White Paper: Automotive
Testing High-Performance Engine Components with Dewesoft Combustion Analyzer
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The components of today's premium-class and motorsport combustion engines are subjected to high, recurring loads during operation. Validating the quality of manufactured lightweight components such as pistons and connecting rods is essential to ensuring a long service life. Engineers conduct intensive testing on both tensile and compression testing machines in the laboratory and on test benches in real-world engine applications. The Testing Department of Pankl Racing Systems provides insight into its daily use of Dewesoft combustion engine analyzer (CEA) technology for detailed analysis.
Pankl Racing initially purchased the SIRIUS measurement module and the CEA software plug-in exclusively for the combustion measurement, i.e., recording and evaluating cylinder pressures and crank angles. Engineers collected data and calibrated the model, enabling a comparison of the CFD calculation.
Since then, the application area has expanded to include many additional measurement channels. The engineers verify ECU data (parameter verification), record injector current using current clamps, and measure delay times. Simultaneous recording from a load cell provides further insights. The Testbed Plugin and the CEA module can be combined to identify all influencing factors and optimize the ECU's parameters.
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Overview
The document discusses advanced testing methods and technologies used by Pankl Racing Systems to enhance the performance and efficiency of high-performance engines, particularly in motorsports like Formula 1. It highlights the integration of the Dewesoft SIRIUS measurement module and the CEA (Combustion Engine Analyzer) software, which are essential for recording and analyzing combustion data.
Key features of the testing process include the use of a test bench, where engineers can conduct real-time measurements and evaluations of engine components. The document emphasizes the importance of understanding gas exchange dynamics, where the interaction between the exhaust and intake systems can significantly influence combustion efficiency. Engineers utilize gas exchange curves to optimize engine performance, leveraging pressure pulses in the intake caused by exhaust flow.
A notable innovation discussed is the prechamber ignition system, which allows spark-ignition engines to operate under lean air-fuel conditions. This technology improves fuel efficiency by approximately 20% and reduces emissions. The prechamber ignites a smaller volume of fuel, creating a hot flame jet that ignites the main fuel mixture more completely and rapidly than traditional spark plugs. The document outlines the challenges engineers face in controlling fuel injection in the prechamber, particularly under varying engine conditions, and the use of Computational Fluid Dynamics (CFD) simulations to address these challenges.
The document also details the critical parameters for evaluating combustion performance, specifically the Mass Fraction Burned (MFB) points at 10%, 50%, and 90%. These metrics provide insights into combustion speed and efficiency, with a steeper MFB curve indicating better engine performance.
Additionally, the integration of the Testbed Plugin with the CEA module allows for comprehensive analysis and optimization of engine control unit (ECU) parameters, ensuring that all influencing factors are considered during testing. The document concludes by underscoring the necessity of continuous adaptation and customization of engine components, such as ignition systems, to meet the stringent fuel consumption regulations in modern motorsports.
Overall, the document illustrates Pankl Racing Systems' commitment to innovation and precision in developing high-performance engine components through advanced testing and analysis techniques.