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Instruction

Manual
KiBox® To Go
Type 2893A...

KiBox® Cockpit
Version 3.0

for In-Vehicle and


Test Bench Combustion
Analysis

2893A_002-437e-02.17
Preface

Preface
These operating instructions describe how to operate the KiBox To Go Type 2893A…
and the KiBoxCockpit. It applies to
 KiBoxCockpit from V3.0
 KiBox Firmware from V4.2
 Charge amplifier Type 5064B... from Firmware V1.13
and Type 5064C… from Firmware V2.10
 Piezoresistive amplifier Type 4665B... from Firmware V1.22

The information in this manual is subject to change without notice. Kistler reserves the
right to improve the product in terms of technical progress and change, without
obligation to notify persons and organizations regarding such changes.

©2009 … 2017 Kistler Group. All rights reserved.

Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Fax: +41 52 224 14 14
info@kistler.com
www.kistler.com

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

Contents
Preface .............................................................................................................................. 1

Contents............................................................................................................................ 2

1. Introduction .............................................................................................................. 5

1.1 Application Areas of KiBox 5


1.2 Important Notices 5
1.2.1 Tips for Using the Manual ......................................................................... 6
1.2.2 For Your Safety ......................................................................................... 6
1.2.3 Transport and Storage .............................................................................. 8
1.2.4 Disposal Instructions ................................................................................ 8
1.3 Delivery, Accessories and Spare Parts 8

2. Hardware And System Overview ............................................................................... 11

2.1 System Overview 11


2.2 Hardware 12
2.2.1 KiBox To Go Type 2893 Terminals, Display and Controls ....................... 12
2.2.2 Crank Angle Adapter Type 2619 Function .............................................. 16
2.2.3 Optical Crank Angle Encoder .................................................................. 18

3. Installation .............................................................................................................. 19

3.1 System Requirements 19


3.2 Hardware Installation 19
3.2.1 Measurement Setup With Access To An Application System .................... 21
3.2.2 Measurement Setup Without Connection To An Application System........ 22
3.3 Software Installation And Configuration 23
3.3.1 Installing The KiBoxCockpit Software ...................................................... 23
3.3.2 Configuration ......................................................................................... 26
3.4 First Connection 28

4. Parameterization of KiBoxCockpit ............................................................................ 29

4.1 User Interface Design 29


4.2 Important Notices 30
4.2.1 Mental Concept, Basic Settings and Input Errors ..................................... 30
4.2.2 Shortcuts ................................................................................................ 31
4.3 Administration 34
4.3.1 Administration - Signal Types ................................................................ 35
4.3.2 Administration - Calculations ................................................................. 44
4.3.3 User Formula .......................................................................................... 62

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Contents

4.3.4 Administration – Channels ...................................................................... 71


4.4 Engine 74
4.5 Signals 78
4.5.1 Signal: Cylinder Pressure ........................................................................ 79
4.5.2 Signal: Digital Signal, Injection Pulse Digital, Ignition Pulse Digital ......... 83
4.5.3 Signal: Eccentric Angle ............................................................................ 84
4.5.4 Signal: Injection Pressure ........................................................................ 85
4.5.5 Signal: Injection/Ignition Pulse ............................................................... 89
4.5.6 Signal: Intake Pressure/ Exhaust Pressure .............................................. 90
4.5.7 Signal: Torque ........................................................................................ 91
4.5.8 Signal: Universal ..................................................................................... 92
4.5.9 Signal: Crank Angle ................................................................................ 93
4.5.10 Signal: User Formula ............................................................................... 93
4.6 Statistic: General Statistical Calculations From Results 96
4.7 TDC: Determine The Position Of Top Dead Center 96
4.8 Diagrams 103
4.9 Data Output 108
4.9.1 Channels: Data File (.open), Data File (MDF4) , CAN Output and Limit
Monitoring.......................................................................................... 108
4.9.2 Events ................................................................................................... 118
4.9.3 Data File ............................................................................................... 120
4.10 Parameter Check 121
4.11 Hardware 121
4.11.1 Timestamp ........................................................................................... 121
4.11.2 Cascading ............................................................................................. 122

5. Run Measurement ................................................................................................. 126

5.1 Online-View 126


5.2 Storing Data 126

6. Evaluation ............................................................................................................. 128

6.1 Visualization Of Measurement Data With KiBoxCockpit 128


6.2 Saving, Exporting, and Converting The Measurement Data 132
6.3 File Formats 136

7. Integration Into External Systems ........................................................................... 138

7.1 Application Systems 139


7.1.1 ETAS INCA ............................................................................................ 140
7.1.2 ATI Vision ............................................................................................. 150
7.1.3 Vector CANape ..................................................................................... 150
7.1.4 Other Application Systems .................................................................... 150
7.2 Test Bench Automation Systems 152
7.2.1 AVL PUMA ............................................................................................. 153

