ES Knock Intensity Detection Board. KID_SU KID Signal Unit User Manual

Transcription

1 ES Knock Intensity Detection Board KID_SU KID Signal Unit User Manual

2 Copyright The data in this document may not be altered or amended without special notification from ETAS GmbH. ETAS GmbH undertakes no further obligation in relation to this document. The software presented herein is provided on the basis of a general license agreement or a single license. Using and copying is only allowed in concurrence with the specifications stipulated in the contract. Under no circumstances may any part of this document be copied, reproduced, transmitted, stored in a retrieval system or translated into another language without the express written permission of ETAS GmbH. Copyright 2002 ETAS GmbH, Stuttgart, Germany The names and designations used in this document are trademarks or brands belonging to the respective owners. Document AM R3.0.2 EN TTN F 00K ES Knock Intensity Detection Board KID_SU KID Signal Unit

3 Contents 1 Introduction Basics Functions Functions in Normal Mode Functions in Acquisition Mode Overall System Block Diagram Hardware Components KID Signal Unit (KID_SU) Overview Inputs of the KID Signal Unit Outputs of the KID Signal Unit Displays and Controls of the KID Signal Unit Knock Intensity Detection Board (ES1380.2) Overview Block Diagram Cable LEMO 1B FFG - LEMO 1B FFG (CBM150-3) Type 1 Power Cable (K21) Operating Modes Overview Contents 3

4 3.2 Normal Mode Acquisition Mode Acquisition Sub-Mode Acquisition Sub-Mode Acquisition Sub-Mode Acquisition Sub-Mode Technical Data KID Signal Unit (KID_SU) ES Knock Intensity Detection Board Index Contents

5 1 Introduction KID (Knock Intensity Detection) supports the knock detection application. KID allows you to calibrate the filter center frequency, know sensor install locations, and knock detection thresholds. For further information on the KID Device Integration Package software module, please refer to the corresponding user manual (which can be obtained from ETAS). Knock Intensity Detection consists of the following hardware components: KID hardware component Meaning KID_SU KID Signal Unit ES Knock Intensity Detection Board (1-CH, 100 MBit/s) CBM150-3 Cable LEMO 1B FFG (4mc-4mc, 3 m) K21 Type 1 power cable For a detailed description of KID see Chapter Basics Knock control in production vehicles is based on structure-borne sound signals. These structure-borne sound signals are detected by knock sensors (up to four in some engines) and converted to voltage signals. Typical tasks of the control unit are: Integration of these signals during a measurement window (MW) Transfer to the A/D converter of the control unit Calculation of a floating average values (reference level RKR) based on the integration result (integrator end value IKR) A knock event is captured if the IKR/RKR ratio, known as VIRKR, exceeds a defined value (knock detection threshold). To calibrate the knock detection threshold, the combustion chamber pressure is used as a reference signal. Introduction 5

6 Knock event Pressure p Time t Extended meas. window Meas. window Fig. 1-1 Pressure variation during a combustion process with knocking It is measured using cylinder pressure plugs or indexing quartzes and passed through a band-pass filter. From the filtered signal, the pressure peak value and pressure integral are determined in sync with the ignition during a measurement window. The control unit has to consider a combustion to be knocking if the pressure peak value exceeds a defined pressure threshold. In addition to calibrating the knock detection threshold, the KID has the following further applications: Testing of hardware used for knock detection Determining the optimum location of the sound pick-ups during engine development The KID provides two operating modes whose characteristics are briefly described below (see also Chapter "Operating Modes" on page 21). 1.2 Functions Functions in Normal Mode The Normal mode has the following characteristics: Online measurement Calculation of the pressure peak value and pressure integral during an ignition. The cylinder pressure is sampled at 200 khz (i.e. in the 5 µsec grid) and processed in the KID signal unit within the active measurement window. No access to structure-borne sound signals Normal mode is always active 6 Introduction

7 1.2.2 Functions in Acquisition Mode The Acquisition mode of the KID is an extension of the Normal mode; it is used for recording of data. The pressure signals, maximum values, integrals and structure-borne sound signals are recorded. The signals at the structure-borne sound input are sampled at 200 khz and stored in the SRAM of the ES Knock Intensity Detection Board for subsequent evaluation, together with the pressure signals and their maximum and integral values. The following signal recording settings are available: Recorded Signals Time stamp, pressure signal, peak, integral, ignition order counter, status word 4 structure-borne sound signals Settings in Acquisition Mode In Acquisition mode, there are four different configurations: All signals All signals within the measurement window All signals within the measurement window: by cylinder All signals within the extended measurement window: depending on the pressure threshold Introduction 7

