Drivven Combustion Analysis Toolkit The Drivven Combustion Analysis Toolkit (DCAT) is a unique LabVIEW plug-in for creating sophisticated in-cylinder combustion analysis and logging applications for engine research and development. The included examples can be used out-of-the-box for building stand-alone systems, or modified and integrated with engine control applications. Using DCAT, engineers can streamline engine R&D by using built-in functions for NextCycle and Same-Cycle Control. DCAT leverages the latest hardware from Drivven and National Instruments for engine position tracking and synchronization of data collection and processing. DCAT is also packaged in a fixed-executable, called µDCAT, and paired with USB-based DAQ devices for portable, low-cost combustion analysis, starting at $8,995. • • • • • • • • • •

DCAT Features

Supports NI R-Series, S-Series, M-Series and CompactDAQ Simultaneous engine-synchronous and time-based data acquisition Concurrent data monitoring and streaming to disk Many channel configuration, calibration and filtering options Common pegging and cylinder data alignment options Multiple pressure metrics and heat release calculation techniques Engine noise and knock analysis Engine sync from encoders or production engine trigger wheels Built in functions for Next-Cycle and Same-Cycle Control Insert custom analysis blocks for unique test and control applications

DCAT PXI System with Engine Control and SCXI DAQ

Inside

Screen Shots Data Flow Next-Cycle Control Example Systems Detailed Features Selection Guide Price List

2 3 3 4-5 6-7 6 8 The Portable Low-Cost µDCAT cDAQ4

Highly configurable geometry options to accommodate nonconventional engines

Real-time display of cylinder pressure and heat-release while streaming raw and reduced data to disk

Multiple methods for heat-release calculation with or without heat-transfer

Engine knock analysis tools for quick determination of filter coefficients

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DCAT Data Flow The data flow path of the DCAT software is shown below. Data is collected at different rates through PXI S-series cards, M-series cards or cRIO modules, and then passed to the real-time controller. This raw data can be consumed by three simultaneous processes. First, when requested by the operator, the real-time controller can stream all raw data to disk for later post-processing on a PC. Second, the data can be processed continuously for filtering, cylinder alignment, pressure metrics, heat release, statistical analysis and other reductions to be visualized on the host PC and stored to disk in a summary file for further post-processing. Third, critical data can be selected from the DAQ stream for use in Next-Cycle Control. DCAT stores data and all configuration parameters in an open and efficient LabVIEW binary file format called TDMS. These files may be transferred from the realtime controller to a host PC and analyzed using post-processing utilities included with DCAT. The TDMS files may be opened within custom LabVIEW applications or Excel to generate reports.

Next-Cycle and Same-Cycle Control Feedback control is made available in DCAT as Next-Cycle or Same-Cycle Control. Next-Cycle Control is processed in the PXI RT controller, whereas Same-Cycle Control is processed within the FPGA. Common uses of Next-Cycle Control are online feedback to stabilize engine conditions, or as a calibration aid to quickly move between set points. For example, 50% burn location can be controlled by modifying start-of-injection timing. Same-Cycle Control calculates incremental sub-crank-angle-degree heat-release in the FPGA. This information is available for making control decisions within nanoseconds. Examples of Same-Cycle Control are manipulating inter-pulse delay for diesel injections, and misfire detection and spark restrike for SI applications.

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µDCAT USB-6251 Base System With 1 MS/s aggregate throughput, the µDCAT USB-6251 is ideal for low channel count, high sample rate systems

Cost: $8,995

µDCAT cDAQ4 Base System The µDCAT cDAQ4 provides 100 KS/s/ch simultaneous sampling for eight channels with room to customize

Base Cost: $8,995

µDCAT cDAQ8 Custom System

With five spare slots, the µDCAT cDAQ8 not only supports simultaneoussampling combustion analysis, but also knockcalibration and a wide variety of medium-speed I/O

