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Overview of Engine Management Systems

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The document discusses engine management systems (EMS) and provides two case studies. It describes the basic components and functioning of an EMS, including sensors that measure engine speed…

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  • Introduction
  • Working Principle of Four Stroke IC Engine
  • Working of EMS
  • Elements of an EMS
  • Block Diagram of EMS
  • Case Study I: Typical EMS of Bosch Motronic System
  • Case Study II: Typical EMS of Bosch Common Rail Diesel Injection System
  • Summary
  • References

CASE STUDIES OF MECHATRONIC SYSTEMS

“ENGINE MANAGEMENT SYSTEM”

1
EMS-S.V. Saravanan, SREC, Coimbatore

CONTENTS

INTRODUCTION
WORKING PRINCIPLE OF FOUR STROKE IC ENGINE
ELEMENTS OF AN EMS
BLOCK DIAGRAM OF EMS
WORKING OF EMS
CASE STUDY I: TYPICAL EMS OF BOSCH MOTRONIC
SYSTEM
CASE STUDY II: TYPICAL EMS OF BOSCH COMMON RAIL
DIESEL INJECTION SYSTEM
REFERENCES
2
EMS-S.V. Saravanan, SREC, Coimbatore

WORKING PRINCIPLE OF FOUR


STROKE IC ENGINE

3
EMS-S.V. Saravanan, SREC, Coimbatore

ENGINE MANAGEMENT SYSTEM [EMS]

WORKING OF EMS
 The engine management system of a car is
responsible for managing the ignition and fuelling
requirements of the engine.
 The modern car is likely to include many
electronic control systems involving
microcontrollers, the engine control system being
one.
 The figure shows a generalized block diagram of
such a system, its aim being to ensure that the
engine is operated at its optimum settings. 4
EMS-S.V. Saravanan, SREC, Coimbatore

ELEMENTS OF AN EMS

5
EMS-S.V. Saravanan, SREC, Coimbatore

BLOCK DIAGRAM OF EMS

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EMS-S.V. Saravanan, SREC, Coimbatore

WORKING OF EMS (Cond…)

 The system consists of sensors supplying,


after suitable signal conditioning, the input
signals to the microcontroller and it providing
output signals via drivers to actuate actuators.

 The Figure shows some of these elements in


relation to an engine , only one cylinder being
shown.

7
EMS-S.V. Saravanan, SREC, Coimbatore

WORKING OF EMS (Cond…)

The engine speed sensor is an inductive sensor


and consists of the coil for which the inductance
changes as the teeth of the sensor wheel pass it
and so results in an oscillating voltage.

The temperature sensor is usually a thermistor.

The mass air flow sensor may be a hot wire


sensor.

8
EMS-S.V. Saravanan, SREC, Coimbatore

WORKING OF EMS (Cond…)

As air passes over a heated wire it will be cooled,


the amount of cooling depending on the mass
rate of flow.

The oxygen sensor is generally a closed-end tube


made of zirconium oxide with porous platinum
electrodes on the inner and outer surfaces.

 Above about 300°C the sensor becomes


permeable to oxygen ions with the result that a
voltage is produced between the electrodes. 9
EMS-S.V. Saravanan, SREC, Coimbatore

CASE STUDY I: TYPICAL EMS OF BOSCH MOTRONIC SYSTEM

(TYPICAL GASOLINE FUEL INJECTION SYSTEM)

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EMS-S.V. Saravanan, SREC, Coimbatore

WORKING OF TYPICAL GASOLINE FUEL


INJECTION SYSTEM

The different sensors are used in the EMS to detect


the following parameters

Crank shaft position


Coolant temperature
Exhaust Gas Recirculation (EGR) valve position
Exhaust manifold pressure
Knock
Manifold air pressure
Manifold temperature
11
EMS-S.V. Saravanan, SREC, Coimbatore

