Terminals PFI 03 Optional User Input Optional User Input Optional User Input POG Optional User Input NI 9411 Digital Input Module Connections When using the NI 9411 digital input module the crankshaft optical encod
137. tocopying recording storing in an information retrieval system or translating in whole or in part without the prior written consent of National Instruments Corporation National Instruments respects the intellectual property of others and we ask our users to do the same NI software is protected by copyright and other intellectual property laws Where NI software may be used to reproduce software or other materials belonging to others you may use NI software only to reproduce materials that you may reproduce in accordance with the terms of any applicable license or other legal restriction End User License Agreements and Third Party Legal Notices You can find end user license agreements EULAs and third party legal notices in the following locations Notices are located in the lt National Instruments gt _Legal Information and lt National Instruments gt directories EULAs are located in the lt National Instruments gt Shared MDF Legal license directory Review lt National Instruments gt _Legal Information txt for information on including legal information in installers built with NI products National Instruments All rights reserved 192 NI Combustion Analysis System Software for LabVIEW User s Manual 9 3 Trademarks Refer to the NI Trademarks and Logo Guidelines at ni com trademarks for more information on National Instruments trademarks Other product and company names mentioned herein are trademarks or trade names of their
138. ual 3 1 2 7 FPGA Stream Setup The FPGA setup is used to define data streamed from the FPGA The measurements are defined in the FPGA when using an FPGA with the Development Version of NI CAS Software Defining them in the FPGA setup allows the Development Version of NI CAS Software to calculate cycle averages and statistics for the display and summary files s FPGA Stream Setup tol So Name Injector Timing Disabled Cycle Average and Stats Injector Duration Name Add Insert Delete Move Up Move Down 1 Summary of all defined measurements 2 Controls for manipulating the list of measurements Enable Disable engine cycle averages and statistic calculations 3 Detailed setup of the selected measurement Gain ID Name Offset Units Gain associated with each measurement ID associated with each FPGA measurement Name or description associated with each measurement Offset associated with each measurement Units associated with each measurement Only available with the Development Version of NI CAS Software National Instruments All rights reserved 61 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 2 8 Analog Output Channels Setup The analog output setup defines analog outputs channels These channels link to calculated results in NI CAS Software based on name The recent names contain a list of available results from the last time the system ran
139. uire hardware National Instruments All rights reserved 43 NI Combustion Analysis System Software for LabVIEW User s Manual 3 1 1 2 Engine Geometry Setup The engine geometry setup must be configured in the offline mode Information entered should be specific to the engine and test setup as it affects all of the calculations results s Engine Geometry Setup e x Head Area 100 Cylinder Count Clearance Volume 0 028933 liter 4 Displacement Volume 0 477404 liter Cylinder TDC anr DATDC Volume File Enable VA Crown Area 100 0 1 540 2 180 3 e _ gt Stroke 0 0904 m v Compression Ratio 17 5 Pin Offset 0 m Connecting Rod Length 0 1454 m Rotations Per Cycle 2 Intake Valve Open 360 DATDC Intake Valve Close 180 DATDC Exhaust Valve Open 180 DATDC Exhaust Valve Close 360 DATDC Bore 0 082 m Bore Clearance Volume Compression Ratio Connecting Rod Length Crown Area Cylinder Count Cylinder TDC Specifies the cylinder bore Specifies the clearance volume of the cylinder Compression Ratio Displacement Volume Clearance Volume Clearance Volume Indicates the calculated compression ratio Compression Ratio Displacement Volume Clearance Volume Clearance Volume Specifies the connecting rod length Specifies the piston crown surface area relative to the bore area Defines the number of cylinders in the engine Defines the cyl
140. ults 1 S e AIO S N R Raw Data S Summary Data C Configuration Properties O Optional N Names Vary NI Combustion Analysis System Software for LabVIEW User s Manual Cycle crank angle Ensemble average waveform Calculated results for each cylinder Calculated values National Instruments All rights reserved 175 NI Combustion Analysis System Software for LabVIEW User s Manual 5 2 Summary Files Summary files contain all the calculated results and ensemble averages for all the waveforms Opening Summary Data Files 1 Determine the file version and if it is a raw or summary file 2 Read configuration data a General settings are found at the group level b Channel settings are found at the channel level 3 Read ensemble averages for desired cylinder 4 Read calculated results for desired cylinder National Instruments All rights reserved 176 NI Combustion Analysis System Software for LabVIEW User s Manual 5 3 Raw Files NI CAS Software includes several SubVIs to handle all the raw opening and processing These subVIs are are part of an example application that can be used to view raw data files Please note that the raw data files start at an arbitrary crank angle and must be aligned using data encoded in the file The files store data as it is read from the device Therefore the individual cylinder offsets must also be accounted for In the figure below cycle X is the first available cycle LabVIE
