Professional Documents
Culture Documents
Manual
KiBox® To Go
Type 2893A...
KiBox® Cockpit
Version 3.0
2893A_002-437e-02.17
Preface
Preface
These operating instructions describe how to operate the KiBox To Go Type 2893A…
and the KiBoxCockpit. It applies to
KiBoxCockpit from V3.0
KiBox Firmware from V4.2
Charge amplifier Type 5064B... from Firmware V1.13
and Type 5064C… from Firmware V2.10
Piezoresistive amplifier Type 4665B... from Firmware V1.22
The information in this manual is subject to change without notice. Kistler reserves the
right to improve the product in terms of technical progress and change, without
obligation to notify persons and organizations regarding such changes.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Fax: +41 52 224 14 14
info@kistler.com
www.kistler.com
Contents
Preface .............................................................................................................................. 1
Contents............................................................................................................................ 2
1. Introduction .............................................................................................................. 5
3. Installation .............................................................................................................. 19
Index ………………………………………………………………………………………………………….202
1. Introduction
By choosing this quality product from Kistler, you have selected a device characterized
by high technical innovation, precision, and durability. The KiBox To Go type 2893 with
the KiBoxCockpit is the ideal system for mobile indication.
With the KiBox combustion analysis system, Kistler Instruments AG has developed a
measurement and analysis system designed specifically for the cylinder-pressure
indication in the vehicle. In addition to an innovative data collection approach and the
simple integration into engine application systems (e.g. INCA) the KiBox is
distinguished by a variety of novel properties. Combustion analysis results can be
presented and analyzed synchronously in real time and simultaneously with other
control and process variables of the engine control unit (ECU).
A conventional operation at test benches can be realized by means of a universal test
bench interface.
During development particular emphasis was placed on creating a user friendly
experience. The resulting concept now allows the system administrator (usually a
measurement technician familiar with motor indication measurements) can prepare all
the basic settings in the administration level. Without further indication knowledge the
vehicle applicator can then configure the appropriate signals for the specific
measurement tasks. This reduces the parameterization of the end user to a minimum
and at the same time allows for a group-wide standard for indication signal settings.
Please note the following details. They serve to your ensure personal safety when using
the KiBox To Go and guarantees on the other hand a long life and trouble free
operation of the device.
A step marked with this symbol can be omitted under the indicated
circumstances.
This symbol points out that something has to be waited for and
watched.
The symbol alerts you to hazards that can have serious consequences,
whether the damage is to hardware or a possible injury to persons.
The KiBox may not be used for the purpose of personal protection.
Keep the local safety regulations, which govern the use of mains-powered electrical
and electronic equipment.
If safe operation based on the above features is no longer be ensured, the device
should be immediately sent to a competent Kistler sales company/agent for repair.
If opening covers or removing parts and it is not possible by hand, live current parts
can be exposed
Before dismantling for calibration, maintenance, repairing or replacing parts,
disconnect the device from all voltage sources.
Calibration, maintenance and repair work on equipment that is open and connected
to a power source should not be performed if at all possible. If such work is
unavoidable, however, it should be done by a professional who is familiar with the
dangers involved.
Any disruption of the protective conductor inside or outside the unit or the
dissolution of the protective earth connection can be fatal. Intentional disconnection
is prohibited!
The mains plug shall only be inserted into a socket that has an earth contact. The
protective effect may not be nullified by an extension cord without a protective
earth connection.
Fuses may be replaced by the appropriate type with the specified nominal current.
The use of "repaired" fuses or short circuiting the fuse holder is not allowed.
The grounding screw on the underside of the unit connects the grounding of the
power plug to the housing. This must not be removed.
Do not ever connect the system KiBox directly to the Internet. It should always be
operated behind a firewall and/or a router, which shields the system from direct access
from the Internet. The router and the firewall are not included in the KiBox system. The
KiBox system is therefore not specifically protected against attacks from the Internet.
Accessories:
To order items without a specified item number, please contact your Kistler
representative.
2.2 Hardware
Front side:
Error LED/Red
Operating LED/Green
For manual switching on and off of the KiBox without the use of the automatic
on-off function of the KiBoxCockpit. Switch on by briefly pressing the button on
and turn off by pressing the button for about 5 seconds.
Local measurement data storage via USB flash drive or hard disc drive (FAT32
formatted).
Connection of digital signals (input low level: <1V, high level: >4.5V, max ±30V)
Crank Angle 1 1 unit crank angle adapter for Kistler Type 2619
Connection of the crank angle signal from crank angle adapter Type 2619.
Connection of the crank angle signals from the optical crank angle encoder. The
following types are supported:
Connection of current probes (Kistler Type 2105, Fluke Type 80i-110s) for
detection of the injection signal.
Slot for Kistler measurement amplifier. The following types are supported:
Of the total of 8 signal inputs per channel, only either the analog input
(top) or the equivalent amplifier input can be used.
Back side:
Ethernet 100/10 1 unit 100 Base-T with green and orange LED
Inactive
Shows the main characteristics of this KiBox To Go (type, serial number, power
source, ...). Please always keep this information handy in case of a support or
warranty request.
Shows the main characteristics of this KiBox To Go (type, serial number, power
source, ...). Please always keep this information handy in case of a support or
warranty request.
Power 1 unit
Remark The standard blade fuse itself can be replaced with the
Short Description
The crank angle adapter is the connecting link between the vehicle's crank angle
sensor (hall or inductive) and the KiBox Crank Angle 1 connection. It converts the
analog signals of the crank angle transmitter from the hall or inductive sensor in a
uniquely evaluable, digital LVDS pulse sequence at, which is then used in the KiBox for
calculating solid angle measurement data. The power supply and configuration of the
adapter takes place via the KiBox.
Key features of the crank angle adapter Kistler type 2619 at a glance:
The crank angle adapter is specifically designed for use in the car and for installation
in the engine room. Here the vehicle specific crank angle sensor signal of the hall or
inductive sensors, required from the ECU (engine control unit), can be tapped and
attached on the three-pin plug of the crank angle adapter 2619A11 (connection:
"sensor"). The communication takes place between the crank angle adapter and the
KiBox via the 14 pin Crank Angle 1 interface. The following figures show the necessary
connection schemes for the corresponding hall and inductive sensors in the vehicle.
3. Installation
The following chapters will guide you through the installation of the KiBoxCockpit
software and hardware measurement setup.
To ensure the reliable operation of the KiBox system, the following minimum
requirements of the PC must be met:
5 GB (data storage)
Ethernet : 1 Gb
Please make sure your Windows user account has sufficient rights (such as changing
the firewall settings).
Due to its compact size and diverse mounting options, the KiBox To Go may be placed
in various locations in the test vehicle:
Trunk (with mounting straps, etc.)
Foot space between the front seats and rear seats
Rear seat (easy fastening with seat belts)
Cab (trucks)
Iso-Fix attachment (accessory is being planned)
Figure 5: Proposed placement in the vehicle: Trunk (left), foot space in front of the rear seat
(center), rear seat (right)
Use of the KiBox To Go requires the previous installation of the software KiBoxCockpit
and other components (such as additional drivers, etc.) on a notebook. Furthermore, a
functioning Ethernet connection for communication is required. The following sections
provide further guidance to both the software installation and the subsequent
configuration of the software and network settings.
Software at a glance:
KiBox INCA Interface between KiBoxCockpit and application system INCA from
driver: ETAS, necessary for the integration of the hardware component
"KiBox" in INCA; for standalone operation this is not necessary
IFile Converter: Allows the conversion of KiBox measurement files (*. open) to
IFiles
MDF converter: Allows the conversion of KiBox measurement files (*. open) into
MDF files(*. DAT).
Matlab PlugIn: Allows to open KiBox measurement files (*. open) in Matlab
directly.
Remote Client Demo software including MS Visual Studio project so that the
KiBoxCockpit Remote API can be visualized on another PC via
TCP/IP network connections.
Testbed DCOM Interface which enables the KiBox to be connected to test benches
driver using the DCOM protocol
Also available on the CD under the heading "Documentation - KiBoxCockpit" are the
following documents:
Instruction Manual for KiBox To Go
Quick Guide to KiBox To Go
Readme files
Sensor Mounting Instructions
Installation:
1. Insert the CD into the drive. If the installation application does not start automatically,
start the application "KiBoxToGoSetup.exe" on the CD.
2. Select the desired installation language
3. Overview of the components that will be installed with KiBoxCockpit; continue with
"Install" button
4. Selecting the installation method: "Measurement Installation" or "Office Installation"
5. Set paths for the installation files and user files (such as parameter files, etc.). Individual
installation components may be added or unselected.
6. When "Measurement installation" is selected, all INCA installations on the PC are shown.
The user must then select the version of INCA in which the KiBox is to be used (it is not
currently possible to select multiple versions. To work in KiBox with another version of
INCA, KiBoxCockpit must be re-installed or changed).
3.3.2 Configuration
The communication between the KiBox To Go and the KiBoxCockpit (Notebook) will
take place over a Gigabit Ethernet connection. This connection must be configured
accordingly. This is done by comparing the IP addresses between KiBox To Go, and the
notebook. If required, the IP address of KiBox To Go can be changed.
The Ethernet configuration of the notebook operating system is set under "Control
Panel - Network Connections - LAN connection". In the context menu of the LAN
connection used, "Properties" of the Internet Protocol (TCP/IP) must be selected within
the "General" tab. The "Properties" button then leads to the input mask of the IP
configuration of the operating system.
The KiBoxCockpit Ethernet settings can be adapted with the active KiBox as follows:
Notebook KiBox
The KiBox system is delivered with the standard IP 192.168.0.100. In order to be able
to connect directly, the address of the Gigabit Ethernet card on the notebook must be
set to the value of 192.168.0.101. The subnet mask of KiBox and the notebook must
match. The default gateway of the KiBox must be set to the IP 192.168.0.254.
Generally speaking, the KiBox and the notebook must use the same network segment,
but set to a different IP.
The notebook and the KiBox can be alternatively connected through a switch to a
corporate network. It should be noted, that in this case, the company-specific network
settings are standard.
In general, mobile computers have an energy manager, which should extend the
duration of battery operation. Please make sure you use an energy scheme that allows
for the maximum processor and fan performance.
3.3.2.3 Speaker
The KiBoxCockpit software has an audio feedback that can give you helpful feedback
information. Please make sure your speakers are turned on with sufficient volume.
When you first launch the KiBoxCockpit the default IP settings are preconditioned. If
default setting is not the case the IP configuration must be adjusted. This can be done
via the menu "View - Search KiBox" (or press F3) in the menu bar. Then select the IP
address found with "Apply". Alternatively, you can also enter the IP address of KiBox by
hand. If necessary, the KiBox IP address can be changed by pressing the "Edit" button.
After confirming with "OK", the KiBoxCockpit will try to connect with the hardware.
With the proper IP configuration, the message "KiBox Online" will appear in the status
bar and be announced on the speakers.
4. Parameterization of KiBoxCockpit
In the figure above, the individual components of the user interface are graphically
highlighted. Basically it consists of the following five general components:
Menu Bar
Symbol bar
Navigation Bar
Status Bar
Dialogue field
Message Window
To validate the input in an input field, you must first exit the input box
(e.g. by pressing the TAB key or by clicking in another field)
Input errors:
In the event of an incorrect input, a red exclamation mark appears next to the
appropriate input box. Move the cursor over this red exclamation mark and you get a
text message.
Decimal seperator:
The KiBoxCockpit software uses the default decimal seperator setting of the operating
system. Please note that incorrect use of decimal and thousands separators may lead
to incorrect entries that are not recognized by the software. The following example
illustrates this:
4.2.2 Shortcuts
Using a mouse during mobile use in vehicles is very difficult. For this reason, the ability
to control the KiBoxCockpit was made possible primarily with the keyboard. An
overview of all the additional Windows standard shortcuts is available at the end of this
chapter (or in the KiBoxCockpit by pressing the "Ctrl" + "F1").
By pressing "Alt", under each menu name in the menu bar an underlined letter appears
(example "D" in the File menu). With the key combination of "Alt" + "D" the "File" menu
opens.
