International Workshop of Advanced Manufacturing and Automation (IWAMA 2016)

Designs and Development of Engine Measurement

System for Experiment Test
Zongzheng Ma, Shaohua Dong, Qianzhu Zhang, Bobo Pan, Yan Huang
Department of Mechanical Engineering,
Henan Institute of Engineering
Zhengzhou, China

Abstract—With the development of computer technology, data bus. However, due to the prices and some specialized
acquisition is more and more easily which can replace the manual systems, the universal data acquisition system is not suitable
recording process and improve the accuracy and efficiency of the for all application [2]. Then one data acquisition system
data. So one experiment data acquisition system for the internal based on VC++ platform is designed in this paper for the
combustion (IC) engine was designed including the hardware and engine experiment measurement.
software system. And the hardware was completed based on the
different sensor and sensor processing circuit, meanwhile, the The hardware of the system is divided into data
software of the data acquisition system is realized based on VC++ acquisition, real-time signal acquisition module and data
platform. Then the real experiment was done using this system and processing module which can be seen in figure 1.
accurate data was achieved based on the engine. It is proved by the
experiment test that the measurement system can achieve engine The data acquisition includes the sensor and communication
cylinder pressure measure. So this data acquisition system is system. The real-time signal acquisition module is the PCI
helpful to improve the understanding of the theoretical knowledge. data acquisition card. And the data processing module is the
computer software.
Keywords—data acquisition; engine experiment; hardware;
software; design

I. INTRODUCTION
With the development of computer technology in all
areas, real-time data acquisition, data display, real-time
control are possible for the experiment measurement which
can reduce the manual recording and ensure accurate and
effective data acquisition.
In the 50s of 19th century the data acquisition device
began to appear. US-developed test system for data Fig. 1. Diagram of the system
acquisition is the symbol which was mainly used in the
military field. This kind of data acquisition device can be
II. SENSOR PROCESSING
operated by person who is not needed to familiar with the
system. At the late 1960s, data acquisition products The sensor signal can be divided into analog and digital
appeared in foreign markets and these data acquisition signal. The digital signal can be input the computer directly
products are used in more specific areas. At the late 1970s, but the analog signal should be processed. For the IC
with the development of micro-computer, data acquisition engine, most of the sensor signals are analog signal which
and control computer equipment acquisition integration can be roughly classified into linear signal and the sine
appeared. Then in the 1980s, with the popularity of signal.
computer the universal data acquisition device began to
appear and it is mainly composed by the acquisition board, A. Sine signal processing method
interface bus communication based on GPIB and control In order to determine the dead center (DC) position of
computer [1]. But at the late 1980s, the hardware is replaced the engine the magnetic sensors was used in the engine.
by the software which can reduce the cost and size of the According to the output characteristics of the magnetic
data acquisition system and increase its performance. After sensors the output analog signal is sine signal which is
the 1990s, the data acquisition technology has been widely shown in Fig. 2.
used in military, aerospace and industrial applications in
developed countries. With the development of integrated Since the position between the top dead center (TDC)
circuit technology, there has been a high-performance and the magnetic sensors is fixed, the magnetic sensors
single-chip data acquisition system DAS whose resolution is signal can be used to determine the TDC position and it also
16 bit and the sampling rate is up to hundreds of thousands can be used to calculate the speed [3,4]. In addition, in order
times per second. And at this period, data collection devices to be input into the computer the first thing is to convert the
modular structure was divided into parallel bus and serial magnetic signals to TTL signal (digital signal). The

© 2016. The authors - Published by Atlantis Press 163

processing circuit is shown in Fig. 3, where the 6N137 is IC engine, the outputs signals of the throttle position sensor
used as digital switching which the sine signal is converted signal and the intake pressure sensor are linear which are
into digital signal (Fig. 4). Then the signal can be directly shown in Fig. 5. And the output signal is a voltage signal
input microcontroller utilizing the I/O port [5]. between 0~5V whose amplitude range is within the PCI data
acquisition capacity and it can be input directly to A/D
It should be noted that this method has error due to that ports.
there is transmission time for the 6N137 chip.

(a) Intake air pressure (b) Throttle vale angle

Fig. 5. Liner signals

III. SOFTWARE DESIGN

Fig. 2. The output signal of magnetic sensor
In this part, the programming process is emphasized
based on VC++ platform and it can be achieved through two
stages, basic interface design and coding.