141. ummary File SAVE cocci oe scat cade cess ce hic ha ceesnces sock caacgs caceeeabe cee cineccnag edaetaasuacoeuayectnets 89 ss oe IS a eer eho nal Asse ttt a a ae eee aT e5 Galt Sella staal E ae ee asennad had Ble 91 2c ENGING s2c c cba Sak ce es eda ea sae aes ae a ae Saket aed aa Satta cae 92 3 20 2 RESOURCES Gos hres cites cites Lacan T E A E Oh cei n ETE 93 Doe oe BP Vises a ee Saco eee ate Cae cere eee EE 94 3229 4 EXCGUUOM AAE EE EEEE AEA EE AEAEE Gl ee ae Nias es Gatti cians Nal tees 95 3 2 9 9 BUSI cece Sek a e in ee es A ak at eae a ee ok kee athe ek ets ee a ee 96 CIES A OOD create cca EE as ev dncie antes Sutures antes E A E ARE E E 98 AAT fam KO Pee Pee Een ee ee 99 Ses a CLT B85 oh heel Et le seat act enl crate N eh E AAE EAEE EE 100 CS M ED aS ee ney yey ee eee 101 EE A Coe ee ae Beane OEE ER RD Rene ene Seer anne ane E EETAS 102 CRS 90 al lt er Per E ne ee eee 108 doo AIEO I EA aie AEE 2h fal A Cane seta ae peek Gl een ON tel atta he Stee 109 4 Processing and CalCulatiOMs vssiscicccecses cesece rae cdase cele ccs Cebacata sshd SavgabadacdedksaNeetacelecns geutaecdsbdatueeieus 110 A PAIE AAT ere V ONIN Genes ets cierto os cua ve beth alts 2s eth rete ith Os el heh E EEE 111 4 2 Waveform Filters corer fez aeina einan aanaeio eena nEn Sseeus ces cae rameeas ceceucsut eet meeateaageceececeugaxeenyiciee 113 AZ A 10 CAM E a Os eee E A EEA EEEE EAEE EE EA 114 4 2 2 ROINN CyCIES diiic aaea naa re Eaa aaaea a Aaaa EAEE AA RE
142. ure etc and engine asynchronous knock etc domains Support for mapping calculated parameters to analog output channels ae X e Complete set of engine geometry inputs for cylinder volume calculation X e Optionally load volume from file e Online motoring test assists with engine geometry verification X e TDC probe channel configuration and analysis i X e Allows online adjustment of TDC index lt 2 CAD feo l X License Version Diaan a Sil CI Vieira ce OO CE re er OE a e Use of Engine Position Tracking EPT block for extrapolation of lower resolution production trigger wheels for high resolution sampling and control License Version File Saving Development Deployment e Supports simultaneous streaming of raw and summary data to TDMS file X X continuously by cycle count time or file size e Raw data files include channel configuration engine geometry and test data to allow full reconstruction of the test environment in post processing e Supports an external hardware trigger for file saving e Saves all non NI CAS Software related CalPoints e g engine controls S ae National Instruments All rights reserved 7 NI Combustion Analysis System Software for LabVIEW User s Manual License Version Pre Processing S e a iai e E rr alignment of data in both engine synchronous and engine asynchronous domains e Data Bac cs ac ag cs to engineering units e Broad range of signal filte
143. ure Rise Rate kPa CAD FAW Y 31007 5350 1 02 42 PM 02 44 PM 2 4 Show Statistics mi 4 1 Parameter A list of parameters calculated by the specific calculation group 2 Show Statistics Turns on or off rows of statistics 3 Values History of calculated results 4 Plot Controls Controls for controlling zoom and cursors National Instruments All rights reserved 109 NI Combustion Analysis System Software for LabVIEW User s Manual 4 Processing and Calculations National Instruments All rights reserved 110 NI Combustion Analysis System Software for LabVIEW 4 1 Cylinder Volume User s Manual Cylinder volume is calculated using the following equation for the typical crank slider mechanism no wrist pin offset 2 Smax atl s axcos 41 a sin ca 1 a cos 17 ax sin m B vans A An Ac B a 1 a cos 6 V17 la w sin 0 For engines requiring a wrist pin offset the following geometry calculations are used Smax y a 1 x s a cos 17 a sin x V V g V P a a cos V1 a sin 8 P A A A x B VG 1 x a cos 6 VI a sin 6 x 2 where National Instruments All rights reserved 111 NI Combustion Analysis System Software for LabVIEW User s Manual 1 Heywood J B Internal Combustion Engine Fundamentals McGr