By pressing the "Alt" key, however, only the File menu is selected but not opened.
Using the cursor arrow keys any menu and each menu item, respectively, and its sub-
points can be marked and opened with "Enter".
Figure 13: Menu bar after activation of the key control by the "Alt" key
A. Main features
F2 Parameter Check -
Maximize/minimi
The message window is maximized or
F8 ze message
minimized at the lower edge of the screen
window
TDC
determination
F9 -
from cylinder
pressure
Start TDC
determination Only in the "TDC" dialog, Register "from
Space bar
from cylinder cylinder pressure" active.
pressure
Skip to the
Only in the "TDC" dialog, Register "from
previous cycle of
Ctrl + left arrow cylinder pressure" active. After successful
the TDC
TDC determination.
determination
B. chart functions
Go to the
Ctrl + Page Down Only active in the "data display" registers.
previous tab
Go directly to a
1 to 9 With "1", the first register is activated.
specific tab
Zoom -
"View" menu> menu item "Zoom" or via
Ctrl + A automatically
symbol bar. Only for each active chart.
scale
4.3 Administration
Settings are made in the administration area. In the daily operation normally there is
no (or no longer) need to change (e.g. measuring principle of a sensor, signal names
used, definition of calculations, etc.). These settings are protected with the default
password "kibox".
The change of the default password is made in the password entry field under "View -
Enter admin password" by pressing the "Change" button. You must then type in both
the old password and then twice the new password.
In the section signals, all signal types are defined, which will later be available for a
measurement. In addition to the types of signals, the associated calculations for each
signal type must also be defined.
By right-clicking on the words "Signal Type" and selecting "Signal Type add", new types
of signals can be defined.
To add a new calculation, you must click on the right mouse button on the lettering of
a defined signal type and select the choice of "Add Calculation". "Delete" with the
option of the command from the context menu (right click on the type of signal or
calculation), to delete signal types or calculations.
In the "Channels" area, the physical input channels can be divided into any number of
virtual channels.
Moving average:
The moving average is used to smooth out the raw signal before the calculation of the
result. This kind of averaging is used mainly for dynamic analysis of measured values.
The moving average is defined with the specification of a range over which the
averaging will take place each time. This +/- °CA value is indicated in most
calculations. If the value is set to +/-0 °CA, there is no moving averaging.
Pressing the "Reset" button will return the default settings for the
currently selected signal type or the calculation, even if there was
previously no entry.
Channel
see injection pulse
selection:
Edge
Input range: rising edge, falling edge
selection:
Display
see injection pulse
range:
Threshold for
Determines the threshold that has to be exceeded by the signal
detection of
to detect the ignition signal
ignition
Input range: +1 V to -1 V
timing:
Threshold for Determines the threshold to which the signal should decrease
detection of after crossing the threshold so that the ignition timing is
ignition detected
timing: Input range: +1 V to -1 V
Generally the thresholds can be on the same level. But if there are
disturbances on the signal, it can make sense to adjust threshold on
a high level and threshold on a low level.
Threshold for
Determines the threshold that the signal must exceed so the
detection of
digital conversion recognizes the start of the injection.
start of
Input range: +1 V to -1 V
injection:
Threshold for Determines the threshold that the signal should drop after
detection of crossing the threshold of the start of injection so that the digital
the end of conversion recognizes the end of injection.
injection: Input range: +1 V to -1 V
4.3.1.11 Torque
4.3.1.12 Universal
The high sampling rate of the KiBox makes it possible to measure angle marks with an
angle resolution of 0.1 °CA up to 15 624.9 rpm
For the detection of the crank angle and engine speed, the falling
slopes of the encoder are used
Figure 27: Administration: Signal type crank angle with optical encoder
Number of
Number of angle marks of the selected transmitter type.
angle marks:
Pressing the "Reset" button will return the default settings for the
currently selected signal type and calculation, even if there had
previously been no entry.
Reflects the incremental cycle number that is incremented at the end of a cycle from
the reference cylinder (at +360 °CA) to "1". It can be used mainly for navigation in the
measurement files.
Logical value
Result name:
Example: DIN_STATE
The calculation of the heat release is performed without taking into account the wall
heat losses and with a constant polytropic exponent (input value "calculation: Zero
point correction ").
Heat release
Result name:
Example: Q
Settings:
Moving
see above
average:
Calculation Input range: -59 to 179°CA (start value is less than end value!)
window: Example: -30 °CA (start)/90 °CA (end)
Statistics
see the indicated mean effective pressure
window:
Calculation
Input range: 0.1 °CA (fix)
solution:
Calculation Input range: -90 to 60 °CA (start value is less than end value!)
window: Example: -60 °CA (start)/40°CA (end)
This calculation determines the indicated mean effective pressure, whose shares in the
high-pressure and gas exchange area as well as some of the related statistical values.
Settings:
Calculation Performed crank angle resolution for the calculation of the IMEP.
resolution: Input range: 0.1; 0.2; 0.5; 1 °CA
Moving
see above
average:
This calculation reflects the injection timing and duration of each number of injection
for diesel engines, including pre-, main- and post-injections. The number of pre- and
post-injections are numbered beginning with "1" and each attached to the calculation
names (..._#). As the main-injection, the longest injection process is defined.
Settings:
resolution:
Calculation
see injection timing gasoline
window:
This calculation gives the injection timings and durations of each number of injections
for gasoline engines. The number of injections depends on the signal automatically
detected (max 10) numbered beginning with "1" and each attached to the calculation
name (..._#).
Settings:
Calculation
Input range: 0.1 °CA (fix)
resolution:
Input range: -719.9 to 359.9 °CA (start value is less than end
Calculation value, with overlapping cycles of injection time detection the
window: range may not exceed a total of 720 °CA!)
Example: -360 °CA (start)/359.9 °CA (end)
4.3.2.9 Knocking
Settings:
Rolling
see above
average:
For more information on knocking detection algorithm: see Knocking in the Appendix.
4.3.2.10 Maximum
This calculation enables a determination of the maximum value of a signal and its
crank angle position within a cycle.
Settings:
Moving
see above
average:
Settings:
Moving
see above
average:
Input range: -359.5 to 359.4 °CA (start value is less than end
Calculation
value!)
window:
Example: -30 °CA (start) / 60 °CA (end)
Settings:
Calculation
Input range: 0.1 °CA (fix)
resolution:
Input range: -360 to 359.9 °CA (start value is less than end
Calculation
value!)
window:
Example: -185 °CA (start)/-175 °CA (end)
4.3.2.13 Noise
Calculation Entry field for the structure damping alongside the relevant
table: third-octave center frequency.
Calculation
Input range: 0.1 °CA (fixed)
resolution:
The noise calculator is intended primarily for tests carried out on diesel
engines.
The CNLA calculation is only used to provide a complete overview and
will therefore not give any results that can be used in practice.
4.3.2.14 Speed
When using piezo electric pressure sensors, the activation of a zero point correction is
absolutely necessary. The KiBoxCockpit provides three possible variants of the zero
point correction.
Thermodynamic
Intake pressure reference sensor
Static value
Thermodynamic settings:
Moving
see above
average:
Moving
see above
average:
The user has the option of storing a description for the formula.
Description: This allows for a quick overview of the calculation processes of
the formula.
By activating "Previous Cycle", the user can use the input signal
of the previous cycle for the calculation.
Special text editor that the user can use to implement his
Calculation calculation. The already defined input variables, formula
window: variables and output variables can be used here. The formula
syntax is explained in chapter 4.3.3.1.
The formula can be exported by right-clicking on the formula name in the structure
tree . In this way the formula can, on the one hand, be stored separately and, on the
other hand, imported into a different kip file with little effort. This is performed by
right-clicking on the "Formulas" node and then selecting "Import Formula".
The change in the unit for the output variables may affect the calculated
values. (See chapter 4.3.3.1).
4.3.3.1 Formula-Syntax
The formula syntax of the User Formula is based on the Matlab programming language
and was developed to give the user the opportunity to create special, engine-specific
calculations and signals. It is noted here that the scope of functions already
implemented in the User Formula does not correspond to the scope available in
Matlab. All functions of the User Formula are shown in the table below. It can be seen
here that self-developed functions were also integrated in order to improve the
handling of the programming.
The calculations of the User Formulas are performed in the same way as the default
calculators in the KiBox. This has the great advantage that the user-specific User
Formula calculations are also real-time capable.
A created User Formula can be assigned to any cylinder or to the engine on the
"Signals" tab. Any signal that is allocated to a cylinder or the engine can then be used
as input variable for the User Formula (see chapter 4.5.10). A calculation over all
cylinders is not possible (e.g., engine average). This can, however, easily be realized in
post-processing or in application software, such as Inca.
Variables
In principle, all variables are to be handled as vectors, which can be assigned different
sizes. In the case of the "Formula inputs" variables, the size is dependent on the signal
that is assigned to these variables. In the case of a result, such as Pmax, the vector has
the size 1 and is addressed with index 1. If the input signal is a vector signal, the size
is dependent on the calculation window and the computing resolution. If, for example,
the heat release with a computing resolution of 0.5°CA and a calculation window of
30°CA before TDC to 90°CA after TDC is used as input variable, this vector has a size of
240, since the heat release has this number of values per cycle (one value from -30°CA
to +90°CA every 0.5°CA). If the value of the heat release is to be read out at position
0°CA, index 61 must thus be addressed.
The size of the "Formula Variables" is defined by the user as described in chapter
4.3.3. To point to a specific vector position, the position is written in parenthesis after
the variable. If the third element (third index) of the variable "Var" is to be five, it can
be written in the calculation window as follows:
Var(3) = 5;
Units
In the calculation window, the calculation is always performed in the Si system of units.
If, for example, the maximum pressure (Pmax) is used in the calculation window as
input signal, it is considered in pascal. Assuming this lies in the considered cycle at 80
bar, calculations are then performed with 80 ∗ 105 Pa. If 10 bar is to be added to the
result Pmax, 10 ∗ 105 must thus be added to this signal.
If no unit "-" is defined for the "Output variable", the output value is given in the
corresponding Si unit. In the above example, this would be 9,000,000. It would,
however, make sense here to set the "Pressure" unit. In this case, the value of the
output variable is converted to the given unit set by the user under Layout properties.
The layout properties can be found in the Cockpit under "Edit" -> "Layout properties" -
> "Units" (see Figure 44). In this example, the "Pressure" unit is set to bar, whereby the
output variable in the above example was divided by 105 , with 90 bar thus appearing
as the result.
Syntax
Described in the following is the syntax of the User Formula, which was implemented
on the basis of Matlab.
Control structures
For loop for i=1:10
Do something;
end
If instruction if logical expression
Do something;
end
If/Else instruction if logical expression
Do something;
else logical expression
Do something;
end
If/ElseIf/Else instruction if logical expression
Do something;
elseif logical expression
Do something;
else logical expression
Do something;
end
Functions
Specifies the cycle number current_cycle()
Outputs the cylinder number assigned cyl_number()
to the calculator
Specifies the rotational speed speed()
Angle-based functions (in rad)
Time-angle relationship atr(x)
returns the TimeSampleNumber for
each angle
Example: After downsampling the
AnalogIn inputs, their sampling rate is
1
312500 , whereby 312500
𝑠
TimeSampleNumbers per second are
assigned
Constants
Converts an angle in units of degrees Deg2Rad
to rad
Converts an angle in units of rad to Rad2Deg
degrees
Specifies the sampling rate (e.g., TimeSamplingRate
1
Analog In = 3125000 )
𝑠
Specifies the length of a vector in x.Length
indices.