8 1.3 Overall System Block Diagram The figure below shows a block diagram of the individual KID components. The two hardware components KID Signal Unit and ES Knock Intensity Detection Board are shaded gray. INCA-PC p VIRKR ES ES1120 KID-Driver ETK-Driver ES DPR MPC555 ES1232-A ETK Interface DRAM FPGA 100 Mbit interface ETK- FPGA A/D converter KID Signal Unit Bandpass filter 8:1 PMux Pressure signals (1...8) DPR Cylinder 1 detector p Zyl.1 Engine KID- FPGA A/D converter Low-pass filter Sound pick-up signals (1...4) Control Unit MW In Out Cyl. 1 Out (TTL) PMux Out Meas. window ETK Fig. 1-2 Block diagram 8 Introduction

9 Introduction 9

10 10 Introduction

11 2 Hardware Components In this section, you will find the following descriptions: "KID Signal Unit (KID_SU)" on page 11 "Knock Intensity Detection Board (ES1380.2)" on page 16 "Cable LEMO 1B FFG - LEMO 1B FFG (CBM150-3)" on page 18 "Type 1 Power Cable (K21)" on page KID Signal Unit (KID_SU) Overview The KID_SU (Fig. 2-1) is the interface between the captured engine signals and the ES in the ES1000 (see also Fig. 1-2 on page 8). It also has the following components: 4 A/D inputs for structure-borne sound signals (knock sensor) 8 pressure signal inputs (Pressure) Input for measurement window from ECU (MW In) Cylinder 1 signal output (Cyl.1 Out) Ignition order counter signal output Out Pressure signal output (behind multiplexer/band-pass filter) (PMux Out) Status LED for Cylinder1 signal (Cyl.1) Status LED for power supply (KID_SU operational) Potentiometer for Cylinder 1 synchronization (Cyl.1 Ref.) Side ports: 100 Mbps interface for connection to ES Power supply 5.5 V V Hardware Components 11

12 Knock Sensor A/D-Channel Pressure Ignition Order KID_SU KID Signal Unit MW In Cyl.1 Out Cyl.1 Power Out Cyl.1 Ref PMux Out Fig. 2-1 KID Signal Unit Inputs of the KID Signal Unit The KID signal unit has the following inputs: 4 A/D inputs for structure-borne sound signals (knock sensor) 8 pressure signal inputs (pressure) Input for measurement window from ECU (MW In) Sound Pick-Up Signals (Knock Sensor) Number of inputs 4 Input voltage ± 2.5 V input impedance Differential input, kω Input capacitance 11 pf Input overvoltage protection ± 85 V (continuous) Subsequent Low-pass filter 40 khz, 8th order, 12-bit sampling, 200 khz sampling rate 12 Hardware Components

13 Pressure Signals (Pressure) note To be connected according to the ignition order. Number of inputs 8 Input voltage 0-10 V, max. ± 10 V Input impedance Differential input, kω Input capacitance 11 pf Input overvoltage protection ± 90 V (continuous) Subsequent 8-fold multiplexer (ignition order) After multiplexer: Band-pass filter 4-40 khz, 8th order, 12-bit sampling, 200 khz sampling rate Other The 8 pressure signal inputs at the A/D converter are multiplexed and provided at one output (see Section "Multiplexed Pressure Signal (PMux Out)" on page 14). Measurement Window (MW In) Number of inputs 1 Input voltage 0-5 V Input impedance kw Input overvoltage protection + 85 V, - 80 V (continuous) Electrical insulation (common with 560 V Cyl.1 output) against remaining inputs/outputs Hardware Components 13