CASE STUDY II: TYPICAL EMS OF BOSCH COMMON RAIL


DIESEL INJECTION SYSTEM

1. High pressure pump


2. Element shutoff valve
3. Pressure control valve
4. Fuel filter
5. Fuel temperature sensor
6. Battery
7. High pressure accumulator (rail)
8. Rail pressure sensor
9. ECU
10. Fuel tank with pre filter and
pressure supply pump
11. Coolant temperature sensor
12. Crankshaft speed
13. Accelerator pedal sensor
14. Injector
15. Camshaft speed sensor
16. Intake air temperature sensor
17. Boost pressure sensor
18. Air mass meter
12
19. Turbocharger
EMS-S.V. Saravanan, SREC, Coimbatore

WORKING OF TYPICAL EMS OF BOSCH COMMON


RAIL DIESEL INJECTION SYSTEM

The different sensors are used in the EMS to detect


the following parameters

Engine speed
Air mass flow
Crank speed
Cam shaft position
Turbo air boost pressure
Fuel rail pressure
Air temperature
Coolant temperature
Accelerator pedal position, etc… 13
EMS-S.V. Saravanan, SREC, Coimbatore

WORKING OF TYPICAL EMS OF BOSCH COMMON


RAIL DIESEL INJECTION SYSTEM (cond…)

The functioning of all electronically controlled fuel


control systems depends on the inputs from
different types of sensors.

The ECU (Electronic Control Unit) receives these


signals from sensors and after manipulation and
calculations sends outputs to vary the injection
timing, fuel quantity, ignition timing etc and also to
control systems like the fuel injection pump, idle
speed control unit, particulate trap regenerator (in a
diesel engine), coolant supply etc.
14
EMS-S.V. Saravanan, SREC, Coimbatore

SUMMARY

In general the engine management system consists


of the following main units.

Sensor
Signal conditioner
Analogue to digital converter
Electronic control unit
Output signal driver and actuator

Note:There will be more than one input and output


involved in controlling the engine at any given
instant. 15
EMS-S.V. Saravanan, SREC, Coimbatore

REFERENCES

1. W. Bolton, Mechatronics, Longman, Second


Edition, 1999
2. V. Ganesan, Internal Combustion Engines,
Second Edition, Tata McGraw-Hill Publishing
Company Ltd., New Delhi 2003
3. [Link] 2000

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1. High pressure pump
2. Element shutoff valve
3. Pressure control valve
4. Fuel filter
5. Fuel temperature sensor
6. Battery
7. High pressure accumulator (rail)
8. Rail pressure sensor
9. ECU
10. Fuel tank with prefilter and
presupply pump
11. Coolant temperature sensor
12. Crankshaft speed
13. Accelerator pedal sensor
14. Injector
15. Camshaft speed sensor
16. Intake air temperature sensor
17. Boost pressure sensor
18. Air mass meter
19. Turbocharger

22

1 CASE STUDIES OF MECHATRONIC SYSTEMS “ENGINE MANAGEMENT SYSTEM”
2 CONTENTS INTRODUCTION WORKING PRINCIPLE OF FOUR STROKE IC ENGINE ELEMENTS OF AN EMS BLOCK DIAGRAM OF EMS
3 WORKING PRINCIPLE OF FOUR STROKE IC ENGINE EMS-S.V. Saravanan, SREC, Coimbatore
4 ENGINE MANAGEMENT SYSTEM [EMS] The engine management system of a car is responsible for managing the ignition and fuellin
5 ELEMENTS OF AN EMS EMS-S.V. Saravanan, SREC, Coimbatore
6 BLOCK DIAGRAM OF EMS EMS-S.V. Saravanan, SREC, Coimbatore
7 The system consists of sensors supplying, after suitable signal conditioning, the input signals to the microcontroller a
8 The engine speed sensor is an inductive sensor and consists of the coil for which the inductance changes as the teeth of
9 As air passes over a heated wire it will be cooled, the amount of cooling depending on the mass rate of flow. The oxyge
10 CASE STUDY I: TYPICAL EMS OF BOSCH MOTRONIC SYSTEM EMS-S.V. Saravanan, SREC, Coimbatore (TYPICAL GASOLINE FUEL INJECTION S

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