Engine constants
Specifies the cylinder bore in meters BORE
Specifies the conrod length in meters CONROD
Specifies the number of strokes (2 or ENG_TYPE
4)
Specifies the number of cylinders NUM_CYLS
Specifies the cylinder number of the REF_CYL_NUMBER
reference cylinder
Specifies the stroke STROKE
Engine constants (cylinder-related)
Specifies the compression ratio of COMP_RATIO(x)
cylinder x
Specifies the crank offset of cylinder x CRANK_OFFSET(x)
Specifies the firing distance of cylinder FIRING_DIST(x)
x relative to the previously ignited
cylinder
The "Formula Inputs" signal inputs are generally addressed with a one-
based vector syntax. Scalar signal inputs (results) are considered to be
vectors of length 1. With vectorial input signals, there are
correspondingly more indices. The cylinder pressure with a resolution
of 0.1°CA and a representation range of ±360°CA thus has 7200
indices. The number of indices of a vector is, thus, dependent on the
resolution and the representation range (note multi-cylinder function!).
Note that the User Formula calculates using the generally valid
international system of units (SI units). If no unit "-" is specified under
Default Units, the output is then in SI units (e.g. rad , Pa,…). If a unit is
selected, a conversion of the SI unit to the units set under "Edit" ->
"Layout properties" -> "Units" is performed.
Example 1:
An intake manifold pressure signal recorded by a sensor in the manifold. It contains
information for all of the cylinders connected to the manifold. When an intake pressure
signal is used to correct the zero point of a cylinder pressure signal, however, only the
range of the intake pressure signal used for the zero point correction (e.g., –175 °CA)
is important. It is therefore enough to subdivide the intake pressure signal into the
relevant number of cylinders, assign the respective range to the corresponding cylinder
as an intake pressure signal, and carry out the zero point correction with this.
Example 2:
The signal from a current probe, which encompasses several control lines for different
injectors and therefore outputs their drive current profile as a signal. This type of
signal can also be subdivided into virtual ranges again as the combined cylinders (if
the cylinders have been combined intelligently in a probe) are only injected in certain
ranges (e.g., –180 °CA to 180 °CA). A corresponding signal section (virtual signal) can
be implemented for injection timing calculations (when connected to a current probe
input) or to evaluate the current signal profile (when connected to an analogIn) for all
cylinders included in this signal.
Example 3:
Combining a cylinder pressure signal from several cylinders in one signal. This can
then be divided into the corresponding ranges in which combustion takes place in the
respective cylinder and used as a virtual cylinder pressure signal in the system. As a
result, all calculations in the KiBox which do not require the full combustion cycle, such
as the indexed mean effective pressure, are available. This means that knocking, for
example, can be analyzed or the PMAX can be monitored, even for more than 8
cylinders.
The tree structure under "Administration – Channels" displays all of the available
physical signal input channels in the KiBox hardware. It is divided up into the 8 analog
and 8 digital inputs, and the 2 current probes.
Each of these channels can be subdivided into any number of virtual channels. The
ranges can be selected at will and can even overlap one another if necessary. Each
divided range, i.e, virtual channel, must be defined with a start and an end in the angle
range and must be given a channel name. The start and end must be between –
720 °CA and +720 °CA. The limits can be a maximum of 720 °CA apart, which
corresponds to the complete physical signal. The angle position refers to the TDC
which has already been set and which, in turn, refers to the reference cylinder.
Oscilloscope
The oscilloscope is used to help with configuration and marks the start and the end of
each configured virtual channel with a vertical green line.
In the oscilloscope, signals can only be displayed after the engine parameters have
been entered.
For physical signals connected to one of the two current probe inputs, it is possible to
select whether the digitalized injection or ignition pulse signals or the analog input
signal is displayed in the oscilloscope. However, the x-axis is only available in °CA for
the digitalized signals. If the digitalization is not activated for the preview in the
oscilloscope ("Off" selected), the physical input signal is only available on a time basis –
it is only present so that the physical signal can be checked. The green limit lines are
not displayed. The digitalized signals can only be displayed in a useful way after the
thresholds have been configured in "Administration – Injection and ignition pulse
signal types".
For physical signals connected to an analogIn or an amplifier, it is possible to choose
between the amplifier input or connection to the TopConnector ("Top connection"
active) for the preview.
Physical signals on one of the digital inputs can be inverted in the preview.
If no cylinder pressure signals have been configured previously, a phase shift may need
to be carried out to ensure that the angles are assigned correctly (with the F4 button or
the icon in the tool bar).
Virtual Signals
A configuration example for a real application – the division of two current probe
signals for injection timing calculations for a four-cylinder engine – can be found in
the Appendix under Configuration Example for Using Virtual Channels.
4.4 Engine
Engine type:
Geometry:
The definitions of the following quantities can be extracted from the drawing on the
right side of the interface.
An alternative volume function can be used in the "Expert" user level (Options: User
Level). This function is primarily intended for the use of engines that are able to vary
compression ratio whilst in operation using a control variable (e.g. an eccentric angle).
However, a completely free volume geometry can also be used. Doing so will require
ASCII files that show the characteristic diagrams for both the volume function and the
correction angles for position-based results (e.g. 50% offset position) depending on
the crankshaft and the adjustment parameter (eccentric angle).
Use
alternative
Check box to activate the use of the alternative volume function
volume
function:
Load volume
Opens window to browse to volume ASCII file
ASCII file:
Load offset
Opens window to browse to offset ASCII file
ASCII file:
Eccentric
angle, Manual entry of the eccentric angle (° eccentric angle)
constant:
Cylinder
displacement, Manual entry of a constant cylinder displacement [cm³]
constant:
Cylinder
The cylinder displacement is calculated according to the volume
displacement,
function in use at the time.
calculated:
The ASCII files for the volume function and the offset characteristic diagram must be
configured as follows:
The first column must contain at least the crank angle reference points -360 °CA to
359.9 °CA (increment of 0.1 °CA).
The first row must include the used eccentric angle reference points, between 0° and
180°. An increment of no less than 5° and no greater than 180° will be accepted here. A
first value of 0° and a last of 180° is not necessary.
The volume must be entered in cm³ and the offset in °CA.
The decimal separator must be used according to the KiBox Cockpit language setting,
as with other entries.
The system applies linear interpolation between the given reference points. If the
signal value for the eccentric angle is outside the reference points, the volume or offset
function of the lowest resp. highest given angle is used when using the eccentric angle
from the signal.
Otherwise, the relevant volume function is taken from the table during a cycle in real-
time, depending on the contiguous eccentric angle (manually entered or taken from
signal), and is used directly in calculations. The appropriate offset value is added for
position-related results.
4.5 Signals
Here you define which types of signals are picked up from the "Administration" and
recognized as actual signals to the available hardware channels. A distinction is made
among the assignments "cylinder" and "motor".
The heading "cylinder" can be defined in accordance with the multiple assignments of
cylinders in "Administration". All types of cylinder signals are built exactly the same,
but can be configured individually. The name is set at the administration level. There
are all signal types may be defined in the administration level.
Signals that generally apply to the entire engine, are usually assigned to the engine
(e.g.: SPEED_AVG, CYCLE)
Channel Selection
The channel must be selected for every signal to be recorded. The option to do this is
available in every signal type dialog. All virtual channels are available. By default, every
physical channel under "Administration – Channels" is pre-configured as a virtual
channel for the entire combustion cycle (–360 ° to +360 °CA).
In every drop-down menu, all signals that are suitable for the respective signal are
provided. Channels highlighted in gray are already in use in the system. To help the
user, the name, physical connection, and available configured range is displayed for
every channel provided.
Method:
Settings:
Depending on the type of connection of the cylinder pressure signal, the further
necessary settings of the signal type vary.
Input for the calibration factor for converting the voltage signal
Sensitivity: received from the sensor signal into a pressure value.
Input range: any [bar / V]
Serial
Input range: any
number:
Option: Amplifier
Other settings:
Expert Mode:
The voltage range for the charge amplifier output can be modified in the Expert User
level.
4.5.2 Signal: Digital Signal, Injection Pulse Digital, Ignition Pulse Digital
This type of signal makes it possible to record digital signals (TTL: >4,5V high, <1V
low level). These signals are then transmitted, either by ECU or statically from a test
bench, in order to activate injectors or ignition, for example.
Figure 54: Signal: Digital Signal, Injection Pulse Digital, Ignition Pulse Digital
Settings:
Settings:
Serial
Input range: any
number:
Settings:
Serial
Input range: any
number:
Other settings
Realtime
see injection pulse
Oscilloscope:
Option: Amplifier
Expert View:
Other settings
Realtime
see injection pulse
Oscilloscope:
Settings:
Settings:
Serial
Input range: any
number:
Realtime
see injection pressure
oscilloscope:
Shown in the signal pool are all signals and calculations that
result from the signals and formulas that were assigned to the
Signal pool:
heading (here: Cylinder 1). These can be used as input signals
for the User Formula.
Input Name: Here, the names of the input variables used in the
formula are stored automatically.
Input Signals: Signal: Here, the user can use drag & drop to insert the input
signal from the signal pool .
The setting of the output variables affects the number of indices of the
vector. This must be taken into account when implementing the User
Formula. An example can be found in the appendix in chapter 9.8.2.
The unit used in the Output Signals area affects the size of the
calculated value or signal (see chapter 4.3.3.1).
The "Statistics" area is used to configure general statistics parameters from the
existing results. This means that predominantly statistical evaluations can be carried
out for results which are not a predefined part of a calculation (e.g., IMEPL_AVG).
Approach:
All available results can be moved from the signal pool to the table area at will using
drag and drop. Next, the number of cycles needed for the statistical calculation and
the statistical values for the respective result must be selected. The following statistical
values can be selected: Average, minimum, maximum, standard deviation, and
coefficient of variation. As soon as a statistical value is selected, the corresponding
result appears in the signal pool of the statistical results on the right. These signals are
subsequently available and can be used in all areas of the KiBoxCockpit in the same
way as the normal results (e.g., for displaying and outputting data, etc.).
In this section, the settings and the actual implementation of the determination of the
top dead center (TDC) can be made. These always refer to the reference cylinder. Three
types for determining the TDC are available:
Direct input of the differential angle (if it is already known)
Transient determination from cylinder pressure(the differential angle must be
determined)
As a basis for further steps in connection with the TDC, the loss angle has to be
specified . Background information can be found under thermodynamic loss angle
in the appendix.
The determination of the TDC, can only take place in the non-fired
engine operation of good quality. Therefore, the reference cylinder
must be in coasting mode during the TDC-determination. This can
occur when driving downhill without pressing the accelerator, or by
disabling the injection at the reference cylinder.
If the TDC position of this engine is already known, it can also be
entered manually.
The angle difference found is only a relative angle and therefore cannot
be transferred to other systems or other measurement systems.
To ensure quality, the raw data used for TDC-finding can be saved as a
measurement file (*.open) (no zero-point corrected values).
Current Values:
1. User input of the loss angle and the number of cycles to be used for determining
the TDC
2. Start TDC-determination (in coasting mode!): Cycles are recorded and mapped
3. If necessary, manually delete bad cycles
4. Display of the retrieved TDC position: calculated differential angle [°CA], and its
deviation [°CA]
5. Accept calculated TDC position
Current TDC
Display of the TDC-shift based on the last TDC-determination
shift:
With the selection buttons "next" and "prev" you can jump back
next and and forth between the individual cycles, select unsuitable cycles
prev. button: and then delete them. A selected cycle is shown in white and
bold.
Absolute TDC
Calculated interval (angular ignition space) to reference cylinder
interval:
Save new By pressing this button, the calculated angular ignition spacings
firing are transferred to the angular ignition spacing table in the
intervals: "Engine" area.
Enter the loss angle (see Appendix: Thermodynamic loss angle) exactly
for the condition of where you want to later carry out the TDC-
determination, i.e., engine operating temperature, desired rotational
speed, and the position of the throttle (if present). Note that the testing
of the loss angle is very often used with a fully opened throttle and
switched off injection. But this is often not possible in the vehicle. The
loss angle for operation with the throttle closed is usually about 0.1 to
0.5 °CA greater than that for the operating point with fully opened
throttle.
If individual cycles with combustion are visible in the chart, you should
delete them from the calculation.
Pressing the Save button saves the raw data of the TDC
Save: determination as an *.open file for quality assurance. It is
possible to select where this should be saved in the next dialog.
By pressing this button, the new TDC shift is saved and applied
Apply:
for further calculations and evaluations.
4.8 Diagrams
In "Diagrams" is defined which of the signals and calculated results are presented on
the display while measuring.
