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Engineering

Powertrain Instrumentation and Test Systems

Profile image of Michael PaulweberMichael Paulweber

2016, Powertrain

https://doi.org/10.1007/978-3-319-32135-6
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19 pages

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Abstract

The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use.

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References (158)

  1. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  2. 2 Types of Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
  3. 1 Combustion Engine Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
  4. 1.1 Scope of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  5. 2.1.2 Setup of a Test Bed for Internal Combustion Engines . . . . . .
  6. 2.1.3 Steady-State Engine Test Beds . . . . . . . . . . . . . . . . . . . . . .
  7. 2.1.4 Non-Steady-State Test Beds . . . . . . . . . . . . . . . . . . . . . . . .
  8. 2.1.5 Research Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  9. 2.1.6 Special-Purpose Engine Test Beds . . . . . . . . . . . . . . . . . . . .
  10. 2.2 Component Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
  11. 2.1 Test Beds for Components of Internal Combustion Engines . . . .
  12. 2.2.2 Test Beds for Hot Gas Components . . . . . . . . . . . . . . . . . . .
  13. 2.2.3 Test Beds for Transmission Components . . . . . . . . . . . . . . .
  14. 2.2.4 Starter Motor Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  15. 2.2.5 Electric Motor Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . .
  16. 2.2.6 Inverter Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  17. 2.2.7 Battery Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  18. 2.2.8 Fuel Cell Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
  19. 3 Control Unit Test Beds (HiL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
  20. 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  21. 2.3.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  22. 2.3.3 Control Unit Component Testing . . . . . . . . . . . . . . . . . . . . .
  23. 2.3.4 Control Unit Integration Testing . . . . . . . . . . . . . . . . . . . . . 61 ix 2.3.5 Test Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  24. 2.3.6 Model-Based Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 63
  25. 4 Powertrain Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
  26. 4.1 Powertrain Test Beds with Internal Combustion Engine . . . .
  27. 2.4.2 Powertrain Test Beds with a Prime Mover as Drive Unit . . .
  28. 2.4.3 Hybrid Powertrain Test Beds . . . . . . . . . . . . . . . . . . . . . . . . 75
  29. 5 Vehicle Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
  30. 5.1 Chassis Dynamometers for Emissions Development and Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  31. 2.5.2 Chassis Dynamometers for Fuel Consumption and Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  32. 2.5.3 Chassis Dynamometers for Endurance and Durability Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  33. 2.5.4 Chassis Dynamometers for NVH Analysis . . . . . . . . . . . . . .
  34. 2.5.5 Chassis Dynamometers for EMC Analysis . . . . . . . . . . . . . .
  35. 2.5.6 Chassis Dynamometers for Advanced Applications . . . . . . .
  36. 2.6 Racing Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
  37. 6.1 Engine Test Beds for Racing . . . . . . . . . . . . . . . . . . . . . . . .
  38. 2.6.2 Component Test Beds for Racing . . . . . . . . . . . . . . . . . . . . 93
  39. 7 Emission Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
  40. 7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  41. 2.7.2 Exhaust Emissions Testing for Passenger Cars on the Chassis Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  42. 2.7.3 Exhaust Emissions Testing for Commercial Vehicles . . . . . .
  43. 2.7.4 Exhaust Emissions Testing for Non-Road Engines . . . . . . . .
  44. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
  45. Hardware Perspective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
  46. 1 Test Bed Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
  47. Isolated Base Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  48. 3.1.2 Mounting Systems and Pallet Systems for Units Under Test . . .
  49. 3.1.3 Shaft Connections and Safety Covers . . . . . . . . . . . . . . . . . .
  50. 3.1.4 Shaft Dimensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
  51. 2 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
  52. 2.1 Mechanical Load Systems . . . . . . . . . . . . . . . . . . . . . . . . . .
  53. 3.2.2 Other Mechanical Load Systems . . . . . . . . . . . . . . . . . . . . .
  54. 3.2.3 Electric Load Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  55. 3.2.4 Climate/Media Conditioning Systems . . . . . . . . . . . . . . . . . 148
  56. 3 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
  57. Temperature Measurement . . . . . . . . . . . . . . . . . . . . . . . . .
  58. 3.3.2 Measuring Electrical Quantities . . . . . . . . . . . . . . . . . . . . . .
  59. 3.3.3 Strain Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  60. 3.3.4 Force and Pressure Measurement . . . . . . . . . . . . . . . . . . . . .
  61. 3.3.5 Acceleration Measurement . . . . . . . . . . . . . . . . . . . . . . . . .
  62. 3.3.6 Torque Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
  63. Speed Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  64. 3.3.8 Fuel Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
  65. 9 Air Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
  66. 3.10 Oil Consumption Measurement . . . . . . . . . . . . . . . . . . . . . . 179
  67. 3.11 Ignition Timing Measurement . . . . . . . . . . . . . . . . . . . . . . . 181
  68. Lambda Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
  69. 3.13 Exhaust Emission Measurement . . . . . . . . . . . . . . . . . . . . . 184
  70. 3.14 Particulate Measurement and Exhaust Gas Opacity . . . . . . . . 209
  71. 3.15 Swirl and Tumble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
  72. Indicating Measurement Technology . . . . . . . . . . . . . . . . . . 241
  73. 3.17 Fuel Cell Measurement Technology . . . . . . . . . . . . . . . . . . . 242
  74. 4 Errors and Accuracy of Measurement . . . . . . . . . . . . . . . . . . . . . . .
  75. 3.4.1 Measuring Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  76. 3.4.2 Effect of the Sensor Installation Location . . . . . . . . . . . . . . .
  77. 3.4.3 Measurement Uncertainties . . . . . . . . . . . . . . . . . . . . . . . . .
