DCAT Overview

The Drivven Combustion Analysis Toolkit (DCAT) is a unique LabVIEW plug-in for creating sophisticated in-cylinder combustion analysis and logging applications for engine research and development. The included examples can be used out-of-the-box for building stand-alone systems, or modified and integrated with engine control applications. Using DCAT, engineers can streamline engine R&D by using built-in functions for Next-Cycle and Same-Cycle Control. DCAT leverages the latest hardware from Drivven and National Instruments for engine position tracking and synchronization of data-collection and processing. DCAT is also packaged in a fixed-executable, called µDCAT, and paired with USB-based DAQ devices for portable, low-cost combustion analysis, starting at $8,995.

DCAT Brief Features

• Supports NI R-Series, S-Series, M-Series and CompactDAQ
• Simultaneous engine-synchronous and time-based data acquisition
• Concurrent data monitoring and streaming to disk
• Many channel configuration, calibration and filtering options
• Common pegging and cylinder data alignment options
• Multiple pressure metrics and heat release calculation techniques
• Engine noise and knock analysis
• Engine sync from encoders or production engine trigger wheels
• Built in functions for Next-Cycle and Same-Cycle Control
• Insert custom analysis blocks for unique test and control applications

DCAT Data Flow

The data flow path of the DCAT software is shown below.  Data is collected at different rates through PXI S-series cards, M-series cards or cRIO modules, and then passed to the real-time controller.  This raw data can be consumed by three simultaneous processes.  First, when requested by the operator, the real-time controller can stream all raw data to disk for later post-processing on a PC.  Second, the data can be processed continuously for filtering, cylinder alignment, pressure metrics, heat release, statistical analysis and other reductions to be visualized on the host PC and stored to disk in a summary file for further post-processing.  Third, critical data can be selected from the DAQ stream for use in Next-Cycle Control.  

DCAT stores data and all configuration parameters in an open and efficient LabVIEW binary file format called TDMS.  These files may be transferred from the real-time controller to a host PC and analyzed using post-processing utilities included with DCAT.  The TDMS files may be opened within custom LabVIEW applications or Excel to generate reports.

Next-Cycle and Same-Cycle Control

Feedback control is made available in DCAT as Next-Cycle or Same-Cycle Control.  Next-Cycle Control is processed in the PXI RT controller, whereas Same-Cycle Control is processed within the FPGA.  Common uses of Next-Cycle Control are online feedback to stabilize engine conditions, or as a calibration aid to quickly move between set points.  For example, 50% burn location can be controlled by modifying start-of-injection timing.  Same-Cycle Control calculates incremental sub-crank-angle-degree heat-release in the FPGA.  This information is available for making control decisions within nanoseconds.  Examples of Same-Cycle Control are manipulating inter-pulse delay for diesel injections, and misfire detection and spark restrike for SI applications.

DCAT Example Systems

µDCAT USB-6251
With 1 MS/s aggregate throughput, the µDCAT USB-6251 is ideal for low channel count, high sample rate systems

Cost: $8,995

µDCAT cDAQ4
The µDCAT cDAQ4 provides 100 KS/s/ch simultaneous sampling for eight channels with room to customize

Base Cost: $8,995

µDCAT cDAQ8
With five spare slots, the µDCAT cDAQ8 not only supports simultaneous-sampling combustion analysis, but also knock-calibration and a wide variety of medium-speed I/O

Base Cost: $9,395

DCAT Base System
NI’s PXI RT Controllers, S-series simultaneous sampling, and FPGA reconfigurable I/O cards form a solid foundation for a high-speed combustion analysis system

DCAT System with SCXI DAQ
The addition of SCXI low-speed DAQ, a second S-Series card for time-based sampling and cRIO modules for specialty I/O make a more complete integrated test cell DAQ system

DCAT System with Engine Control
The addition of Drivven automotive I/O modules turn the DCAT base system into a full authority engine controller capable of Next-Cycle Control




DCAT System with Engine Control and SCXI DAQ
Our most popular system combines all features of full authority control and test cell DAQ into a complete package

DCAT System Selection Guide

Detailed Features

Measurement Configuration and Engine Geometry

• Supports multiple S-Series cards for simultaneous sampling of signals in both angle (cylinder pressure, MAP, etc.) and windowed time (knock, ionization, etc.) domains
• Individual channel calibration features
• Channels can be assigned to cylinder groups, supporting dual-MAP, multiple knock sensors, etc.
• Complete set of engine geometry parameters for volume versus CAD calculation
• Geometries of unique engines can be loaded directly via spreadsheet and defined on a per-cylinder basis
• Online motoring test assists with engine geometry verification