For diagrams, only signals and results can be selected, that previously
were defined in the settings of the navigation button "signals". A signal
may then only be defined there if the desired signal type and the
corresponding calculations have been previously defined in the
"Administration".
Overview of the available display types for data visualization. There are charts of signal
processes based on crank angle or time, pV-charts (linear, logarithmic), bar charts,
tables, and trend graphs available for results.
Signal pool with the display of all available signals and calculations that can be added
to a display element of area B (activated by click) and by using drag and drop.
1. By using drag and drop, the desired display type from the area A can be place in
area B.
2. The desired signals and calculations elements seen in the C area of the signal pool,
can be place with drag and drop into the currently selected (highlighted in gray)
display element.
3. The display choices can be individually customized by adding, deleting or moving
displays, signals, or calculations.
Angle / Time signals This type of display presents signals and results as
vectors (highlighted in orange). All curves have the
same x-axis (crank angle, respect. time) and per
unit of its own y-axis.
Bar chart for This display type provides results that are in the
cyclic results form of scalar values (highlighted in light green),
as a bar. All values per chart must have the same
physical unit. Therefore, if necessary, several bar
graphs should be defined.
Table for cyclic results Any results (shaded light green) can be displayed
in a table.
Trend diagram for cyclic Any results (shaded light green) can be shown in
results the trend chart as a trend indicator.
All values that can be calculated and thus also displayed are divided into two
categories:
Signals as curves (vectors) Signals (orange background) are available as vectors and
are shown as curves.
Example: Cylinder pressure, intake pressure, exhaust
pressure, ...
Example: OP_P01
In the data pool, only those signals and calculations are displayed that
match a selected (highlighted dark gray) display in the B area. If no
display is selected, then the data pool (Area C), also shows no visible
signals or calculations. If a signal or a calculation from the data pool is
moved into a display, this element will disappear from the data pool of
the corresponding display.
Statistics Chart
All this and also further statistical values like 3 times of standard deviation, coefficient
of variation, median, minimum in % and maximum in % can be activated/deactivated in
the context menu by the user for the visualization in the table.
The statistical analysis is based on the amount of cycles, which can be configured by
“history length” in the context menu, too. The current value of history length is
displayed in the top left cell of the table.
In one statistics chart only values with the same unit are accepted.
X-Y Diagram:
As with other types of diagram, the X-Y diagram can be configured with the required
results using drag and drop. However, the diagram window is split into two sections: y
(top) and x (bottom). Placing results deliberately in one of the two sections can have an
impact on the axis assignment. While only one result (from one cylinder) is possible for
the basis, the x-axis, the y-axis can be assigned any number of results from any
cylinders. The assignment, which is the basis of the signals, can also be adjusted in the
online display by right-clicking "Select signal on x-axis". The number of cycles for
which value pairs are displayed by the diagram is also set in the "Statistics window"
context menu in online mode.
To support the clarity and the work process, various tabs can be defined in the data
view and for each one of these tabs, a separate display configuration can be created. In
an active measurement, you can easily switch back and forth between different data
displays with a single button (number of the tab).
Tabs can be added to, removed or renamed. By right-clicking on a tab, the appropriate
context menu is invoked. See figure below.
In connection with the navigation button "Data Output", three things are defined.
Firstly it must be determined which channels (measurement data) for a measurement
event are actually stored and which channels are used for CAN-output. Then there is
the possibility of selecting which measurement events are to be included in your
measurement projects. Furthermore, information such as name or file path of the
measurement data of the particular events should be entered.
The sections in the user interface are:
Channels
Events
Data File
4.9.1 Channels: Data File (.open), Data File (MDF4) , CAN Output and
Limit Monitoring
Signals and calculated results can only be selected for the data output,
if they were previously defined in the settings of the navigation button
"signals". A signal may only be selected under the navigation button
"Signals" when the desired signal type and the corresponding
calculations have been previously defined in the "Administration"
section.
Data pool with the display of all possible signals and calculations that can be added to
the data storage in the area B.
Area with the selection of signals and calculations which should be considered when
storing data.
Procedure:
With the help of drag & drop move the desired signals and calculations from the area A
into the area B.
If a signal or a result is moved into the data storage pool from the
signal pool, these elements disappear.
By using the two arrow buttons between the areas A and B, all results
can be moved together from one to the other side.
Moving the signal name means a shift of the signal for all the cylinders.
Upon detection of the corresponding cylinder symbol before the signal
name, only the signal for the selected cylinder is moved.
Local data storage can be configured here. Depending on the actual configuration, all
measurement signals can be continuously saved onto a Flash or HDD data storage
device connected to the front of the KiBox via USB. This data streaming is only limited
by the storage capacity of the external storage device. To this end, it is possible to
limit the volume of data stored, by storing only the required resolution of the relevant
signal, thereby saving storage capacity.
The local data storage can also be used in standalone mode, without the need for a
connection to the KiBox Cockpit. The MDF recording function must only be activated
once, and starts as soon as the KiBox is switched to measurement mode. Measurement
mode is activated as soon as the KiBox is switched on (no PC connection necessary),
provided that the KiBox has been fully configured.
The MDF setup is configured similarly to the diagram selection setup.
Overview of configurable signal groups. Vector signals, digital signals and scalar
signals can be selected.
Area with the relevant selection of signal groups and respective signals.
Signal pool displaying all of the signals and results available for the signal groups
entered/selected in area B. These can be dragged and dropped into the signal group.
Configuration procedure:
1. The required signal group can be dragged and dropped from area A to area B.
Alternatively, signal groups can be moved by clicking on the button.
2. The required signals and calculations, visible in area C of the signal pool, can be
dragged into the selected signal group (shaded gray).
3. Data reduction can be applied or modified using the settings at the bottom of the
selected signal group.
4. It is also possible to add or remove entire signal groups or individual signals from
here at a later date.
5. MDF data can be written by pressing the button on the toolbar. This process can
be activated or deactivated directly from the configuration mode or from the
measurement mode. However, data is only recorded while in measurement mode. At
the start of each measurement procedure, a new MDF file is created, which contains
the relevant measurement start time in the file name.
Settings for general window area. Entry field for start of the
Resolution: window and end of the window, as well as a drop-down menu
for the resolution of the window area.
Use high Activates a second window area that can be used for a higher
resolution: resolution in the area around the TDC, for example.
Digital signals can only be entered onto the MDF file via this signal group. Data
reduction is not necessary here as the digital signals only take up a small amount of
data.
Data can also be reduced in the scalar signal group. The highest resolution is "1 cycle",
which means that every cycle is stored. The lowest resolution, "100 cycles", means that
only every 100th cycle will be stored.
To ensure that the evaluation tools run effectively, the result files will
automatically be split into files of approx. 1 GB in the case of long-term
measurements.
CAN Output:
Data pool with the display of all possible results that can be added to the CAN output
in B.
Procedure:
With the help of drag & drop, move the desired signals and calculations from the area
A into the area B. Distribution/ field size for results can are made by KiBoxCockpit and
cannot be edited at this user level.
In the expert setting, the individual parameters of the editing view, which otherwise
appear only in the detailed view can also be changed.
Sets the priority of the frames. Low ID's have higher priority.
CAN ID
Input range: any beginning with 2
For each CAN frame, 8 bytes (standard frame) are available for user
data. These are shown here in columns (1 byte per column). The more
bytes available for a result, thus the finer the resolution is of the value
in the CAN output. These can be resized by dragging the horizontal
margin of the result.
Further action and the involvement of the KiBox CAN output in other measuring
systems is described in the chapter Integration into external application systems.
Limit Monitoring:
This area is where the limit monitoring is configured. This configuration makes it
possible to monitor existing measurement results. If a result reaches or exceeds the
limit defined here, the system can respond in 2 different ways, which can be selected
here. One option is to activate a digital output signal. The second option is to trigger a
capture.
The configuration process is as follows:
Error Bit Duration of error bit Digital Out 01 as soon as one of the
DO01 configured conditions has been exceeded.
Duration: Input range: any natural number(s)
Configuration:
Test Bed
This area is used to configure the test bench interface on which all signals to be
transferred to the test bench are defined.
Every result, even results from selected cylinders, can be moved from the signal pool
to the table using drag and drop so that it can be output. When it is subsequently
linked up, the test bench then receives the results with the name provided in the alias
and the suffix configured in the table above. Both the alias and the suffix can be
parametrized at will. This means that they can be transferred conveniently to test
bench variables that have already been pre-configured. The following types of transfer
can be selected for a result:
1. Current value: "Online" transfer – the information is transmitted continuously in
measuring mode at a frequency specified by the test bench (approx. 10 Hz).
2. Last value: Transfers the last value from the previous single measurement
(procedural measurement).
3. Average: Transfers the average value from the previous single measurement
(procedural measurement).
4. Minimum: Transfers the minimum value from the previous single measurement
(procedural measurement).
5. Standard deviation: Transfers the standard deviation from the previous single
measurement (procedural measurement).
Provided that the test bench automation system supports this, two
types of transfer (e.g., current value and average) can be transferred
with the same suffix (or without a suffix) if the alias is the same. This
means that it is not necessary to assign additional test bench variables.
By right clicking and choosing “remove” on an already configured test bed output
result, it will be removed from data output.
4.9.2 Events
In this section, which events lead to a data storage are defined. In addition, you specify
the amount of data to be stored before and after each event.
The following events are available:
Manual Capture
Engine start capture
Engine stop capture
Remote Capture
Limit Monitoring
Engine start Settings for the data storage, both of the period before, and the
capture number of cycles after the beginning of the event "Engine Start".
(optional): Input range: 1 to 30 s; 0 to 500 cycles
Engine stop Settings for the data storage, both the number of cycles before,
capture and of the period after the beginning of the event "Engine Stop".
(optional) Input range: 0 to 500 cycles; 1 to 30 s
No. Description
Storage of data files (*. open) for all capture types in the same path.
Storage of data files (*. open) for all capture types with the same file prefix.
Select whether to append to the file name, the index number or the exact time
of the capture event.
The navigation button "Parameter Check" performs the automatic validity check after
the parameterization of KiBoxCockpit is completed. It will be checked on the basis of
different criteria, whether all inputs are in range, whether all necessary adjustments
have been made, and whether the connection to the KiBox is working properly.
The result of the parameter check can either be displayed as "check completed" or with
a different system status. This reference to such text notes give clear instructions on
what needs to be corrected in order to achieve a successful configuration.
The text between the two colons "::" in this case indicates the exact
path of a faulty configuration. Navigate to the appropriate dialog in the
KiBoxCockpit and make the corrections noted, until the check of the
parameters of the system status: "check completed" is displayed.
4.11 Hardware
In the "Hardware" tab, it is possible, on the one hand, to prepare the kip-file for a
cascaded parameterization by selecting "Use cascaded KiBox" and, on the other hand,
to freely select the point of time of the timestamp.
4.11.1 Timestamp
In Figure 84 it can be seen that the time in °CA in which the timestamp is to be set can
be freely selected in the work cycle. This enables optimum synchronization of the
engine control-device data and the KiBox data. By default, the timestamp is set to the
end of a combustion cycle (359.9°CA).
4.11.2 Cascading
It is possible to cascade two KiBoxes in order to obtain a channel expansion to 16
analog channel inputs, 14 digital channel inputs and 4 current-clamp channel inputs.
For this purpose, a new "Hardware" tab was implemented in the Cockpit (see Figure
84). If the check mark for "Use cascaded KiBox" is set here, 16 AnalogIn channels, 4
current clamp channels and 14 DigitalIn channels can now be configured in the
following tab "Administration". The Digital Out 8 channel of the master KiBox and the
Digital In 8 channels of the master and slave KiBox are, however, needed for the
synchronization of the two KiBoxes and, as a result, should not be changed.
Once the ranges of all channels have been defined in the "Administration" tab, they can
be assigned to the respective cylinder or to the engine under "Signals" (see figure
below). The signals can now be used in "Diagrams" and "Data Output" in the
accustomed manner.