14 2.1.3 Outputs of the KID Signal Unit The KID signal unit has the following outputs: Pressure signal output (at A/D converter after multiplexer/band-pass filter) (PMux Out) Ignition order counter signal output Out Cylinder 1 signal output (Cyl.1 Out) 100 Mbps interface for connection to ES Multiplexed Pressure Signal (PMux Out) Number of outputs 1 Output voltage range ± 5 V Output impedance 321 W Output overvoltage protection ± 85 V (continuous) Staircase Signal Number of outputs 1 Output voltage range 0-5 V Output impedance 321 W Output overvoltage protection + 85 V, - 80 V (continuous) Cylinder 1 Signal (Cyl. 1 Out) Number of outputs 1 Output voltage range 0-5 V Output impedance push 498 Ω, pull 125 Ω Output overvoltage protection + 85 V, - 80 V (continuous) Electrical insulation (common with measurement window signal MW In) 560 V against remaining inputs/outputs 14 Hardware Components

15 2.1.4 Displays and Controls of the KID Signal Unit Displays The front panel of the signal unit has two LEDs having the following functions: LED (color) Power (green) Cyl.1 (red) Meaning Power supply ok, KID_SU operational Lights when ignition is detected in Cylinder 1; the detection threshold can be set via potentiometer Cyl.1 Ref (see below). Potentiometer for Cylinder 1 Synchronization The potentiometer Cyl.1 Ref is used to set the ignition detection threshold for Cylinder 1. The optimal potentiometer setting can be best determined using an oscilloscope. For this, display the staircase signal and Cyl.1 Out. Turn the potentiometer clockwise until the red LED goes dark or the Cyl.1 Out signal is low. Then turn the potentiometer counter-clockwise until the LED starts flickering, while the oscilloscope shows a clean rectangular signal. Make sure that the staircase signal rises evenly without vantage points. Hardware Components 15

16 2.2 Knock Intensity Detection Board (ES1380.2) Overview The ES Knock Intensity Detection Board (Fig. 2-2) is the interface between the KID_SU and the ES1000 system receiving the data of the KID_SU. A ES ES1113 Fig. 2-2 ES Knock Intensity Detection Board The ES computes the maximum values and the integral of the captured pressure values. Storing the data sent from the KID signal unit in a ring buffer of the DPR makes it possible to expand the measurement window beyond that of the control unit. note Some components of the plug-in card may be damaged or destroyed by electrostatic discharges. Therefore, keep the plug-in card in its storage package until it is installed. The plug-in card may only be taken from the storage package, configured and installed at a working place that is protected against static discharges. 16 Hardware Components

17 2.2.2 Block Diagram Fig. 2-3 shows the block diagram of the ES with its major functional units. PowerPC MPC555 Sync. Burst- SRAM 32 Bit 1 MByte Async. Boot- FLASH 16 Bit 1 MByte Serial ETK Interface (100 MBit/s and 8 MBit/s) VME 64x IRQs Buffer IRQs Slave Interface VME64x A24/D16 A40/MD32 Buffer DPRAM 32 Bit 128 kbyte DPRAM 16 Bit 64 kbyte DAMC Phyter Transformer 5 V Power Supply 5 V 3.3 V 2.5 V SRAM 16MByte on Board ETK Fig. 2-3 Block diagram of the ES VME Slave Interface: The card includes a VME slave interface supporting A24/D16 access from a master card. The slave interface converts accesses to the VME bus into accesses to corresponding memory areas locally on the card. Power Supply: The power supply unit provides voltages of 5 V, 3.3 V, and 2.5 V. Mainly ICs with low supply voltages are being used to keep the power requirements at a low level. PowerPC: The PowerPC with its memory modules connected can be addressed via the VME bus. DAMC: The Data Acquisition Memory Controller contains a fast RISC processor that is designed for applications in real-time data acquisition and realtime control of external modules. Measured data are time-stamped. The RISC processor is interrupt-driven and can also be controlled from the VMEBus. Data is transferred via the memory modules connected to the DAMC. Memory management for the connected measured value buffer (SRAM) is also performed by the DAMC. Simultaneous access to this buffer from the VME bus and the PowerPC is possible. Hardware Components 17

