Proc.

XXV International Scientific Conference Electronics - ET2016, September 12 - 14, 2016, Sozopol, Bulgaria

Development of a Specific Electronic Control

System for an Engine Dynamometer
Basri Kul, Yahya Ulusoy, Rıdvan Arslan
Department of Electronics, Agricultural Machinery, Automotive, Vocational School of Technical Sciences,
Uludağ University of Bursa
Nilufer,16059, Bursa, Turkey
{basri, yahyau, ridvan}@uludag.edu.tr

Abstract – With the numerous and complex parameter
interactions that take place during the operation of an engine,
the optimization of its performance in terms of alternative
fuels is difficult, as dynamometers with conventional
technology are unable to make significant measurements for
alternative fuels. In this study, an electronically controlled
dynamometer system capable of measuring a number of
specific values was developed. The system allows the optimum
values for different fuels to be found for the test engine by
monitoring parameters such as injection advance, and at the
same time communicating with the electronic control unit via
a computer interface. The study presents the algorithm and
test results of the system.
Keywords – Dynamometer, electronic control, eddy current
brake, engine test bed, biogas
1. INTRODUCTION
The expanding use of alternative fuels in gasoline or
diesel motor vehicles will be realized in a major way in the
near future. However, performance optimization in terms
of alternative fuels is not an easy matter when the engines
are operating with a numerous and complex interplay of
parameters. For this reason, instead of designing a new
electronic control system for these engines or developing
new software, a method for making changes in existing
software or commissioning additional systems was
adopted. Consequently, the creation of relevant electronic
control and measurement strategies dealing with the
optimization of the engine-fuel pair, along with the
literature on this topic, will be examined in the sections
below.
Erkuş and Sürmen [1] studied the structural changes
required in order to optimize operating conditions when
using natural gas in a gasoline engine. With this aim, they
developed electronic subsystems on their created test
system with an algorithm for the program performing
control of these subsystems. In another study, Arellano et
al. [2] presented a dynamometer-control design for systems
with stiff and flexible shafts. Its practical implementation
for position control of linear and nonlinear emulated loads
was conducted and the experimental results were compared
with corresponding simulated loads in order to validate the
emulation strategy. The comparisons showed a good
agreement between the experimental and the simulation,
978-1-5090-2883-2 /16/$31.00 ©2016 IEEE
which confirmed that the system had preserved the
dynamics of the desired load when used in a closed-loop
system. Yanakiev [3] stated that nonlinear, strongly
coupled engine dynamometer plants can be more
successfully controlled by applying multivariable
techniques rather than by using independent PID
controllers. The author also presented an application of the
model-referenced adaptive control approach to the engine
speed and torque control problem. Bunker et al. [4] stated
that the large degree of loop interactions, induction-to-
power delays, combustion uncertainties, and engine
nonlinearities were included in the difficulties in
controlling engine-dynamometer systems. The performance
goal was realized by balancing the bandwidths of the loop
transfer functions to avoid excessive loop interactions in
the closed-loop system. The controllers were designed
using a sequential frequency domain approach. In another
study, Çelik et al. [5] designed and manufactured a
computer-aided engine test stand. This stand enabled the
internal combustion engine to be tested with computer
control and allowed for experimental data to be transferred
to a computer in real time. Engine performance evaluations
could be easily carried out with engine tests performed
using the stand. Westmayer et al. [6], in their study,
proposed an approach for high dynamic torque control of
an industrial engine test bed. The main goal was to develop
a control concept that was capable of periodic reference
tracking at a high control bandwidth while at the same time
sufficiently rejecting disturbances coming from external
excitations. For that reason, a model predictive control was
utilized which offered major benefits compared to classical
controllers. Ergenç and Koca [7] developed a
programmable logic controller (PLC) control system aimed
at using dual-fuel in a mechanical injection system diesel
engine. Diesel fuel and LPG were used in the study and, in
order to determine the optimum injection advance, they
examined the effects of engine performance optimization
made via the engine management system. Erkuş et al. [8]
evaluated a four-stroke LPG-injected spark ignition (SI)
engine run by using a specially developed engine control
unit (ECU) to control the ignition timings. Ignition timing
values two and four degrees retarded and advanced were
applied in addition to the original values of the gasoline
engine. Results showed that the engine ran without any
problem with up to four degrees of the advanced ignition
timing values. However, the retarded values caused
improper combustion.

As a research project on biogas for use in engines, the

present study provides details of the dynamometer
apparatus developed to measure the engine parameters that
need to be controlled.

2. MATERIALS AND METHODS

2.1. System Design

The software was specially designed for measuring

specific engine running and loading parameters and real-
time rpm, injection mapping depending on knock control
and other operation parameters. The general structure of
the system and the software is shown in Figure 1.