Figure 85: Range settings of the channels under "Administration" (left) and subsequent cylinder
assignment in the signal level (right)
In addition to the familiar KiBox setup, two cascaded KiBoxes require an LVDS splitter
box of type 2633A to transmit the crank angle signal to both KiBoxes. For this
purpose, either the engine's own crank angle signal (Hall/inductive sensor) or the
signal of an optical encoder is connected to port "Crank Angle 1" or "Crank Angle 2" of
the splitter box. Inside the splitter box, the signal is duplicated and then sent via two
CA1 cables or two CA2 cables to the two KiBoxes (see Figure 86). It is thereby ensured
that both KiBoxes receive the identical signal.
Figure 86: LVDS splitter box (type 2633A) at left and synchronization cable at right
By means of the synchronization cable, it is ensured that both KiBoxes always run
simultaneously. This synchronization cable consists of one male and two female 25-
pin Sub-D connectors.
The male Sub-D connection is connected to the digital output of the master KiBox.
Here, a signal is output via DigitalOut 8 which is split at the connector and transmitted
via the two channels to the digital inputs of the master KiBox and the slave KiBox. The
female Sub-D ends are then connected to the two digital inputs of the KiBoxes.
The two KiBoxes can be connected to the PC with the help of the switch included in the
scope of delivery of the KiBox.
The network settings are made via the "Tools" tab -> "Options" in the "KiBox" tab. The
IP address of the master KiBox is transferred to the upper field in the accustomed
manner with the "Use" button (see Figure 87).
If a second KiBox is to be cascaded, the check mark for "Cascade" must first be set.
The KiBox that is to be used as a slave can then be clicked (blue background) and
transferred to the lower field using the "Use cascaded" button. A connection is now
established to the two KiBoxes. If the KiBoxes were previously used in non-cascaded
operation, they are rebooted before a connection is established, providing them with
the correct configuration in the process.
5. Run Measurement
Using the menu item "Measure - Start", the shortcut "F5" or the button , KiBox starts
the continuous measurement. Here, the actual measured data is continuously stored in
a ring buffer. If the amount of data of the current measurement exceeds the size of the
ring buffer, the latest resulting data is still stored. At the same time, however, the
oldest data in the storage ring will be deleted. Thus, even after "measuring stop" the
last measured data is temporarily stored in the storage ring and can be saved manually
when needed.
5.1 Online-View
After the measuring starts, KiBoxCockpit changes to the so-called online view. This
allows for a continuous monitoring of indication values during a test. All signals and
results that were previously defined in the parameter "Diagrams" are visible. Only the
chart properties such as the coloring of the sizes, etc., can be changed in the context
menu (right click) of the corresponding chart.
Data from an ongoing measurement can be saved by triggering both by the event
"manual capture" (Shortcut: "F6" or "Spacebar") or after stopping the continuous
measurement by the targeted saving in "File - Save Data" (F12). After stopping the
measuring, the KiBoxCockpit changes into the so-called post measurement view. Here,
all data in the storage ring can be considered and saved manually as required. It differs
only from the online view in that charts, displays, etc. can be added to the current
layout, or can be removed and processed. The manual storage process opens the
following dialog.
No. Description:
targeted select and deselect of individual signals, in order to reduce the data
file to the signals of interest
6. Evaluation
KiBoxCockpit in principle offers the possibility of evaluating the created data. For
specific requirements for presentations or further calculations, an offline analysis tool
should be used. The following programs can be used for evaluation of KiBoxCockpit
data files (*.open):
Turbolab
Uniplot
Concerto / Indicom (using Ifile-Converter/Concerto-PlugIn)
Matlab
FlexPro
Diadem
all programs that can handle ASCII format ( it is not recommended because of large
file size)
Basically, the data visualization between online view, post measurement view and
offline view (viewing of the recently stored data) must be differentiated. So features
such as layout processing only for post measurement and offline view or the "ASCII-
export" are only active for the offline view. To look at data in the offline view, it must
first be opened under the "File - Open data file" (F10) or by of the symbol bar. The
measurement data is then now displayed in a local layout. This means that an accurate
display of the data is loaded, which was set in the parameters during the creation of
the open file. If additions or amendments are now made in the display of data, they
can either override the local layout (File - Save layout), or a new layout can be stored
("File - Save Layout As"). This can also be used for the evaluation of other
measurement files. However, the local layout applies only to the currently loaded test
file. A quick change to other saved layouts and saving the current layout can be done
using the button in the symbol bar.
After opening the display selection on the right side of the screen ( ), analog changes
to the layout can be made as described in the chapter Parameter Diagrams.
The figure below shows a selection of the most important possibilities and actions that
can be used in the offline view.
No. Description
Use the toggle button for "show data file" (offline-view) or "show data"
(online or post measurement view)
Move the display or chart ( a cross cursor will appear near the edge)
Data player
Zoom display
No. Description
Cursor activation
"Crossed signals" -> is a result or a signal that is not available in the area shown;
this will be shown crossed out in the chart legend
"No data" -> If no data is available for an illustrated chart, this text appears. This
can especially be the case at the beginning or end of a measurement.
"Yellow warning triangle" -> appears when during the recording of data, a system
integrity warning is active. If you move the mouse cursor over the triangle, the
cause for the warning is shown.
automatic switching between time and angle data -> if there is no angle data for a
certain signal but only time data (or vice versa), the display changes automatically in
accordance with the available mode.
To customize the chart options to meet specific requirements, the context menu (right
click) of the chart can be used. The following options usually are available:
Chart Title
"Chart characteristics"> font, size, background color, grid color, font color, - Chart
properties, set to default
Autoscale
Signal color
"Chart characteristics"> font, size, background color, grid color, font color, "Reset
to Defaults"
Autoscale
Chart title
The data player is available in the post measurement as well as in the offline view in
the KiBoxCockpit in the lower left corner of the window. This is used to start the
animated display of measurement data. It can be operated much like a music player.
No. Description
Cursor functions:
For a more precise analysis you can choose between two graph cursor types. The data
cursor for reading certain specific values of signals within a chart, or the difference
cursor which calculates the signal value at the cursor position 2 minus the signal value
at the cursor position 1.
The cursor is activated and deactivated with the button from the symbol bar. In each
chart of "mixed signals" one of the two cursor types are now represented. The
selection and display of the cursor in each chart must be activated by right-clicking
and then the "Show data cursor". By means of another right-clicking in the appropriate
chart and the subsequent selection of "show difference cursor" that is also activated.
The cursors appear as vertical red lines in the chart.
For analog, the current cursor types can be removed by right clicking and disabling
"Show data cursor/show difference cursor".
The table with the cursor values consists of four columns. These list the values of
cursor C1, from cursor C2 and their difference (C2-C1; Warning: Note sign) for all
existing signals in the chart, the crankshaft position and the time.
In the menu "File - Save data", the settings are initially defined in a dialog window, as
the data after measure stop should be stored in a measurement data file (*.open) see
chapter: Start measurement - save data
In the menu "File - Export data", all settings are defined in a dialog box, with which the
data from an *.open file containing reduced information content can be exported in a
*. csv file. (Not recommended!)
No. Description:
Separator
Input range: Comma, semicolon, tab
When activated, the cycle numbers are additionally written into the export file.
In the menu "File - convert data" the KiBoxCockpit data files can be converted (*.open)
in the IFILE(*.ifi) or MDF(*.dat) data formats. The selection opens a file browser in
which the converted data file (*.open) is selected. The conversion process is
automatically started. The converted file is saved under the same file path as where the
original data file is located.
Only pre-stored data files (*.open) can be converted. For the conversion
of data from the storage ring, they must first be saved manually.
Exporting information about a data file and parameters from an *.open file
In the menu "File - Data Properties", the properties of an open data files (*.open) can
be called up. In addition, the parameters with which the open data file was created can
be exported in a parameter file (*.kip), can subsequently be loaded and reused.
Matlab Plugin:
The Matlab plugin is a .m-file that facilitates the loading of the open-file signals and
results in Matlab. By default, "openimport.m" is located under path: "C:\Program Files
(x86)\
Kistler\MatLabPlugin". Figure 93 shows the interface that appears after executing the
openimport.m-file. The export of the open-data in Matlab occurs here.
No. Description:
After loading the open-file in , all values stored in the open-file are
displayed.
With the help of the "Structured import", all open-file values are transferred to
subdirectories in a structured manner.
Use the "Import Data Tracks" button to add the selected data to the workspace
in Matlab; the data can then be used for analysis in Matlab.
A template (*.kit) does not differ in content from a parameter file (*.kip). Both contain
settings that are configured in KiBoxCockpit. However, they differ in function. The
template (*.kit) should be serve as "pattern files", to be used as a starting point for
measuring tasks. Based on these, individual (done) configured parameter files should
be created. A "default template" including default values is already supplied. These
default values can be called up for configuring via the respective "reset button", i.e.
transferred into the input fields.
If a template is loaded, the KiBox opens the KiBoxCockpit and opens a parameter file
with the template properties and automatically assigns it the name "unnamed.kip".
This should be changed using the "File - save parameters as - parameters".
The template is stored in the directory "... My
Documents\Kistler\KiBoxCockpit\template" under the name "DefaultTemplate.kit".
In the layout file, specific layout settings for data visualization can be defined. The
layout of a measurement is always stored within the data file. Additional layout files for
the offline or post measurement view can also be defined.
The following properties are stored in the layout:
Chart layout
Color Schemes
Fonts
Font Sizes
Line width of signals
Measurement data files with the extension .mf4 are only stored locally in streaming
mode on USB mass storage devices.
The following data is saved to a .mf4 file in a time-based manner only:
Angle and time data
Continuous angle track
It is possible to convert KiBox data files (open) into different file formats
(MDF, IFile, ASCII). (see Chapter: Saving, exporting, and converting
measurement data)
Depending on the type it is also possible to connect more than one external system.
The Use of the test bench interface or of the remote API supports not only the transfer
of results but also a control of KiBoxCockpit.
This can only be realized by one external system, the master system, at the same time.
In case of master rights for all interface types the chronological order of the
connection build up is significant.
Which connection type is permitted in KiBoxCockpit and if the master rights are
allowed is displayed in the options dialog (tab: remote) of the menu: tools and can
partly be configured. Additionally the permission of a remote capture for each type can
be defined.
Figure 94: Options RemoteFigure 94 shows the dialog of the remote configuration in
KiBoxCockpit. In the Remote access area all installed drivers are listed. Beside the test
bench also the remote server driver is installed by default. According to the installed
features, several additional drivers (e.g. INCA driver) might be listed.
In the lower section of the dialog the interface to the test bench (when using RS-232 to
the left, when using TCP to the right) can be configured.
Once a remote client has connected to KiBoxCockpit the general remote icon or a
driver specific icon will appear in the status bar. In case of a simultaneous connection
of several remote clients the corresponding amount of icons will be displayed. The first
system which connects in chronological order and has master permissions takes the
control of KiBoxCockpit. The corresponding icon will be highlighted by a blue border.
Individual remote connections can be terminated by right click on the icon.
In general remote operation can be locked or authorized by the button Disable/Enable
Remote Control / which changes its icon depending on the state.
Especially in connection with the application of all engine control parameters, the
knowledge of values of indication is of enormous importance. There are two
possibilities available for integration into application systems. Optimal support is
provided for users of the INCA application system from the ETAS, CANape from Vector
as well as Vision from ATI. In addition, by means of a CAN-interface, indication values
could also be sent to other application systems by the KiBox.
7.1.1.1 Configuration
INCA from ETAS is a very extensive and complex system. At this point,
it can therefore not be claimed that the following instructions
completely explain how to work with INCA.
Connect KiBox:
Start KiBoxCockpit
Wait until the connection has been made according to the previous connection
configuration (chapter: Installation).
If the KiBox is off, it must be automatically turned on when starting the
KiBoxCockpit through INCA. You can set the switch on option of the KiBox through
INCA in the KiBoxCockpit menu, "Tools - Options - Power Management" tab.
Make sure that the automatic settings are disabled. Select your Gigabit Ethernet
card and click "Continue".