Engine Position Tracking and Sample Clock Generation

• Use traditional optical encoders with advanced sync and sampling options via R-Series FPGA card
  • Online adjustment of TDC index
  • Optionally use pressure signal for 4-stroke phase information
  • Extrapolate low-resolution encoder to higher resolution sampling
• Optionally use Drivven Engine Position Tracking (EPT) blocks to sync with production N-M or N+1 crank trigger patterns and sample data at high resolution

Medium/Low Speed Time-Based DAQ

• Supports additional DAQmx devices (M-Series, SCXI)
• Supports data sources from R-Series FPGA cards
• Simultaneously recorded with engine-synchronous data
• Aligned with engine cycles (raw or averaged)
• Temperatures, pressures, switches, etc

Pre-Processing

• Individual channel data alignment to selected cylinder
• Data scaling to engineering units
• Broad range of signal filtering options
• Multiple pressure pegging and data windowing options

Pressure Metrics

• Peak pressure and location
• Polytropic coefficients of compression and expansion
• Maximum rate of pressure rise and location
• Pressures at IVO and EVC
• Gross MEP (IMEP), Pumping MEP (PMEP), Net MEP (NMEP)

Heat Release Analysis

• Heat release methods include
  • Single zone
  • Modified Rassweiler and Withrow
  • Pressure ratio
  • Supports dual transducers per cylinder for pre-chamber engines
• Locations of Mass Fraction Burned (5%MFB, 25%MFB, 50%MFB, 75%MFB, 90%MFB, Custom)
• Maximum heat release rate and location
• Variety of heat transfer correction methods
• In-cylinder temperature estimation

Engine Knock and Noise Analysis

• Bandpass / Rectify / Integrate / Compare (BRIC) algorithm for knock signal processing
• Offline FFT analysis of knock signals for calibration of BRIC
• Raw, time-domain-filtered and angle-domain-filtered combustion noise indication

Data Saving and Post Processing

• Selectively or continuously stream raw data to disk by cycle count, time, or file size
• Data stored to National Instruments open binary TDMS file format
• Channel configuration and geometry stored to allow reconstruction of test environment in post processing
• Cycle-by-cycle summaries can be streamed to disk simultaneously with raw data
• Data can be post-processed with Drivven utilities, opened in Excel, or analyzed further with LabVIEW

Next-Cycle Control

• DCAT example includes data processing of selected parameters in time for Next-Cycle Control algorithms
• Uses watchdog to ensure computations are completed in time for Next Cycle Control
• Applications include:
  • Diesel engine control (PID control of 50%MFB using start of injection)
  • SI engine control (PID control of peak pressure location using ignition timing)

Same-Cycle Control

• Real-time FPGA-calculated heat-release for multiple cylinders
• Applications include:
  • Manipulate direct injection pulse spacing based on real-time heat-release
  • Compensate for misfires with additional fuel pulses or high-energy ignition

Pricing and Licensing

DCAT (Software Toolkit Only): $14,995
(See example systems above for hardware/software kit pricing)
Licensing
Each purchased seat of DCAT software is licensed according to the computer ID of the PXI RT controller.

µDCAT (Software Only): $6,995
(See example systems above for hardware/software kit pricing)
Licensing
µDCAT is a fixed executable derived from DCAT and is licensed according to the serial number of the DAQ device.

Mass Deployment: $4,995
Licensing
Customers may create customized DCAT applications or integrate DCAT into existing products and deploy to multiple systems. The Mass Deployment licesne fee will be paid for each deployment.  A full DCAT development license must be purchased first.  The mass deployment systems are licensed according to PXI RT controller ID (DCAT) or DAQ device serial number (µDCAT).  Mass deployment systems are supported by the system developer.

DCAT and µDCAT Support and Maintenance
For each development seat of DCAT and each µDCAT system Drivven provides one year of technical support and software maintenance to one named contact.  An additional year of software support and maintenance is available for 20% of the original purchase price.  All software licenses are perpetual. Software upgrades and support are provided with a current maintenance agreement.

Prices are subject to change without notice.
Prices are set for immediate to NET30 payment terms. 
Prices are increased by 1.5% per month for longer terms.