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Combustion Analysis

High-accuracy combustion analyzer system for engine research, development and optimization and testing of ignition systems, exhaust systems, and valve control gear.

Strain / Stress
Strain / Stress
CAN bus
CAN bus
High-speed video
High-speed video
Thermal video
Thermal video

Main Features

  • FLEXIBLE ANALOG INPUTS: 8 analog inputs with sensor supply for any sensor and signal type - Charge, IEPE, Voltage, Strain, Torque, Temperature, ...
  • DIRECT RPM SENSOR CONNECTION: The system allows direct connection of any RPM sensor. E.g. InCar (e.g. 60-2), Encoder, CDM+Trg.
  • SYNCRONISED CAN ACQUISITION: 1 CAN 2.0b port is available for direct and synchronized high-speed CAN acquisition. The Dewesoft X software offers additional support for OBDII, J1939 and CAN DBC files for easy channel configuration. 
  • HIGH-SPEED: high-speed analog amplifiers with 16-bit ADC and 1 MS/second/channel sampling rate, ideal for combustion analysis on the high-speed engines.
  • HIGH-DYNAMIC: SIRIUS high dynamic, 160 dB amplifiers with dual 24-bit ADC and 200 kS/second/channel sampling rate, ideal for combustion analysis on low RPM diesel engines.
  • EXPANDABLE: The system can be easily expanded to hundreds of analog, counter and CAN channels at any time, without any additional software license costs.
  • TEST-BED AND INCA INTEGRATION: The system can send combustion analysis results to the testbed via AK-protocol or to ETAS INCA and similar systems via CAN. The testbed is supported additional plugin.
  • SYNCHRONIZED ACQUISITION OF MULTIPLE SOURCES: Additional synchronized acquisition of other sources is possible within the same system CAN, OBDII, J1939, FlexRay, XCP/CCP, Video, etc.
  • ADDITIONAL OPTIONS: The same system can be used to perform simultaneous online analysis of torsional and rotational vibration, order tracking, electrical power, combustion noise, sound power and more...

Application overview

Dewesoft provides a total solution for engine research, development, optimization and also for component development and testing, such as ignition systems, exhaust systems, and valve control gear.

High-end isolated SIRIUS DAQ hardware and the award-winning Dewesoft X software offer easy to use measurement and analysis. The system supports angle and time-based measurement and uses highly sophisticated algorithms for online or offline mathematics and statistics to calculate heat release and other thermodynamic parameters.

The combustion analyzer system can either be used in-car (via the INCA interface) or it can be fully integrated into a test-bed environment. Additional synchronized acquisition from other data sources like video, GPS, CAN, FlexRay, XCP/CCP, Ethernet, can easily be combined.

In addition to combustion analysis, the same system can be used to combine other measurement applications such as hybrid vehicle testing on the powertrain, noise, and vibration measurement, all with perfect synchronization.

In-car and testbed use

For testing under the real conditions, the combustion analyzer is perfectly suited for in-car testing applications. The combination of different supported interfaces like CAN,  XCP/CCP, FlexRay, any direct connection of any sensor allows acquisition of all relevant data together with the combustion cycle. The combination with INCA via CAN interface offers a complete solution for the ECU calibration.

On the engine testbed, a combustion analyzer is a standard tool to calculate and visualize relevant physical parameters from the combustion engine and to monitor and protect the unit under the test. Different communication protocols to the control room are supported via Ethernet or RS-232 interfaces - e.g. Tornado, AVL Puma Open, D2T. It is possible to export and import the complete transfer channel list. Channels not needed, can simply be disabled with a click of a button instead of having to remove them from the list. Multiple combustions analyzers can run in parallel and it is possible to select which one is the reference for the cycle count for the TestBed. Instead of storing and triggering based on cycles only, the time interval can be defined in seconds. This makes the testbed perfect for electric and hybrid motor testing or NVH applications.

The combustion analyzer system can be used on all types of combustion engines, such as car, truck, ship, motorcycle, power-saw, etc.