Set address pool: Enter the range of addresses that should be available to INCA. The
stop address must be chosen so that it matches the KiBox adress (see also
KiBoxCockpit, shortcut F3). Press "Finish". Otherwise, the ETAS Network Manager
changes the IP address of KiBox precisely to the stop address defined here. Then an
automatic restart of the KiBox is necessary (time loss).
After creating a work environment, open the hardware configuration (HWC, for
example by pressing "Ctrl + F3"). Using the context menu and "Insert" button (or
pressing the "INS") a list opens in which the "Kistler KiBox system" can be selected
(assuming the KiBox INCA driver is installed).
Parameterization:
Then you must include a valid KiBox configuration in the INCA database. Highlight
the entry in the hardware device "KiBoxCockpit" and right click on the button below,
"Configure".
The KiBoxCockpit parameter editor starts. You can now load (for example with "Ctrl
+ O") a valid parameter file (*.kip) as a copy in the INCA environment or configure a
new parameter file.
Using the "Close" button, the dialog for setting the parameters of the KiBoxCockpit
under INCA closes. Thus, the parameters are saved as a copy in the INCA database.
Please note that this is done in INCA with a copy of the KiBox parameter
file. If changes are made directly over the KiBoxCockpit, and these are
saved as a parameter file of the same name, the modified parameter file
must be newly reloaded into the INCA hardware configuration.
With F3 you can now initialize the hardware in INCA. This is done automatically by
opening an experiment. If you want to open your experiment without a KiBox
connection (e.g. at the office), you can either create a copy of your work
environment and delete the KiBox from the hardware list, or use the toolbar button,
"Experiment without hardware", and open the experiment again.
In the opened experiment, you can now use as normal variables, the ones that had
been previously provided by the KiBox. Please note that there is a different sampling
rate in the KiBox and in the engine control interface. As a rule, for the variables
from the engine control, only time frames of 10 ms and 100 ms and the
synchronous segment compilation are available (e.g. "synchro" as equivalent to a
four-cylinder four-stroke engine 180°CA). In addition to the two time grids between
10ms and 100ms, in KiBox you can also select between motor and cylinder
synchronous raster.
The available variables are all those that are also available in the signal
pool of the KiBoxCockpit as scalars (e.g. PMAX). Vectors (e.g. PCYL) are
not available.
7.1.1.2 Measuring
In the status bar of the KiBoxCockpit, the INCA icon appears. This
means that the KiBoxCockpit is remotely controlled by INCA. The
remote operation is also indicated by a greatly reduced variety of
menus and icons.
At the start of the INCA measure data display or recording, in the KiBox
the measurement mode is started, i.e. the online view is started, results
are calculated and transferred to INCA. Once the INCA display or
recording is stopped, then the measuring in the KiBoxCockpit is also
stopped. There, the post measurement view is now active.
In INCA under configure recorders> output file, the option for "Wait for
user comment" can be selected. This may result under certain
conditions in INCA-/Hotfix versions that INCA cannot be exited as long
as the measurement mode is running until the user closes the save
dialog. Thereby important data in the ring storage of KiBox can be lost!
In INCA version 7.0 and later, a capture can be triggered remotely in the KiBox Cockpit.
For this to occur, an additional recorder must be installed alongside the default
recorder in INCA Experiment. All INCA Experiment variables (of ECU, KiBox or other
hardware) can be selected as the trigger for this recorder. As soon as the recorder
detects an event (several options available), and a measurement is saved in INCA, the
remote capture command is sent to the KiBox Cockpit.
The following settings must be made to allow the KiBox Cockpit to then process the
capture.
Under the "Remote" tab in the "Options" menu, both the "Enabled" and "Remote
capture" boxes must be checked for the INCA driver. These options are
automatically activated when KiBox Cockpit, including the INCA 7 Driver, is
installed. The "Remote capture" box should not be checked if the capture is not to
be triggered by the INCA recorder. The KiBox Cockpit will need to be restarted if any
changes are made.
"Remote Capture" must also be activated in the configuration settings under "Data
output — Events" and each cycle number required in the measurement file must be
entered before and after the recorded event.
Name transfer
If a trigger is set in INCA (see above) that triggers an INCA measurement and a KiBox
measurement, it is possible beginning with INCA 7.2 to transfer the recorder name
defined in INCA to the Cockpit and to use it as a file name for saving the open-file. As
a result, the INCA dat-file and the open-file have identical names, thereby making the
assignment very simple. This feature can be activated under "Tools"->"Options" in the
"Remote" tab (see figure below). Click on button to open another window .
If the check box for "Use Recorder File Name for Capture" is activated, the Inca
recorder name is sent to the open-file and stored under this name. Furthermore, the
open-file, like the INCA measurement file, is stored under the path that was defined in
the INCA recorder (see Figure 104)
Beginning with INCA version 7.2, it is possible to switch on MDF streaming in the
Cockpit by activating the default recorder in INCA. This is activated by setting the
check mark for "Auto-activation of MDF streaming" as shown in the upper Figure 103
the filename / MDF streaming”.
If this function is activated, MDF streaming is automatically activated in the KiBox as
soon as the default recorder is activated in INCA.
For INCA version lower than 7.0 there is also a workaround of triggering a capture in
KiBoxCockpit. This is done by using a customized formula. To use this function, the
following installation steps have to be carried out:
Quit INCA.
Copy the file "KistlerTrigger.pm" from the "IncaDriver \ KiBoxCapturesByInca" folder
on the installation CD into the target directory
"<ETASData>\INCAX.X\CalculatedSignals\PM\online"
Start INCA.
Define the desired trigger signal in the INCA experiment under "Variables -
define/manage" (Alt Gr+C).
With the following example, a unique capture process starts in INCA when the engine
speed value exceeds 4000 rpm.
As input, all INCA variables (including ECU labels) can be used. The desired monitoring
window is defined with the values "const_low" and "const_high". To save each event of
leaving the monitoring windows in INCA as *.open file, set "const_retrig" = 1. For
"const_retrig" = 0, only the first exceeded threshold is captured since the start of
measuring.
To activate the trigger, you must subscribe to the trigger formula in the
experiment (display or use as a trigger signal in a recorder definition).
Then in the hardware configuration, add the CAN hardware for CAN monitoring by
automatic search or by pressing "Insert".
Be careful when configuring your CAN interface that the project CAN baud rate is set to
1 Mbps and the proper CAN port (CAN1/CAN2) was selected.
For the connection between KiBox and the CAN monitoring device, a minimum of two-
conductor, twisted pair and shielded cable must be used. For the correct layout, please
refer to the figure below.
When you connect the CAN cable, use only the CAN port 1 on the KiBox.
This interface is not internally terminated.
Standalone operation:
As well as the local data storage function, the KiBox can also be used in standalone
mode using the CAN monitoring function. This means that the most recently loaded
parameter file, once correctly configured, will automatically load internally when the
KiBox is started and will activate the CAN output. CAN will then continuously transfer
indexed values (as defined in the chapter entitled Configurations: Data Output,
Channels ). Two temperatures and the watchdog variable (changing the value from 0 to
1 and back in a defined time period) can be read out from the CAN-Bus in order to
check the CAN function, even when the engine is at a standstill.
The connection to a test bench automation system is possible for all those systems
which support the simple serial protocol (KiBox document: KiBox Testbed
Communication Protocol) or DCOM protocol.
Apart from that a general integration to test bench systems can be done via CAN
monitoring, too. The KiBox supports CAN-Bus speed of 125, 250, 500 and 1000
kBaud.
The triggering of a capture for instance can be done by calling "KiBoxCockpit.exe -
As hardware connection a null modem cable (crossed) must be used between the PUMA
interface for a combustion analyzer and the KiBox RS-232 connector (back plane). The
serial interface of the KiBox must be configured, like explained in chapter 7,
corresponding to the one of the automation system. The PUMA setup takes place
analog to the connection of other popular indicating systems.
The following restrictions in configuration and operation of the KiBox have to be
noticed:
- Only procedural measurement, no continuous
Since PUMA Open V1.3 the RS-232 interface for combustion analyzers has not been
supported anymore. When using the CDH block the same protocol can operate via
TCP/IP, too. The needed files for an installation in PUMA are located in the AddOn
directory of the KiBoxCockpit installation disc.
The following steps have to be executed in PUMA for the installation of the KiBox CDH
driver:
2. Start PUMA parameter manager PAM and open in your SYS parameter file the
parameter block MDV (Measurement Device).
8. In the following KiBox device tab pages you can define the name translations and
communication settings. To finish click “OK”.
9. In PUMA POI reload the changed SYS parameter file. Open KiBox POI window
KiBox.wnd and control your new KiBox device.
The delivered Files for the integration of KiBox via CDH block basically
serve as draft. Per default only the common results for maximum 4
cylinders are preconfigured. If any additional results might be required
they can be configured in the CDH wizard.
When the DCOM Puma interface is used, the KiBox behaves in the same way as other
popular indicating systems. The test bench automation system must therefore be
configured as described in the instructions for use of indicating systems. The signals
that should be transferred must be configured in the KiBox via "Data output – Channels
– Test bed".
When the DCOM interface is used, the following restrictions apply for the KiBox:
1. Only results (1 value per combustion cycle, e.g., PMAX), but no vectors (complete
signal curve, e.g., PCYL), are available for online measurement data transmission
from the KiBox to the test bench.
2. It is not possible to perform a recalculation using some of the calculators inside the
KiBox after the actual measurement has been carried out and the operating
parameters for the test bench, which were transferred immediately beforehand
(2nd step calculation), have been taken into account.
There is a tool included in the KiBoxCockpit which can be used to apply all of the
necessary settings automatically. To find this tool, go to the "Tools – Options" menu,
find the "Remote" tab and click on the "..." button in the Testbed DCOM driver line.
When the dialog window opens, select the second tab, "DCOM Register".
The following steps should then be performed consecutively on the KiBoxCockpit PC.
1. Click on the "Enable DCOM" button: To change system settings that are generally
required to use DCOM. In the log window, "Completed successfully" should appear
for the last entry.
2. Click on the "Register" button: To register the KiBoxCockpit software for DCOM. In
the log window, "Completed successfully" should appear again for the last entry.
3. To unregister the KiBoxCockpit software for DCOM (e.g., if other systems need to
communicate via DCOM on the PC), click on the "Unregister" button.
4. Close the window by clicking "Close".
The DCOM interface must also be activated on the client PC (PC test bench
automation). If the supplier of the client system has not provided a tool, the entire
"TestBedDCOMRegisterClient" folder can be copied to the test bench PC from the add-
ons directory on the installation CD. The executable file
"TestBedDCOMConfiguration.exe" can be found under
"..\Driver\TestBedDCOMDriver\Registration". This starts the same dialog window that
is included in the KiBoxCockpit software.
After executing the tool on the client PC (test bench), the following steps should be
carried out.
1. Click on the "Enable DCOM" button: To change system settings that are generally
required to use DCOM. In the log window, "Completed successfully" should appear
for the last entry.
2. Click on the "Register" button: To register the KiBoxCockpit software for DCOM. In
the log window, "Completed successfully" should appear again for the last entry.
3. Click on the "Register Client" button: To carry out the additional registration for the
client PC.
4. Close the window by clicking "Close".
The test bench can specify a number of combustion cycles which should be used for a
measurement point. If this is not the case, the KiBox uses the configured number of
cycles found under "Capture Type Remote Control" in "Data output – Events".
In addition, the test bench can also trigger the process for saving the measurement file
relevant for the last measurement point. The data can be saved in the following ways:
a. The file name is specified by the test bench in conjunction with the save
command (the transfer name is configured in the test bench automation
system)
b. The file name is not specified by the test bench. The KiBox uses the file
name as it is configured by default under "Capture Type Remote
Capture" in "Data output – Data file", including the file suffix.
c. The file name is not specified by the test bench but should be
configured differently to how it is configured in "Data output" (as these
are intended for INCA captures, for example). The intended file name
can be modified by clicking on the "..." button in the Testbed DCOM
driver line in the "Remote" tab in the "Tools – Options" menu. It is also
possible to create the file name using transmitted user variables. To do
this, the user variables to be used must have been transmitted
previously (%Name). The default configuration is
<%TSTSERIES>_<%TSTNAME>_<%BRBLATT>_<%MESPKTNR>. This
indicates a combination made up of four different user variables. If one
of these user variables is not transmitted from the test bench via the
operating parameters, the file name configuration for the KiBox will not
be complete. In this case, the naming method specified in point b is
applied again. If, however, all of the user variables configured here are
transferred from the test bench, the file name is composed of the
relevant transmitted values of the variables. Every variable must be
surrounded by <...>.