A. Basic interface design

The basic interface design was build based on basic
controller including the text controller, edit controller,
button controller and Com-box controller.
For text controller, its function is data and label display
and it is used to display the input and output parameters.
Fig. 3. Diagram of processing circuit
For the edit controller, it can be used to input initial data
which can realize the copy, cut, paste and delete operation.
The button controller is also common used in basic interface
design and its ability is to achieve calculation.
The Com-box controller combines the features of edit
box and list box which can be used to data input and list box
selection. In the basic interface the Com-box controller is
used to display the curve.
The basic interface divided into three parts, the first part
is data input, the second part is value monitor and the third
part is data acquisition, which is shown in Fig. 6.
In the data input part, the basic parameters such as
Fig. 4. The convert signal engine parameters, experiment time, experiment place,
experiment temperature, path of storage can be input.
B. Linear signal processing method In the monitor part, the different channel value can be
If the output of the analog signal is voltage value and checked using the curve display.
there is a linear relationship between the measured
parameter and the output signal, it can be input the computer In the data acquisition part, the value can be stored in the
by A/D converter [6]. However, if the amplitude of the computer.
analog signal is small the A/D conversion precision cannot
be full used and the signal should be enlarged while the
limit processing is required if the amplitude is large. For the

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 fprintf(fp,"%f %f %f %f %f
%f\n",m_fOff0,m_fOff1,m_fOff2,m_fOff3,m_fOff4,m_fOf
f5);
fprintf(fp,"%d %d %d %d %d
%d\n",m_iUnit0,m_iUnit1,m_iUnit2,m_iUnit3,m_iUnit4,m
_iUnit5);
fprintf(fp,"%d %d\n",bFirstCH,biCHselect);
for(i=0;i<6;i++)
{
fprintf(fp,"%d ",biCH[i]);
}
for(i=0;i<6;i++)
Fig. 6. Main interface of the system {
fprintf(fp,"%s ",strChSet[i]);
IV. USING THE TEMPLATE }
fclose(fp);
A. 3.2 Coding }
The main coding process includes the data acquisition V. APPLICATION
and data storage which are designed based on VC++[7].
And the data acquisition coding is shown in the following. The experiment test bed consists of K157 FMI engine
(specific parameters shown in table 1), electric eddy current
void CDiagnoserView::OnConfirm() dynamometer, dynamometer control system, gasoline
{ engine ECU, computer and data acquisition system and
UpdateData(true); sensors of related parameters. The experiment test bed is
biCHselect=0; shown in figure 7, where the electric eddy current
bFirstCH=0; dynamometer and dynamometer control system are used to
for(short i=0;i<6;i++) control and measure the load of the engine, engine fuel
{ injection system control fuel injection and ignition, and the
if(biCH[i]!=6) computer's serial communication can also be used to control
{ gasoline engine ECU as to control fuel injection and
if(biCHselect==0) ignition.
{
bFirstCH=i;
}
biCHselect++;
}
}
FILE *fp;
fp=fopen("d:\\Experiment.txt","w");
fprintf(fp, "Experiment time: %s\n", m_strTime);
fprintf (fp, "Experiment place:%s\n", m_strArea); Fig. 7. Diagram of experimental system
fprintf(fp,"Experiment person: %s\n", m_str People);
fprintf(fp, "Experiment test:%s\n", m_strWork);
TABLE I. K157 FMI ENGINE PARAMETERS
fprintf(fp, "Temperature:%d; Humidity: %d;
m_siTemperature, m_siHumidity, m_siPressure); Parameter Value
fprintf(fp,"Engine parameters：\n"); Type Single cylinder,
four-stroke
fprintf(fp,"Type ： %s; Cylinder number ： %d; Operation Bore × stroke (mm) 56.5×49.5
type：%s; Number of tooth：%d\n",
Total displacement /L 124
m_strModal,m_siCylinder,m_strSequence,m_siGear);
fclose(fp); Rated power (kW)/(r/ min) 7.0/7500
fp=fopen("c:\\para.ini","w");
Compression ratio 9：1
fprintf(fp,"%d %d %d %d %d
%d\n",m_iCH0Select,m_iCH1Select,m_iCH2Select,m_iCH Cooling style wind cooling
3Select,m_iCH4Select,m_iCH5Select); The cylinder pressure measured using the data
fprintf(fp,"%f %f %f %f %f acquisition system can be seen in figure 8 when the engine
%f\n",m_fScale0,m_fScale1,m_fScale2,m_fScale3,m_fScal speed is 1500r/min and throttle opening angle is 20% of
e4,m_fScale5); wide open throttle.

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 It can be seen from the figure that the highest cylinder is VII. ACKNOWLEDGEMENT
1.05MPa which appears at 374CA (Crank angle) under this The authors would like to express appreciation of
speed. It can be concluded that this system can realize data financial support by the Key Subject of Machine Design and
acquisition and is helpful to the understanding of the Theory, the Reliability Test Center and Modern Design
theoretical knowledge. Method Research Center of Henan Institute of Engineering.

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Fig. 8. Real cylinder pressure
[4] J. F. Kong, "1.3L gasoline engine crankshaft strength analysis of car,"
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