144. used to calculate the polytropic exponents Specifies the end of the polytropic compression calculation Specifies the start of the polytropic compression calculation Specifies the end of the polytropic expansion calculation National Instruments All rights reserved 70 NI Combustion Analysis System Software for LabVIEW User s Manual Polytropic Expansion Start Specifies the start of the polytropic expansion calculation National Instruments All rights reserved 71 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 6 Unit Conversions Settings The unit conversion dialog allows the user to define a set of unit conversion rules The rules affect the tables trends and plots They do not change the units of settings or results in a file s Unit Conversions Settings U Z kPa psi 0 145038 a kPa abs psia 0 145038 ns sec 1E 9 kw hp 1 34102 Unit conversions are controlled in 2 places 1 This window is used to convert units on Tables Trends and Plots 2 Settings with units can be modified using CalVIEW Please see the c CalVIEW users manual for details on setting up unit conversions National Instruments All rights reserved 72 NI Combustion Analysis System Software for LabVIEW User s Manual 3 2 1 7 Temperature Settings The temperature settings define how the in cylinder temperature estimation is calculated 2s s Temperature Settings Residual Fracti
145. ws for the calculation of the polytropic coefficient The polytropic coefficient is uses in many other calculations including heat release Therefore it is necessary to calculate the polytropic coefficient The polytropic coefficient n is derived in the following equations Py_4 Any P v eR a log g P 1 V Vi In order to calculate the polytropic coefficients of compression PolyC and expansion PolyE the associated ranges for PolyC and PolyE must be set within the Pressure Metrics Settings window of the NI CAS Software Interface The following methods are then available for the calculation of PolyC and PolyE 1 The Point by Point method uses the entire ranges specified for PolyC and PolyE Within the ranges the equation for n is solved repeatedly for each successive pair of discrete points The collection of PolyC and PolyE results is then averaged for the reported PolyC and PolyE 2 The Endpoints method uses the start and end locations of the ranges specified for PolyC and PolyE as endpoints In order to eliminate error caused by noise in the pressure waveform a window around each endpoint is specified in which the values are averaged to calculate the endpoint value 2 CAD represents 2 CAD on each side of the given point The equation for n is solved using the endpoints resulting in the reported PolyC and PolyE 3 The Power Fit or Least Squares Fit Power Law method uses the entire ranges spe
146. xpansion The TDC probe location result is calculated and recorded with the pressure metrics as it relates to the phasing of the pressure and volume waveforms National Instruments All rights reserved 122 NI Combustion Analysis System Software for LabVIEW User s Manual 4 4 1 Pressure and Pressure Rise Rate The standard method of calculating the peak pressure and peak pressure rise rate values and locations involves simply using the built in LabVIEW array functions to search a pre defined window of the pressure and pressure rise rate arrays for the maximum values and locations The spline method of calculating the peak pressure and peak pressure rise rate values and locations involves creating a splined waveform for each array that has ten times the resolution of the pressure array The splined waveform arrays are searched for peak values and locations using the built in LabVIEW array functions Note The spline method is very resource intensive and should be avoided on less powerful processors National Instruments All rights reserved 123 NI Combustion Analysis System Software for LabVIEW User s Manual 4 4 2 Polytropic Coefficients The compression and expansion of the gas inside the engine cylinder can be approximated as a polytropic process The compression and expansion of the gas obeys the relationship Ppa Cc where C is a constant Applying the relationship to several points on the compression or expansion curve allo
147. y mg cycle e Ignition parameters of timing and dwell e Optional user developed LabVIEW VI National Instruments All rights reserved 9 NI Combustion Analysis System Software for LabVIEW User s Manual 1 2 Data Flow The Development Version of NI CAS Software example project employs the real time data flow structure shown below with an optional next cycle control path In the next cycle control path the DAQ alignment is stopped early to allow selected calculations to complete before the subsequent cycle begins The example application also provides an estimated angle of completion of next cycle calculations The Deployment Version of NI CAS Software utilizes a similar data flow structure however the data processing takes place within a Microsoft Windows operating system and lacks next cycle calculation capability Actuators SN Online Display Real Time Post Processing Report National Instruments All rights reserved 10 NI Combustion Analysis System Software for LabVIEW User s Manual 2 Getting Started National Instruments All rights reserved 11 NI Combustion Analysis System Software for LabVIEW User s Manual 2 1 Recommended System Requirements Note System requirements will vary based on many factors including e Number of measurements e Maximum sample rate e Enabled real time calculations Development Version of NI CAS Software Target System Recommended Real time System

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