Fig.2. Block diagram of the system

2.3. Eddy Current Control Unit

The AC eddy current control circuit was designed as a

single alternans. The eddy current circuit accomplished the
brake force by controlling the single alternans of the grid
voltage. A block diagram of the eddy current control unit
circuit is given in Figure 3.

Fig. 1. Layer structure of the system and software

2.2. Data Acquisition System (DAS) and Control Software

The system was designed to control and measure engine

operating parameters for all alternative fuels. However, in
this study, the system was used to detect the ECU
parameters of biogas and CO2 blended fuel usage.
Proportional and controlled experiments were conducted
for biogas and other gas mixtures and eight temperature
points. The system was operated to detect the confirmed
optimum engine performance variables according to their
sensor measurements together with the applied brake force
fuel-air ratio and gas controls. Under the system, in order to Fig.3. Block diagram of eddy current control unit circuit
test the obtained optimum values of the movement, the fuel
injection could be determined for different fuels or applied
to the ignition map. In order to obtain the correct mappings
for the different fuel options, knock control as well as
performance parameters of the system were taken into
account. The eddy current brake system, an important part
of dynamometer, was designed for the engine performance
and loads; the ECU performance was obtained with other
gas and fuel flow sensors. A block diagram of the system,
including the developed MS Windows-based software with
which all the measurements and controls were made, is
given in Figure 2.
Fig.4. Thyristor phase control
As shown in the block diagram, the load control unit is
controlled by a thyristor control unit. Furthermore, the Er.m.s
is controlled by a multipoint control unit (MCU) with one
microsecond resolution from zero crossing and is changed
as seen in Figure 4. The Ir.m.s and also Pr.m.s changes
depend on the Er.m.s. The PC software calculates the phase
control angle α and then sends it to the control unit. A flow
diagram of the main program controlling the system is
given in Figure 5. Installing the software allowed the
search for the knock-free operating point of the engine
while increasing the gas level times. As a result of all these
data under varying loads, the timing control system
infrastructure was then designed after the lowest knock
behavior and the lowest engine temperature had been
determined.

Fig.5. Software algorithm flowchart

3. EXPERIMENTAL STUDY
In this study, the performance tests were conducted on
a 4-cylinder 4-stroke direct injection 48 HP diesel engine
connected to a conversion kit to allow biogas (methane)
use. When the engine was under operation, the
developed electronic control system was mounted as
seen in Figure 6. The Schenck-215 kW dynamometer,
standard commercially available diesel, natural gas and,
as a regulator, CO2 were used for the study. A view of
the data collection software is presented in Figure 7.

Fig.6. Dynamometer and control system


Fig.7. Screenshot of data analyses
Using the diesel and the fuel blends given in Table 1,
the engine was started in idling mode, and then, with the
engine performing on the secondary fuel supply, it was
given full throttle and brought to the desired speed (2600
rpm) after which it was slowed with the braking system
until it dropped below 1000 rpm and the engine was
braked. At this stage the engine braking force, fuel
consumption, soot and temperature values were
measured.
Table 1. The fuel blends used in the tests
________________________________________
Fuel Fuel addition Name
Diesel fuel D2
Diesel + natural gas Level 1 F1
Diesel + natural gas Level 2 F2
Diesel + natural gas + CO2 Level 1 FC1
Diesel + natural gas + CO2 Level 2 FC2
_____________________________________________
As an example, the torque values in terms of the
diesel and the other biogas blends are presented in
Figure 8. The suitable rates and operating conditions and
all the obtained results in the biogas assessment in terms
of of both performance and environmental pollution
indicated that it could be used as an alternative fuel in
diesel engines.
Fig. 8. Torque values for diesel and fuel blends
4. CONCLUSION
The concrete outputs of the hardware of this study
were integrated with the software to develop a
performance testing system. In this way, a control
strategy could be established; whichever engine or
alternative fuel is used does not matter for enabling this
engine-fuel pair to achieve optimum performance.
Already, work is being conducted on another diesel
engine under the same system controlled by an ECU for
reading engine management parameters in order to
optimize these parameters for biodiesel use.
As a result, each passing year meets with new
vehicle users and fuels like gasoline and diesel in the
market, each more efficient in many ways, with the
proposed fuel being environmentally friendly and
enabling them to use it correctly. Thus, this study is a
step towards the development of original electronic fuel
control strategies and units. The development of the
system in different dual-fuel engine trials is continuing.
Studies on the system are expected to contribute to the
use of alternative fuels, especially for fully electronically
controlled engines.
ACKNOWLEDGMENT
This study is a result of Project No. 2013/88 and was
supported by the Uludag University Scientific Research
Foundation of Turkey.
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