Engine R&D

The Dewesoft combustion analyzer can perform various tasks for engine research and development:

  • Misfire and knock detection
  • Friction analysis
  • Injection and ignition analysis
  • Valve control system timing
  • Combustion noise and vibrations
  • Mechanical stress diagnosis
  • Energy balance
  • Gas exchange analysis
  • Residual gas verification
  • The exhaust gas after treatment
  • Engine mapping

Intuitive configuration

The award-winning Dewesoft X software offers easy and very intuitive configuration process. Simply define the engine type with the number of cylinders and its geometrical parameters and you are ready to measure. 

The cylinder menu offers a selection of the analog channel for each cylinder and allows you to define the alignment of the cylinder angles. In the engine setup section, additional injection channels and channels for transforming any input channel to angle based measurement can be selected.

The last step is to select the angle sensor type and define the desired output resolution (down to 0.1°). The TDC (Top Dead Centre) can be detected automatically, without firing, using the maximum pressure level or optionally with a dedicated TDC sensor.

When the configuration is complete you can select your desired calculation outputs. Overall or running-average, derivation, temperature, heat release, work, power are just some of the available possibilities.


Heat release

The online heat release calculates the energy for each cycle and its related parameters. Another calculation is the exact angular progression (5, 10, 50 or 90%) of the energy. The SOC (start of combustion) and EOC (end of combustion) are calculated. All these values are based on the heat release algorithm. The software displays all these values as well as the relevant mean values like IMEPg, PMEP, and IMEPn. 

All the parameters can be visualized online in a graphical or in numerical view.

Knocking detection

Knocking on spark-ignition internal combustion engines occur when combustion of the air and fuel mixture do not start off correctly. The robust knocking detection algorithm is based on comparing the signal before and after the TDC.

Combustion noise

The combustion noise option allows the measurement of the noise level caused by an internal combustion engine during operation. The combustion noise must be calculated in the time domain.

First, the value is scaled from bar to Pascal. This is followed by the U-filter, which simulates the transfer function of the engine (1. and 2. filter in the overview).

Additional math and statistics

Additional mathematics channels can be defined based on the acquired or data:

  • math formulas, 
  • statistics,
  • filters (FIR, IIR, ...)
  • FFT's,
  • alarm conditions and
  • many others.

Calculated values may be used for optimization or other automated procedures. RAW data from sensors will always be stored and stayed intact. See Dewesoft X analysis for more information.

CA module features

The module has several features, which are thoroughly described in the CEA webinar.

  • Firing order – predefined from a drop-down menu or by custom input
  • Cylinder deactivation – from a CAN or AI channel
  • Zero level correction – separate correction mode for each cylinder (mixed sensor type)
  • Polytropic coefficient – dual polytropic coefficient, for compression and for expansion
  • Variable compression ratio – Switching between multiple volume curves based on a CAN or AI channel
  • High angle resolution – from 2° to 0.025° angle resolution with raw data also available in the time domain
  • Multiple combustion analyzers – an unlimited number can run in parallel
  • New outputs
    • Compression curve – theoretical compression curve plot
    • Polytropic coefficient – Calculation of polytropic coefficient and automatic input of the calculated polytropic coefficient (dual fuel engines)
    • Thermodynamics 2
  • Automatic channel color and scaling information transfer from analog inputs

Post processing

Since all the RAW data from the sensors is stored in the data file you can apply all the mathematics easily later in post-processing.This allows delaying CPU intense calculations until after the measurement has finished. 

The stored data can easily be export to a variety of formats compatible with today‘s most popular analysis software package like FlexPro®, MATLAB®, Excel®, AVL CONCERTOTM and many more. You can even export the whole measurement view to an AVI video file to create dynamic documentation or print a PDF report.

The data file can be viewed and analyzed on as many computers as needed without the need to purchase any additional software license form us. You can also distribute the data file outside of your company (e.g your customers) and anyone can view, reply and apply additional analysis. Simply let them download Dewesoft X software and open the shared data file.

Free Online Training

You can learn more about sound level measurement at Dewesoft PRO online training by navigating to the Combustion Analysis PRO training course.

Dewesoft PRO training is a free online training for measurement professionals. Learn how to measure signals, data processing and how to use Dewesoft products. Online PRO training is completely free.

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