18 2.3 Cable LEMO 1B FFG - LEMO 1B FFG (CBM150-3) Cable LEMO 1B FFG - LEMO 1B FFG (4mc-4mc, 3 m) Connecting the KID signal unit to the ES requires a special cable that is optimized to meet the requirements resulting from the high transfer rates. Fig. 2-4 Cable LEMO 1B FFG, CBM150-3 (F 00K ) Item Name Code Order Number ETK cable 3 m CBM150-3 F 00K The corresponding ports are located at the front of the ES and on the right-hand side of the KID signal unit. Pin Allocation The A connector contains the wires for the ETK interface. The connector is a 4-pin size 1B Lemo panel jack Fig A connector Pin Function Pin Function 1 TX+ 3 RX+ 2 TX- 4 RX- 18 Hardware Components

19 2.4 Type 1 Power Cable (K21) 1 2 Fig. 2-6 Power Supply Connector Pin Function Pin Function 1 Ground 2 U Batt The correct cable is the power supply cable K21. Fig. 2-7 Power Cable (K21) Item Name Code Order Number Power cable (2 m) K21 Y 261 A Hardware Components 19

20 20 Hardware Components

21 3 Operating Modes 3.1 Overview The KID provides two different operating modes depending on the type and scope of the respective data: Normal mode and Acquisition mode. Common to each mode is the recording of a record for each ignition including the following data: a time stamp the integral of the pressure variation the maximum value of the pressure a status word including, among others, the ignition order counter The timing of the signal recording and data staging is shown in Fig In Acquisition mode, data is captured in the 5 µsec grid and stored in the SRAM of the ES for subsequent evaluation. Some selection is possible regarding the scope of the captured data. Meas. window Pressure Ignition Cylinder 1 Ignition Cylinder 2 Time t Firmware KID data cylinder 1 ready KID data cylinder 2 ready ETK data cylinder 1 ready Time t INCA Time stamp for generating a signal group from KID and ETK signals Cylinder 1 - Sample:KID peak valuekid integraletk- VIRKRETK cylinder counter: Time t Fig. 3-1 Timing of measurement and data staging Operating Modes 21

22 3.2 Normal Mode Online measurements are conducted in Normal mode. Pressure signals are captured at 5 µsec intervals. In between, the pressure peak value and integral are calculated from these data during one combustion process. These data are synchronized with the ETK signals from the control unit and can be displayed on an xy-oscilloscope (for static measurements) or a y(t) oscilloscope (for dynamic measurements). The data are acquired within a measurement window that must be provided by the control unit as a TTL signal. By using a ring buffer, it is also possible to access data prior to the opening of this measurement window (extended measurement window). The continuous calculation of the pressure peak values and integrals results in a cylinder-synchronous data stream. The KID and ETK data are synchronized in the PC via the ASAP1b driver. For synchronization, the system uses the ignition order counter of the control unit and the counter of the KID hardware. The time stamp of the control unit is used for consistent representation of the synchronized data. 3.3 Acquisition Mode In Acquisition mode, the KID is additionally working as a data recorder. Besides the pressure signals, the KID also captures the four structure-borne sound signals. The entire data are stored for subsequent evaluation. This mode can be used to evaluate new knock detection algorithms. The difference from Normal mode is that additionally the A/D values of the PMux pressure input and the four structure-borne sound inputs are stored in the SRAM. The calculations performed in Normal mode continue to run also in Acquisition mode. To limit the generated data volume, the Acquisition mode provides four different sub-modes: Sub-mode 1 all signals Sub-mode 2 all signals within the measurement window Sub-mode 3 all signals within the measurement window: by cylinder Sub-mode 4 all signals within the extended measurement window: depending on the pressure threshold The integral value and maximum value are calculated in the extended measurement window. A new data packet is started with each falling measurement window. A sample consists of five A/D values (four structure-borne sound signals and one PMux pressure signal) and one status word. 22 Operating Modes