Base Cost: $9,395 Cost As Shown: $13,070

DCAT Base System

NI’s PXI RT Controllers, S-series simultaneous sampling, and FPGA reconfigurable I/O cards form a solid foundation for a high-speed combustion analysis system Drivven Hardware Drivven Software NI Hardware NI Software Total *Typical Turn Key

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$0 $14,995 $11,629 $7,797 $34,421 $45,000

DCAT System with SCXI DAQ The addition of SCXI lowspeed DAQ, a second SSeries card for time-based sampling and cRIO modules for specialty I/O make a more complete integrated test cell DAQ system Drivven Hardware Drivven Software NI Hardware NI Software Total *Typical Turn Key

$6,985 $14,995 $21,501 $7,797 $51,278 $80,000

The addition of Drivven automotive I/O modules turn the DCAT base system into a full authority engine controller capable of NextCycle Control

Drivven Hardware Drivven Software NI Hardware NI Software Total *Typical Turn Key

$13,965 $16,490 $16,094 $7,797 $54,346 $90,000

Our most popular system combines all features of full authority control and test cell DAQ into a complete package

Drivven Hardware Drivven Software NI Hardware NI Software Total *Typical Turn Key

DCAT System with Engine Control

DCAT System with Engine Control and SCXI DAQ

$20,945 $16,490 $27,283 $7,797 $72,515 $120,000

* Turn-key systems include cabinetry, wiring harness, application development, and on-site support where applicable

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DCAT Features Measurement Configuration and Engine Geometry • Supports multiple S-Series cards for simultaneous sampling of signals in both angle (cylinder pressure, MAP, etc.) and windowed time (knock, ionization, etc.) domains • Individual channel calibration features • Channels can be assigned to cylinder groups, supporting dual-MAP, multiple knock sensors, etc. • Complete set of engine geometry parameters for volume versus CAD calculation • Geometries of unique engines can be loaded directly via spreadsheet and defined on a per-cylinder basis • Online motoring test assists with engine geometry verification Engine Position Tracking and Sample Clock Generation • Use traditional optical encoders with advanced sync and sampling options via R-Series FPGA card o Online adjustment of TDC index o Optionally use pressure signal for 4-stroke phase information o Extrapolate low-resolution encoder to higher resolution sampling • Optionally use Drivven Engine Position Tracking (EPT) blocks to sync with production N-M or N+1 crank trigger patterns and sample data at high resolution Medium/Low Speed Time-Based DAQ • Supports additional DAQmx devices (M-Series, SCXI) • Supports data sources from R-Series FPGA cards • Simultaneously recorded with engine-synchronous data • Aligned with engine cycles (raw or averaged) • Temperatures, pressures, switches, etc Pre-Processing • Individual channel data alignment to selected cylinder • Data scaling to engineering units • Broad range of signal filtering options • Multiple pressure pegging and data windowing options Pressure Metrics • Peak pressure and location • Polytropic coefficients of compression and expansion • Maximum rate of pressure rise and location • Pressures at IVO and EVC • Gross MEP (IMEP), Pumping MEP (PMEP), Net MEP (NMEP)

DCAT System Selection Guide

µDCAT USB-6251

µDCAT cDAQ4

µDCAT cDAQ8

Portable Low Cost Combustion Analysis

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Portable + Time-Based DAQ + 1 I/O Module Portable + Time-Based DAQ + 5 I/O Modules Greater than 100 KS/s/ch Sampling

DCAT PXI

DCAT PXI + SCXI DAQ

DCAT PXI + Control

DCAT PXI + SCXI DAQ + Control

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500 KS/s/ch Simultaneous Sampling DAQ High Channel Count Medium-Speed DAQ

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Knock Calibration

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Integrated Next-Cycle or Same-Cycle Control LabVIEW Development Tools Not Required

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Upgradeable to Full DCAT (+ $8,000)

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Customized Combustion Analysis

