Internal combustion engine Calibration
With the aim of developing and designing optimal engines in terms of pollution, fuel consumption and power, IPCO uses the most up-to-date methods for calibrating engines. Most of experts’ responsibilities in this field are in two sections is as follow:
- Calibration activities on the vehicle
- Calibration activities on the engine
Calibration activities on the vehicle
This company is able to perform complete calibration activities on a wide range of vehicles, with different engines, different engine control units (ECU) or different gearboxes. These tests are performed with advanced and up-to-date equipment and, for example, include the following tasks:
- Winter and summer test trips in different climate conditions
- Consulting services and verification of calibration done by other companies for all car manufacturers
- Strengths and weaknesses analysis of different ECU calibration in benchmarking activities.
- Tuning services for race cars
- Consulting and other special technical services required by customer
- Confirmation tests and review of achievement of project results
- Achieving EU5 & 6 Emission and Fuel consumption standards
- Optimization of vehicle functions such as acceleration, driving comfort, start quality, drivability and …
- EOBD Calibration
- Services for inspection, identification and elimination of calibration defects on production vehicles (Fails to achieve emission or fuel consumption targets, engine failure due to incorrect knock calibration).
- ECU tuning for specific applications: durability tests, end-of-line engine production tests and …
- Calibration for rapid prototyping: to launch prototype vehicles, concept vehicles, retrofit vehicles and optimized engines
- Optimization of fuel consumption, power and torque and other required parameters
![](https://www.ip-co.com/wp-content/uploads/2020/09/Calibration-Pic.jpg)
Calibration activities on the engine
Execution of the engine calibration is performed in the engine test cell equipped with the most advanced equipment. Some of these tests are as follow:
- ECU tables calibration to optimize fuel consumption, power and torque
- Load detection calibration
- Base mapping calibration
- Torque structure calibration
- Knock calibration
Torque structure calibration
- Maximum torque
- Torque correction based on spark ignition advance
- Torque correction based on air fuel ratio
- Coordination torque by air flow
- Coordination torque by spark ignition
- Dynamic management of torque share between air flow and spark ignition
- Max and min torque
- Friction torque
- Demanded torque: pedal map, accessories torque (AC, Fan, Hydraulic Steering)
Base Mapping calibration
- Base ignition angle calibration
- Nominal lambda for component protection
- Nominal lambda for full load
- Ignition angle correction based on air-fuel ratio
- Injection phase
- VVT angle (cam shaft angle)
- Ignition angle calibration considering knock thresholds: standard fuel, low octane fuel
- Min ignition angle
- Min relative load
Load Detection calibration
- Intake manifold pressure and temperature calculation
- Exhaust manifold pressure and temperature calculation
- Residual gas mass calculation
- Air pressure pulsation
- Intake and exhaust valves timing
- Ambient pressure and temperature calculation
Knock calibration
- Ignition angle calibration based on fuel quality
- Knock sensor position determination
- Knock detection - knock sensor signal filtering frequency
- Knock detection - knock determination window
- Knock detection – knock thresholds
- Knock adaptation
- Dynamic knock detection