23 The time stamp corresponds to the time the measurement window starts to descend; it is included in the data packet just completed by the processor of the ES together with the number of samples, the integral value, and maximum value. In Acquisition mode, either all or a portion (depending on the sub-mode) of the captured data are stored in the SRAM. For each ignition (at the most from one descending measurement window to the next), a record is created that contains all samples. The record header holds the time stamp from the end of the measurement window as well as the calculated integral and maximum values of all samples in the extended measurement window of one ignition and the number of samples for this ignition (of one record in the SRAM) Acquisition Sub-Mode 1 All Signals All signals (1 pressure and 4 sound signals) are captured and stored at 5 µsec intervals. The acquisition rate is approx. 2.4 Mbytes/sec. The pressure peak value, pressure integral and status are captured in sync by cylinder Acquisition Sub-Mode 2 All Signals Within the Measurement Window All signals mentioned above are stored only during the active, non-extended, measurement window Acquisition Sub-Mode 3 All Signals Within the Measurement Window: by Cylinder All signals mentioned above are stored only during the active, non-extended, measurement window and only for one selected cylinder Acquisition Sub-Mode 4 All Signals Within the Extended Measurement Window: Depending on the Pressure Threshold All signals mentioned above are stored first during the active, extended, measurement window. When the measurement window starts to descend, a record is finished, and a check is made whether the maximum pressure value exceeds the specified pressure threshold. If this is the case, the data packet just written is stored in the SRAM, otherwise it is discarded. Operating Modes 23

24 24 Operating Modes

25 4 Technical Data 4.1 KID Signal Unit (KID_SU) ES Interface Transfer rate Connector Cable 100 Mbps 4-pin Lemo size 1B double-shielded twisted pairs Power Supply Supply voltage Electrical insulation against supply voltage Power consumption (typical/max.) 5.5 V 36 V some 100 V 5.2 W/7 W Mechanical Data Dimensions 210 mm x 100 mm x 60 mm (W x H x D) Environmental Conditions Ambient temperature during operation -40 C to +70 C Storage temperature -55 C to +85 C Relative humidity 0 to 95 %, no condensation Technical Data 25

26 4.2 ES Knock Intensity Detection Board Processor Processor Memory Motorola PowerPC MPC555, 40 MHz 1 MB SRAM (32 bits, burst-capable), 1 MB Flash (16 bits) Measured Data Memory On-Board Memory Extension 16 MByte SRAM 256 MByte SRAM VMEbus Interface Type Slave Address and data lines A24:D16, A40:MD32 Interrupter 16 interrupters; level and vector programmable Configuration Auto-ID configuration Connectors 160-pin DIN KID_SU Interface Transfer rate Connector Cable 100 Mbps (block mode) 4-pin Lemo size 1B double-shielded twisted pairs 26 Technical Data

27 Power Supply ES Power supply Power consumption of ES (typical/max.) 6 V - 34 V 5 W/7 W Mechanical Data Circuit board Front panel 100 x 160 mm² Height: 3 HUs Width: 4 DUs (20.4 mm) Environmental Conditions Ambient temperature during operation -40 C to +85 C Storage temperature -55 C to +85 C Relative humidity 0 to 95 %, no condensation Technical Data 27

28 28 Technical Data

29 Index Numerics 100 Mbps interface cable 25 connector 25 transfer rate 25 A Acquisition sub-mode 1 23 sub-mode 2 23 sub-mode 3 23 sub-mode 4 23 C Cable LEMO 1B FFG - LEMO 1B FFG (4mc- 4mc, 3 m) 18 Cyl.1 signal (Cyl. 1 Out) electrical insulation 14 number of outputs 14 output impedance 14 output overvoltage protection 14 output voltage range 14 D Display elements Cyl.1 (red) 15 power (green) 15 E ES Environmental Conditions 27 KID_SU Interface 26 measured data memory 26 Mechanical Data 27 Power Supply ES processor 26 VMEbus interface 26 I Introduction 5 K KID hardware components 5 Index 29

30 KID_SU Environmental Conditions 25 ES Interface 25 Mechanical Data 25 power supply 25 Knock intensity detector 5 M Measurement window (MW In) electrical insulation 13 input impedance 13 input overvoltage protection 13 input voltage 13 number of inputs 13 Multiplexed pressure signal (PMux Out) number of outputs 14 output impedance 14 output overvoltage protection 14 output voltage range 14 O Operating mode Acquisition 7 Normal 6 P Pin allocation 18 Pressure signals input capacitance 13 input impedance 13 input overvoltage protection 13 input voltage 13 number of inputs 13 other 13 subsequent 13 Pressure variation 6 S Solid-borne sound signals 5 Sound pick-up signals input capacitance 12 Input impedance 12 input overvoltage protection 12 input voltage 12 number of inputs 12 subsequent Contents

31 Staircase signal number of outputs 14 output impedance 14 output overvoltage protection 14 output voltage range 14 T Technical data 25 Contents 31