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DCAT Features Heat Release Analysis • Heat release methods include o Single zone o Modified Rassweiler and Withrow o Pressure ratio o Supports dual transducers per cylinder for pre-chamber engines • Locations of Mass Fraction Burned (5%MFB, 25%MFB, 50%MFB, 75%MFB, 90%MFB, Custom) • Maximum heat release rate and location • Variety of heat transfer correction methods • In-cylinder temperature estimation Engine Knock and Noise Analysis • Bandpass / Rectify / Integrate / Compare (BRIC) algorithm for knock signal processing • Offline FFT analysis of knock signals for calibration of BRIC • Raw, time-domain-filtered and angle-domain-filtered combustion noise indication Data Saving and Post Processing • Selectively or continuously stream raw data to disk by cycle count, time, or file size • Data stored to National Instruments open binary TDMS file format • Channel configuration and geometry stored to allow reconstruction of test environment in post processing • Cycle-by-cycle summaries can be streamed to disk simultaneously with raw data • Data can be post-processed with Drivven utilities, opened in Excel, or analyzed further with LabVIEW Next-Cycle Control • DCAT example includes data processing of selected parameters in time for Next-Cycle Control algorithms • Uses watchdog to ensure computations are completed in time for Next Cycle Control • Applications include: o Diesel engine control (PID control of 50%MFB using start of injection) o SI engine control (PID control of peak pressure location using ignition timing)

Same-Cycle Control •

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Real-time FPGA-calculated heat-release for multiple cylinders Applications include: o Manipulate direct injection pulse spacing based on real-time heat-release o Compensate for misfires with additional fuel pulses or high-energy ignition

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Price List of Hardware and Software Products Shown

Related Drivven Products and Services

Item µDCAT USB-6251

Description µDCAT USB-6251 Base System

Price $8,995

Item Spark Driver

µDCAT cDAQ4

µDCAT cDAQ4 Base System

$8,995

ESTTL

µDCAT cDAQ8

µDCAT cDAQ8 Base System

$9,395

Diff IO

ADCombo

Analog and Digital Combination C-Series Module Kit

$1,495

Desktop PC Desktop PC (Mon) Service Service Service Service

O2 Sensor

2-Ch UEGO Sensor C-Series Module Kit

$1,495

NOx Sensor DI Driver PFI Driver Throttle Driver Lowside Driver

1-Ch NOx Sensor C-Series Module Kit 3-Ch Direct Injector Driver C-Series Module Kit 4-Ch Port Fuel Injector Driver C-Series Module Kit 2-Ch Electronic Throttle Driver C-Series Module Kit 8-Ch Lowside Driver C-Series Module Kit

