To develop a Test Bench for complete functionality testing of the Common Rail Diesel Injection (CRDI) system.

• Detect whether the piston inside the cylinder has reached the Top Dead Center or not.
• Capture data from various sensors mounted at different positions of the CRDI system at very high speed. The entire test duration is of 3 seconds.

Using the National Instruments PXI Platform, NI DAQmx and LabVIEW Development System and other third party hardware create a highly flexible, scalable and powerful test system

Our client is a leading R&D organization in the automotive field. Before integrating with the vehicle, the Common Rail Diesel Injection System should be subjected to rigorous testing. When the piston inside the cylinder of a vehicle reaches the Top Dead Center (TDC), fuel has to be injected at a very high pressure inside the cylinder. The PXI Based Data acquisition system is used to acquire signals like High Pressure, Low Pressure, High Temperature, Low Temperature and Flow data from sensors located at various locations around the Common Rail System.

A voltage pulse of 30Volts is generated when the piston reaches the Top dead Center inside a vehicle cylinder. This high voltage pulse is converted into a digital signal using a zero crossing detector. The output of zero crossing detector is a TTL level signal. This signal is used as a trigger for the acquisition process.

Software implementation can be divided into the below mentioned two modules:

• Real Time Acquisition and Online Data Processing
• Offline Data Analysis

Real Time Acquisition and Online Data Processing:

The acquisition was triggered by the occurrence of the TDC pulse.

Online Acquisition and processing had the following features.

• Online display of pre-trigger samples.
• Online display of data with respect to time.
• Online FFT.
• Burst Averaging

This is the Utility provided in the software for user, to do the different analysis like Calculate Slope, Calculate Settling time and Statistical Calculations for already completed Test.

With the PXI platform we were able to put up an extremely reliable and highly precise measurement system. Thus we were able to integrate the measurement system and Data Analysis system to one platform rather than having a separate high speed Data Acquisition system and Data processing System.