Operating Parameters
The KiBox supports the transfer of test bench information via operating parameters.
An operating parameter can contain information from the test bench. This information
contains three values (name, information, unit) for each measurement point or
measurement file. These three values can contain both numerical values and text
information. The test bench automation system is used to configure which parameters
should be transmitted. A visualization of the operating parameters is only provided
offline in a table for data display purposes. In the signal pool, operating parameters
are shown in blue.
The units of all operating parameters will be transferred automatically by the interface
provided that the test bench automation system is set up correctly. If this is not
possible, the units of the respective operating parameters can also be very easily
adjusted using a default XML file (Configuration.xml). The configuration file can be
found in the user directory under ..\Driversettings\TestBedDCOMDriver (e.g.,
D:\KistlerData\DriverSettings\TestBedDCOMDriver).
The KiBox analyzes the transferred name of the operating parameter, searches for this
name in the list, and then applies the corresponding predefined unit if this is available.
Example:
Extract from Configuration.xml:
<OperatingParameters>
<Parameter id="01">
<name>OP_01</name>
<unit>Nm</unit>
Test bench transfers operating parameter: Name=OP_01 and value=50.
Three values in saved open file: OP_01, 50, Nm
3. In the Testbed.log File you can see the ASCII communication between PUMA ( T =
Testbed ) and KiBox ( K = KiBox ). Timestamps are always in UTC. <13><10> are
“end of command” characters (0x0D 0x0A). In case of communication problems
please send this file together with a detailed description to Kistler.
During the entire update the status LEDs for each channel are switched
on and off several times. At the end of the update the system is
automatically switched off and on again.
During the update process may not eliminate the combustion analysis
system or its power supply be interrupted. So pay attention to a stable
power supply (eg, external power supply) during the firmware update.
8.2 Troubleshooting
The KiBox To Go and the KiBoxCockpit assist the user in operation with various
functions to ensure the flow of information and to resolve problems or errors.
Hardware - KiBox:
Various LED indicators on the combustion analysis system, amplifier modules, crank
angle adapter, current clamp and Gigabit Ethernet switch display the current device
status. Details can be found at the appropriate instructions in the "Hardware and
System Overview".
Software - KiBoxCockpit:
Please note in each case the exact type of this message and
information. For more information and support, please contact the local
representative of Kistler.
FAQs:
Two-digit cylinder numbers (eg PCYL_01): Menu: "Edit - Layout Properties - TAB:
Miscellaneous ", then" activate cylinder numbers with two digits. "
Maximum operating temperature: Mainboard warning at temperatures higher than
55 ° C -> warning, greater than 65 ° C-> Emergency shutdown
collect log files for troubleshooting: Menu "Help - Log Collector" a connected KiBox
is necessary!
9. Appendix
In the following sections, detailed and basic information on some of the topics
discussed thus far is given.
Menu File
Export data:
If a data file (*. open) is open so that the symbol "Saved Data" is activated, the
selection "Export data" opens a dialog, with which a new data file with customized data
can be exported separately into an ASCII file (*. csv).
Close Data:
If a data file (*. open) is open so that the symbol "Saved Data" is activated, this
data file is hereby closed.
Convert Data:
Using "convert data", data files (*. open) will be converted into other angle / time-
based formats such as IFILE or MDF.
Data Properties:
If a data file (*. open) is open, it can access via the corresponding data, various
properties such as capture type, creation date, description, information concerning the
KiBox, the KiBoxCockpit and so on. Also, the original parameter file with which the
Open Template :
Opens a previously created template (*. kit). Start a new parameterization with this
menu item.
Open Parameter:
Open a previously created parameter file (*. kip).
Save parameters:
The currently edited parameter file (*. kip) is saved under the current name. The
existing file is overwritten without warning.
If since the last save, changes have been made in the parameter file,
this is identified in the title bar of the KiBoxCockpit window by the
name of the parameter file with a "*". For example: .... Kip *
Save Layout:
Saves the current layout under the name used for the layout already.
New layout:
Creates a new layout. The now visible empty display window is constructed the same as
the display of stored data and is therefore parameterized analogously.
Exit:
Finish KiBoxCockpit. Prior to this you will be prompted to save the configuration if it has
not been completely stored.
Menu Edit
Clear parameters:
By selection all parameters are deleted and there is an empty parameter file (*. kip).
Clear Layout:
Deletes the currently displayed representation (layout) of stored data. There is then a
new layout without any display data, which can be reconfigured.
Layout Properties:
This menu item opens a dialog box with two tabs. The register "units" includes settings
for unit selection for calculations and displays. The tab "Miscellaneous" includes settings to
format the result name. This will determine how accurately the automatically generated
result name of the *.open files should be marked.
Angle °CA
Current A
Electric charge C
Energy J
Force N
Frequency Hz
Length m
Performance W
SPL dB
Temperature: °F, K, °C
Time s
Voltage V
Volume l, m 3
Torque Nm
Angle °,rad
Other details:
Selects whether the auto-generated result / signal name in the form
"cylindernumber_name" or "name_cylindernumber" should be created. In addition, the option
can be selected, to represent the cylinder number in two digits.
If the unit settings are to be made at a certain time, the other settings
in the parameter file that have already been made, the dependent
entries that already exist are automatically converted.
Menu View
Parameters (F11):
By selecting "parameters" the Parameter Editor view opens. The various settings of the
navigation buttons are visible.
TDC (F9):
Displays the dialog of TDC-determination (or navigation key "TDC" in the "parameters").
Show data:
Change to the view of current data of the ring storage (Online-View, Post measurement
View)
Zoom:
Under the menu item "zoom", all sub-items like "zoom in", "Zoom out","zoom window",
"automatic scaling" and "move curves" are visible and can be selected.
Always only one zoom setting can be active (marked with a tick).
Further details on each zoom options are available in the following
"symbol bar" section.
Angle data:
Switches the mode to display the data angle based.
Time data:
Changes the mode to display data on a time base.
Menu Measure
Start (F5)
A measurement is started. Change to Online-View ..
Stop (F7)
A measurement is stopped. Change to Postmeasurement view.
Capture (F6)
By "capture", the recording and storage of measurement data while an ongoing
measurement is triggered, depending on the settings under "Data output - events".
Menu KiBox
Switch on
KiBox is switched on.
Switch off
KiBox is switched off.
Disconnecting
The KiBox can be disconnected from the network via the "Disconnect" button.
Offline operation enables significantly faster parameterization of the kip file. Press
the "Switch on" button to then reconnect the KiBox.
Menu Tools
Updates ...:
Opens the Update Manager. This allows installing firmware updates of KiBox and
amplifiers. The updates will be installed from the appropriate installation folder, or from any
storage medium. Details of the update dialog are explained in chapter maintenance and
troubleshooting.
Options ...:
By selecting a configuration window opens. It contains the registers "KiBox", "User Level",
"Language",”Remote”, "Power Management", "Warnings" and "Directories".
In the register "KiBox" the Ethernet connection between the computer and combustion
analysis system is configured. Also the inversion of digital out signals is available here.
The different user levels have an impact on the visibility of features in the UI.
Remote Control manages the installed remote drivers. It could be chosen which driver
should be used.
In the language section you can set the language and also country-specific number
formats.
The power management defines if switching on and off the KiBoxCockpit also switches on
and of the KiBox.
As part warnings several security queries in connection with the operation of KiBoxCockpit
are defined.
In Directories the paths are set, in which the whole user directory, templates, parameters,
layouts, and EventHandler data files are located or will be stored.
The settings for language and numerical format will take effect only
after restarting the KiBoxCockpit.
Menu Help
Content (F1):
The help function is invoked. This is context sensitive and is possible with the key "F1"to
any point in the KiBoxCockpit.
Log directory:
Opens with the help of Explorer, the folder with the log files of the KiBoxCockpit. Here
the problems and errors during operation of the KiBoxCockpit are saved as *.txt files.
These files can be important for Kistler support. The path is usually located: "... \
Log Collector:
Support Tools: Enabling the collection of various logs, whereby the support can optionally
be accelerated.
Log Control:
Support Tools: Settings, what type of information should be logged (changes will take
effect only after restarting KiBoxCockpit)
System Information:
Opens the Windows system information of the used PC.
Info
With this selection, the information window with basic information about the currently used
combustion analysis system hardware and software KiBoxCockpit displays. Keep this
information ready when requesting support!
Open Data File (F10) Opens an existing data file into the offline view.
Save Data (F12) Saves measurement data into a data file (*.Open)
Save Parameters
Saves an existing parameter file
(Ctrl + S)
Engine:
At this point, all information required for indication of the used engine is specified. In
addition to the name of the engine used, information must be entered on the points of
engine type, geometry, and firing sequence.
Signals:
Management of all signals to be used for measurement.
Statistic:
Configuration of general statistics calculations from any available result.
TDC:
In the "TDC" the settings and the actual implementation of the determination of top dead
center (TDC) have to be done.
Data Display:
In the data display is defined which of the measured signals and the associated
calculations are displayed.
Data output:
At this point it is determined which of the displayed signals with associated calculations to
be stored. It will also give further details about folder and file extension of the data.
Parameter Check
Settings and parameters are subjected to a plausibility check. In order to be found
missing, incorrect or implausible configurations and corrected with the necessary assistance.
The easy entry text gives first information on this dialog and simplifies
the structured work.
Formal description
averaged pressure
Polytropic exponent
A determination of this loss angle can be made by first carrying out a capacitive TDC-
determination. This determines the mechanical TDC. By a subsequent thermodynamic
TDC-determination with the unfired pressure curve and the indication of a
thermodynamic loss angle of 0 °CA you get the TDC-Offset as result. This Offset
defines the exact thermodynamic loss angle in this operating point.
9.4 Noise
Method: From the complete cycle of each cylinder pressure curve is calculated the
frequency spectrum by using a Fast Fourier Transformation to the base 2. Then the
resulting sound pressure level of Terz middle frequencies will be totaled. Depending
on the result of the frequency band is first assessed by means of a transfer function
(addition, because of logarithmic).
Table of Terz middle and cutoff frequencies:
9.5 Knocking
The combustion analysis system uses the Siemens-VDO algorithm for calculation of
knocking values.
The advantage of this algorithm is that knocking can be detected within a combustion
cycle. It requires no information from previous cycles.
Approach of the Siemens VDO algorithm:
1. Finding the maximum cylinder pressure:
If you already have a calculation of the maximum cylinder pressure which is inserted
into the administration, this result is used. Otherwise, the calculation is performed
internally with default settings.
2. Smoothing of the cylinder pressure signal using the input value for the sliding
averaging.
3. Calculation of the high pass filtered signal by subtraction of the raw signal of
cylinder pressure and the smoothed signal.
4. Rectification of the high-pass filtered signal
5. Selection of reference window and knock window depending on settings.
Reference window: Range of input value "before maximum pressure" to value
"Maximum Pressure + Offset"
Knock window: Range of value "maximum pressure+ offset " to value "after
maximum pressure
6. Calculating the knock ratio: Ratio of integral within the range of knock window to
the integral within the range of reference window (knock integral / reference
integral).
A summation of 1.5 for each ratio prevents a divide by zero.
Digital Inputs
Digital outputs
The 8 digital outputs are available once as 5V logic signals and once as electrically
isolated PhotoMOS Relay outputs.
DOx_TTL DOxa/b
The two DOxa/b outputs are symmetrical and interchangeable. The outputs are
passive and can therefore be connected flexibly:
The outputs are overcurrent (e.g. short-circuit) protected. If the protective circuit was
active, the corresponding output hast to be deactivated before it can be activated
again.