$3,995 $1,995 $1,995 $1,495 $1,495 $1,495

Service

$450

Service

$2,000

Service

VR/Hall

6-Ch VR/Hall Sensor C-Series Module Kit

Throttle Body

Bosch DV-E5 Electronic Throttle Body 32-68mm

NOx Sensor

Continental UniNOx Sensor

UEGO Sensor

Bosch LSU-4.2 Universal Exhaust Gas Oxygen Sensor, Cable, Bung Kit

DCAT µDCAT Software

Drivven Combustion Analysis Toolkit µDCAT Software Only

$14,995 $6,995

DCAT Deployment

DCAT Deployment License Engine Position Tracking VI for LabVIEW FPGA (Encoder, N-M, N+1 Patterns) CalVIEW Calibration and Display Toolkit for LabVIEW 4-Slot PXI Chassis, Power Cord 8-Slot PXI Chassis with 4-Slot SCXI, Power Cord Core 2 Duo 2.53GHz RT Controller 2GB DDR2 RAM for PXI-8108 1M Gate R-Series FPGA Card 3M Gate R-Series FPGA Card 8-Ch 500 KS/s/ch S-Series Card 8-Ch 1 MS/s M-Series Card (for PXI-1050) 32-Ch Thermocouple Input Module 32-Ch Voltage Input Module 32-Ch Terminal Block BNC Breakout for S-Series R-Series Expansion Chassis 6-Ch Digital Input C-Series Module 4-Ch +/-10V, 100 KS/s/ch,16-Bit, Simultaneous Analog Input C-Series Module 4-Ch +/-10V, 100 KS/s/ch, 16-Bit, Simultaneous Analog Output C-Series Module 32-Ch +/-10V, 250 KS/s, 16-Bit Analog Input CSeries Module 16-Ch Thermocouple Input C-Series Module 4-Ch 24-Bit Universal Analog Input C-Series Module S-Series Cable (2m) R-Series Cable (2m) LabVIEW Full Development System LabVIEW Real-Time Module LabVIEW FPGA Module LabVIEW Developers Suite with LabVIEW RT and LabVIEW FPGA Modules

$4,995

EPT VI CalVIEW PXI-1031 PXI-1050 PXI-8108RT RAM PXI-7811R PXI-7813R PXI-6123 PXI-6251 SCXI-1102 SCXI-1102B SCXI-1303 BNC-2110 NI-9151 NI-9411 NI-9215 NI-9263 NI-9205 NI-9213 NI-9219 SH68-68-EP SH68-C68-S LabVIEW Full LabVIEW RT LabVIEW FPGA LabVIEW Dev Suite

$250

Discount

$379 $799 $999 $999 $119 $99 $2,599 $2,599 $2,599

$3,995 $2,000 $3,000 $120 $8K-$25K $5,000 $8,000 $4,700 $5,000 $1,000 20% 10%

DCAT Licensing Each purchased seat of DCAT software is licensed according to the computer ID of the PXI RT controller. µDCAT Licensing µDCAT is a fixed executable derived from DCAT and is licensed according to the serial number of the DAQ device. Mass Deployment Licensing Customers may create customized DCAT applications or integrate DCAT into existing products and deploy to multiple systems for a license fee of $4,995 each. A full DCAT development license must be purchased first. The mass deployment systems are licensed according to PXI RT controller ID (DCAT) or DAQ device serial number (µDCAT). Mass deployment systems are supported by the system developer. DCAT and µDCAT Support and Maintenance For each development seat of DCAT and each µDCAT system Drivven provides one year of technical support and software maintenance to one named contact. An additional year of software support and maintenance is available for 20% of the original purchase price. All software licenses are perpetual. Software upgrades and support are provided with a current maintenance agreement.

$9,297

Contact Drivven Drivven, Inc • 12001 Network Blvd, Bldg E, Ste 110 • San Antonio, Texas 78249 • USA Phone : +1 210.248.9308 Web : www.drivven.com • E-mail : [email protected]

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$1,495

Prices set for immediate to NET30 payment terms. Prices are increased by 1.5% per month for longer terms.

$995

$499

Academic Discount

Price $1,495

Prices subject to change without notice

$1,495

$1,008 $2,908 $4,999 $249 $1,599 $2,499 $2,649 $1,199 $1,499 $1,499 $329 $349 $349 $209

Description 8-Ch Inductive Spark Driver C-Series Module Kit 8-Ch Engine Synchronous TTL Output C-Series Module Kit 8-Ch Differential Digital I/O C-Series Module Kit Desktop PC with LabVIEW and Drivven Tools Installed (no monitors) Desktop PC with LabVIEW and Drivven Tools Installed (dual monitors) Custom Application Development (Hourly Rate) Turn-Key System Cabinet Build (Price Range) Turn-Key Harness Design and Build (Starting Price) 1-Week On-Site Support (Domestic Travel Included) 2-Day On-Site Support (Domestic Travel Included) Premium Support Plan: 1 Year, Unlimited, 2 named Contacts Essential Support Plan: 10 incidents / 10 hours 1-Year Continued Software Maintenance for DCAT, µDCAT and CalVIEW