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Engine Harness Tester Combines High Density Multiplexing, High Density Cable Connectors and High Performance Measurement Technology
 

 

1.  Full Authority Engine Control

To achieve this, modern automotive engines have many integrated sub-systems including:

bullet electronic throttle control
bullet electronic valve timing control
bullet fuel injection control
bullet electronic ignition timing control
bullet electronic inlet manifold configuration
bullet anti-knock

An Engine Control Module processes the signals from sensors and produces the required actuator signals for the optimum operation of the engine under the prevailing conditions and demands.

 

2.    Sensors and Actors

Achieving this level of control requires sensors and actuators that are providing and receiving signals representing many aspects of the engine's environment and operational settings including:

bullet accelerator pedal position (driver demand)
bullet engine temperature (water jacket)
bullet oil temperature/pressure/condition
bullet engine speed
bullet crankshaft position
bullet atmospheric & inlet manifold pressure and temperature
bullet inlet airflow
bullet exhaust gas (O2)
bullet knock sensing
bullet throttle positioning
bullet inlet manifold geometry variation
bullet fuel injector regulation
bullet relative cam shaft angles
bullet ignition sequencing/timing

Engine electrical harnesses with their sensors and actuators require 100% testing on the assembly line, leading to a requirement to manage the testing of a large range of sensor technologies and associated electrical connections.

Niksar Australia was commissioned to design, install and commission a comprehensive engine harness tester that manages the connections, configuration and testing of modern engine electronics.

3.   Niksar's Solution

The Niksar solution is based on the use of National Instruments' PXI chassis with interface modules and an industrial computer (PCI bus) for the measurement control, data processing and storage.

A view of the instrument at the heart of the tester - a National Instruments' PXI bus rack with interface peripherals inserted.

The high density multiplexers provide the rapid measurement configuration (topology) changes required to achieve a high measurement count in a short time.

Self-checking of the measurement instrument's connection system (cables and connectors) is carried out during the engine test cycle to ensure the the integrity of the tests.

 

NI 2008 Automotive Solutions Seminar presentation

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Last modified: 03-Sep-2010