  78. 3.4.4 Interpolation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  79. 3.4.5 Calibration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
  80. 3.4.6 Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . 253
  81. 5 Bus Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
  82. 5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  83. 3.5.2 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  84. 3.5.3 PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  85. 3.5.4 Industrial Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  86. 3.5.5 Further Vehicle Buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
  87. 6 PC Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
  88. 6.1 RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  89. 3.6.2 RS422 and RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  90. 3.6.3 Ethernet, TCP/IP and UDP . . . . . . . . . . . . . . . . . . . . . . . . .
  91. 3.6.4 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  92. 3.6.5 IEEE1394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  93. 3.6.6 VXI, VISA, PXI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  94. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  95. 4 Software Perspective: Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
  96. 1 Software Architecture and Interface Standards . . . . . . . . . . . . . . . . . 277
  97. 1.1 Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
  98. 1.2 Interface Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
  99. 2 Measurement Data Acquisition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
  100. 2.1 Types of Data Acquisition . . . . . . . . . . . . . . . . . . . . . . . . . . 287
  101. 2.2 Acquisition Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
  102. 2.3 Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  103. 4.2.4 Modal Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
  104. 2.5 Data Preprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
  105. 3 Signal Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
  106. 3.1 Signal Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
  107. 3.2 Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
  108. 3.3 Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  109. 4.3.4 Limit Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
  110. 3.5 General Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
  111. 3.6 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
  112. Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
  113. 4.1 Steady-State Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 306
  114. 4.2 Continuous Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
  115. 4.3 Post-mortem Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
  116. 5 Test Bed Control and Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
  117. 5.1 Control Systems on the Internal Combustion Engine Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
  118. 5.2 Powertrain Test Bed Controllers . . . . . . . . . . . . . . . . . . . . . 313
  119. 5.3 Control on the Chassis Dyno Test Bed . . . . . . . . . . . . . . . . .
  120. 4.5.4 Simple Vehicle Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  121. 4.5.5 Virtual Test Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
  122. 5.6 Virtual Vehicle Integration . . . . . . . . . . . . . . . . . . . . . . . . . 336
  123. 5.7 Residual Bus Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
  124. 6 Test Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
  125. 6.1 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
  126. 6.2 Test Bed State Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
  127. 6.3 Automatic Control Unit Calibration . . . . . . . . . . . . . . . . . . . 346
  128. 7 Measured Data Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
  129. 7.1 Selection of Measurement Data . . . . . . . . . . . . . . . . . . . . . . 355
  130. 7.2 Measured Data Visualization . . . . . . . . . . . . . . . . . . . . . . . . 358
  131. 7.3 Data Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  132. 4.7.4 Formulas and Calculations . . . . . . . . . . . . . . . . . . . . . . . . . 364
  133. 7.5 Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
  134. 7.6 Efficiency Enhancement in Data Evaluation . . . . . . . . . . . . . 369
  135. 8 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
  136. 8.1 Risk Analysis and Risk Assessment . . . . . . . . . . . . . . . . . . . 371
  137. 8.2 Risk Analysis on Test Beds . . . . . . . . . . . . . . . . . . . . . . . . . 372
  138. 8.3 Safety-Relevant Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .
  139. 4.8.4 Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
  140. 8.5 Safety Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
  141. 8.6 Setup of Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . .
  142. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 xii Contents 5 Software Perspective: The Test Facility . . . . . . . . . . . . . . . . . . . . . . . . . 383
  143. 1 Introduction to the Test Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 5.1.1 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  144. 5.1.2 Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  145. 5.1.3 Test Facility Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
  146. 2 Workflow Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 5.2.1 Task Scheduling in the Test Facility . . . . . . . . . . . . . . . . . .
  147. 5.2.2 Utilization Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
  148. 3 Resource Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 5.3.1 Test Equipment Management Requirements . . . . . . . . . . . . .
  149. 5.3.2 Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 5.3.3 Test Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  150. 5.3.4 Test Equipment Maintenance . . . . . . . . . . . . . . . . . . . . . . .
  151. 5.3.5 Sensor Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
  152. 4 Data and Information Management . . . . . . . . . . . . . . . . . . . . . . . . . 398 5.4.1 Result Data Management . . . . . . . . . . . . . . . . . . . . . . . . . .
  153. 5.4.2 Calibration Data Management . . . . . . . . . . . . . . . . . . . . . . .
  154. 5.4.3 Model Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  155. 5.4.4 Name Management in the Test Facility . . . . . . . . . . . . . . . . 405 5.4.5 Result Data Warehouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
  156. 5 Data Management in Distributed Test Facilities . . . . . . . . . . . . . . . .
  157. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  158. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

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