The following example shows the entire configuration of the injection timing
calculation for a four-cylinder engine. Only the two current probe inputs should be
used here. This is only possible if each current probe input contains the injection
information for two signals, i.e., a multiplexed signal. A current probe therefore
encompasses the control lines for the injectors for two cylinders, which ideally have
the largest possible angular ignition spacing.
Example engine:
4-cylinder diesel
Firing order: 1 – 3 – 4 – 2
Angular ignition spacing: 180 °CA
CurrentProbe 1 is connected to CurrentClamp input 1.
The signal includes injection Cyl 1 and Cyl 4.
CurrentProbe 2 is connected to CurrentClamp input 2.
The signal includes injection Cyl 2 and Cyl 3.
The angular ignition spacing between the two injection processes is 360 °CA in a
physical signal. When dividing into virtual channels, every virtual channel then has 720
°CA/2 = 360 °CA available (entire combustion cycle/number of cylinders included in
the physical signal). The range available for a virtual channel should always be larger
than/equal to the angular ignition spacing of both cylinders included in the physical
signal for the intended measurement. In addition, the signal associated with one of the
two cylinders must remain within the virtual range at all times during the
measurement. Otherwise, the system cannot always assign the injections to the
respective cylinder reliably.
Example: The maximum injection duration (or the difference between the start of the
first injection and the end of the last injection) in the operating range to be measured
for the engine is 200 °CA. A summary of all of the cylinders in a current probe is
therefore not possible as the virtual channels only include 180 °CA (720/4). The four
cylinders must therefore be divided into 2 physical signals!
5. Signals: Add the relevant virtual signal to each of the four cylinders. When selecting
the channel, the correct virtual channel can now be assigned to the corresponding
cylinder very easily using the defined name. Cylinder 1 = INJZ1, Cylinder 2 = INJZ2,
Cylinder 3 = INJZ3, Cylinder 4 = INJZ4
Work with User Formulas is explained in the following chapter using a number of
examples. In the first subchapter 9.8.1, a simple example is presented for a number of
functions that were explained in chapter "Formula syntax" (chapter 4.3.3.1). This is
intended to detail the use of the individual functions.
Calculation functions:
The left side of Figure 126 shows the implementation of the calculation functions. In
the calculation window, it can be seen at the left that names of the output variables are
described with their indices. These names must match the names defined under
"Output Name" (e.g., root). Because the used output variables are scalars (vectors of
size 1), the index is always 1.
At the right in the calculation window, the actual function can be seen. For example,
sqrt(4) returns the square root of 4. All of the functions are ended with a semicolon.
The "Default Signal Name" in the "Formula Output" area can be freely configured. The
result / signal then appears with this defined name in the measurement (see Figure
126, right). In the case of the square root of 4, the signal name was defined as "Root"
and is equal to 2.
Figure 126: Implementation of the calculation functions (left) and the corresponding result in
measurement operation (right)
In the above example, the assignment of the User Formula was not
explicitly declared under Signals. This is, however, mandatory in order
to depict the User Formula signals in the measurement environment.
For the complete implementation of a User Formula, see chapter 9.8.2.
Control structures:
Figure 127 shows a corresponding example for the control structures. Two "Formula
Inputs" were defined with the names "IN_PCYL" and "IN_PMAX". At a later point in time,
these input variables will be assigned the cylinder pressure curve (PCYL) or rather the
maximum cylinder pressure (PMAX) in the "Signals" tab. Thus, if "IN_PCYL" or
"IN_PMAX" is used in the programming, input signal PCYL or input result PMAX is used
in this example.
The first example shows a For Loop that adds each value of the cylinder pressure
signal from index 1 to the last index of the signal (x.Length) with the "plus" variable.
The “plus” variable was defined under "Formula Variables" with the value 10*10^5.
Thus, the cylinder pressure curve is increased by 10 bar (10*10^5 pascal). This
calculated signal is output in the measurement environment (Figure 127) in the
progression chart as a red curve.
In the second example "If / else / end", PMAX is used as the input signal. If PMAX is
equal to or less than 85 bar, output variable DIG_ should have the value 1, otherwise 0.
For a PMAX of 94.7 bar in measurement operation (Figure 127, right), the value 0 is
therefore output. The "If / elseif / end" example behaves in a similar way; no further
explanation is therefore provided.
In the bottom example, the use of a switch / case condition is shown. In this example,
a query is performed to determine the case of the calculated variable "DIG_switch" (this
is defined in the example above). With a PMAX of 94.7 bar, case 2 thus occurs. In this
switch / case example, output variable "DIG_switch2" should receive the value 4 for
case 2. This can also be seen in the measurement environment (see Figure 127, right).
Figure 127: Implementation of the control functions (left) and the corresponding result in
measurement operation (right)
The names of the input variables do not need to include the names of
the signals assigned under "Signals". Thus, the name in the example
above does not need to be IN_PCYL or IN_PMAX. This serves the
purpose of clarity only. Also conceivable would be "In1" and "In2" as
well as any other name.
Function:
The functions are shown in an example in Figure 128. Under "angle based functions", it
can be seen that the TimeSampleNumber is output at 90°CA after TDC and at TDC.
With the help of the sampling rate (TimeSamplingRate), the time in seconds that
elapses between these two points is calculated.
Furthermore, with the help of the "vol()" volume function and a FOR loop, the cylinder
volume can be displayed as a signal on the progression chart (red curve).
Figure 128: Implementation of the functions (left) and the corresponding result (right)
Constants:
The use of the constants described in chapter 4.3.3.1 can be seen in Figure 129.
Figure 129: Implementation of the constants (left) and the corresponding result (right)
Figure 130: Division of the ignition signal into four virtual channels
In Figure 131, the ignition signal (universal signal - Analog In 3A) over the crank
angles of the four cylinders can be seen. With the help of the User Formula, the
ignition time (falling flank) should now be depicted in the progression chart as a
marking and as a scalar value in the table.
Figure 131: Figure of the ignition signal [V] and pressure signal [bar] over the crank angles
Section 1: The first section of the User Formula is used to search for the falling flank of
the ignition signal. For this purpose, all indices of the input signal are checked for the
IF condition. For this test, the "Leveltobecrossed" variable was defined with size 1 and
value 2.5. The condition is met as soon as the input signal exceeds the value 2.5 and
drops below the value of 2.5 in the next index. This is the index being search for,
which is written as the value in variable IGN_index. Because the input signal is a
multiplexed signal with the resolution 0.1 °CA, which begins at -90°CA and not at -
360°CA as is typical, the missing 2700 ("indices") is added to variable IGN_index. The
value of this variable now corresponds to the index of the falling flank, as if the input
signal was not multiplexed. This leads to easier use and, as a result, can avoid errors.
(Another method is likewise conceivable)
Section 2: The scalar output value (ignition time) is calculated in section 2. Considering
that, with a resolution of 0.1°CA, the signals contain 7200 indices but a combustion
cycle consists of only 720°CA, the indices are multiplied by 0.1. Because the indices
begin with 1 but the combustion cycle begins with -360°CA, 360 must first be
subtracted from variable "IGN_index". Output variable "Out1" now corresponds to the
ignition angle. Because the User Formula calculates with SI units, it is imperative that
the value be converted to rad (even if it is to be output later in crank angles!).
The user formula is now validated and can then be added to the cylinders on the
"Signals" tab by right-clicking on the choosen cylinder and selecting "Add Formula"
(Figure 133). Use drag & drop in the main window to assign the input signal. In this
example case, the multiplexed universal signal. A unit can now be assigned for both
output variables. The vectorial output variable is still to be provided with a range and a
resolution. For the example calculation, this must be set as in Figure 133.
Figure 133: Inserting the User Formula and adding the input signal
The "AIGN_Formula" and "Ignition" variables can now be used in the same way as a
result or a vector in the diagrams and data output. The calculated ignition time is
shown in a table in Figure 134. The second output variable calculated in the User
Formula, "Ignition", can also be seen in lower part of the display detail. This is depicted
as a curve and marks the ignition time in the progression chart.
Figure 134: Measurement with the ignition time calculated in the User Formula
List of Illustrations
Index
Add CAN-DB ............................................................................................................................... 150
Administration ........................................................................................................................ 34, 62
Administration - Calculations ....................................................................................................... 44
Administration - Signal Types ....................................................................................................... 35
Alternative Volume Function ......................................................................................................... 76
Appendix: ................................................................................................................................... 167
Application Areas Of KiBox.............................................................................................................. 5
Application Systems .................................................................................................................... 139
capture triggered by INCA: .......................................................................................................... 147
CDM and Trigger ........................................................................................................................... 44
Channels: Data File, CAN Output, Limit Monitoring ..................................................................... 108
Configuration ........................................................................................................................ 26, 140
Crank angle ................................................................................................................................... 41
Crank Angle Adapter Type 2619 Function ..................................................................................... 16
Cursor functions: ........................................................................................................................ 132
Cycle Number ................................................................................................................................ 44
Cylinder Pressure .......................................................................................................................... 35
Data File ...................................................................................................................................... 120
Data Output ................................................................................................................................ 108
Delivery, Accessories And Spare Parts ............................................................................................. 8
Diagrams............................................................................................................................. 103, 128
Dialogue Field ............................................................................................................................. 178
Digital Signal ................................................................................................................................. 36
Digital State and Position .............................................................................................................. 45
Disposal Instructions ....................................................................................................................... 8
Eccentric Angle.............................................................................................................................. 36
Energy Management ...................................................................................................................... 27
Engine ........................................................................................................................................... 74
ETAS INCA ................................................................................................................................... 140
Ethernet Settings On The Notebook Operating System And In The KiBoxCockpit .......................... 27
Evaluation ................................................................................................................................... 128
EventHandler ................................................................................................................................. 26
Events ......................................................................................................................................... 118
Exhaust pressure ........................................................................................................................... 37
FAQs ........................................................................................................................................... 166
File Formats ................................................................................................................................ 136
First Connection ............................................................................................................................ 28
For Your Safety ................................................................................................................................ 6
Hardware....................................................................................................................................... 12
Saving, Exporting, and Converting The Measurement Data ................................................. 132, 137
Shortcuts ....................................................................................................................................... 31
Signal: Crank Angle ....................................................................................................................... 93
Signal: Cylinder Pressure ............................................................................................................... 79
Signal: Digital, Injection digital signal/Ignition digital signal ......................................................... 83
Signal: Eccentric Angle .................................................................................................................. 84
Signal: Injection Pressure .............................................................................................................. 85
Signal: Injection/Ignition Pulse ...................................................................................................... 89
Signal: Intake Pressure/ Exhaust Pressure ..................................................................................... 90
Signal: Torque ............................................................................................................................... 91
Signal: Universal ............................................................................................................................ 92
Signals .......................................................................................................................................... 78
Software Installation And Configuration ................................................................................ 23, 140
Software Updates ........................................................................................................................ 165
Speaker ......................................................................................................................................... 28
Speed ............................................................................................................................................ 60
standalone mode......................................................................................................................... 110
Stand-alone operation ................................................................................................................ 152
Statistical Calculations .................................................................................................................. 96
Status Bar .................................................................................................................................... 178
Storing Data ........................................................................................................................ 126, 133
Symbolbar ................................................................................................................................... 173
System Overview ........................................................................................................................... 11
System Requirements .................................................................................................................... 19
TDC: Determine The Position Of Top Dead Center ........................................................................ 96
Test Bed ...................................................................................................................................... 117
Test Bench Automation Systems .................................................................................................. 152
Thermodynamic Loss Angle .......................................................................................... 96, 101, 180
Thermodynamic Zero Point Correction ........................................................................................ 179
Tips for Using the Manual ............................................................................................................... 6
Torque .......................................................................................................................................... 40
Transport and Storage..................................................................................................................... 8
Troubleshooting .................................................................................................................... 12, 166
Universal ....................................................................................................................................... 41
User Interface Design .................................................................................................................... 29
User Interface Design In Detail .................................................................................................... 167
Visualization Of Measurement Data With KiBoxCockpit ............................................................... 128
Zero point correction .................................................................................................................... 60