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7.2.2 Apicom Horus ....................................................................................... 162


7.2.3 D2T Morphe.......................................................................................... 163
7.2.4 Horiba Stars .......................................................................................... 163
7.2.5 Troubleshooting of the Test Bench Communication ............................. 163

8. Maintenance and Troubleshooting ......................................................................... 165

8.1 Software Updates 165


8.2 Troubleshooting 166

9. Appendix .............................................................................................................. 167

9.1 User Interface Design In Detail 167


9.1.1 Menu Bar .............................................................................................. 167
9.1.2 Symbol Bar ............................................................................................ 173
9.1.3 Navigation Bar ...................................................................................... 177
9.1.4 Status Bar ............................................................................................. 178
9.1.5 Dialogue Field ....................................................................................... 178
9.2 Thermodynamic Zero Point Correction 179
9.3 Thermodynamic Loss Angle 180
9.4 Noise 180
9.5 Knocking 181
9.6 Digital Channel Pin Assignments 183
9.7 Configuration Example for Using Virtual Channels 185
9.8 Example User Formula 188
9.8.1 Simple examples of the User Formula functions ................................... 188
9.8.2 Example implementation of a more complex User Formula .................. 193

List of Illustrations ......................................................................................................... 198

Index ………………………………………………………………………………………………………….202

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Introduction

1. Introduction
By choosing this quality product from Kistler, you have selected a device characterized
by high technical innovation, precision, and durability. The KiBox To Go type 2893 with
the KiBoxCockpit is the ideal system for mobile indication.

1.1 Application Areas of KiBox

With the KiBox combustion analysis system, Kistler Instruments AG has developed a
measurement and analysis system designed specifically for the cylinder-pressure
indication in the vehicle. In addition to an innovative data collection approach and the
simple integration into engine application systems (e.g. INCA) the KiBox is
distinguished by a variety of novel properties. Combustion analysis results can be
presented and analyzed synchronously in real time and simultaneously with other
control and process variables of the engine control unit (ECU).
A conventional operation at test benches can be realized by means of a universal test
bench interface.
During development particular emphasis was placed on creating a user friendly
experience. The resulting concept now allows the system administrator (usually a
measurement technician familiar with motor indication measurements) can prepare all
the basic settings in the administration level. Without further indication knowledge the
vehicle applicator can then configure the appropriate signals for the specific
measurement tasks. This reduces the parameterization of the end user to a minimum
and at the same time allows for a group-wide standard for indication signal settings.

1.2 Important Notices

Please note the following details. They serve to your ensure personal safety when using
the KiBox To Go and guarantees on the other hand a long life and trouble free
operation of the device.

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1.2.1 Tips for Using the Manual

Meaning of warning symbols:

A step marked with this symbol can be omitted under the indicated
circumstances.

This symbol points out that something has to be waited for and
watched.

The symbol alerts you to hazards that can have serious consequences,
whether the damage is to hardware or a possible injury to persons.

Notes provide you with additional information, which is usually not


compulsory, but will help in understanding the working procedures and
using the measurement technology.

Information related to the quality of the measurements, are formulated


under this symbol. For example: Reduction in signal quality, falsification
of the measurement data, etc.

1.2.2 For Your Safety


The KiBox is designed and tested in accordance with EN-Publication 61010-1 (Safety
requirements for electronic measuring devices). The unit left the factory in a safe
operating condition. To maintain this condition and to ensure safe operation, the
instructions and warnings in this manual and on the unit are observed.

The KiBox may not be used for the purpose of personal protection.

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Introduction

Keep the local safety regulations, which govern the use of mains-powered electrical
and electronic equipment.

If it can be assumed that safe operation of the device is no longer


possible, it must be removed from service and secured against
unintended operation.

Safe operation is no longer guaranteed if the device


 is visibly damaged,
 not working correctly,
 has been stored under unfavorable conditions,
 or was exposed to severe transport stresses.

If safe operation based on the above features is no longer be ensured, the device
should be immediately sent to a competent Kistler sales company/agent for repair.

The following warnings must be observed:

 If opening covers or removing parts and it is not possible by hand, live current parts
can be exposed
 Before dismantling for calibration, maintenance, repairing or replacing parts,
disconnect the device from all voltage sources.
 Calibration, maintenance and repair work on equipment that is open and connected
to a power source should not be performed if at all possible. If such work is
unavoidable, however, it should be done by a professional who is familiar with the
dangers involved.
 Any disruption of the protective conductor inside or outside the unit or the
dissolution of the protective earth connection can be fatal. Intentional disconnection
is prohibited!
 The mains plug shall only be inserted into a socket that has an earth contact. The
protective effect may not be nullified by an extension cord without a protective
earth connection.
 Fuses may be replaced by the appropriate type with the specified nominal current.
The use of "repaired" fuses or short circuiting the fuse holder is not allowed.

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 The grounding screw on the underside of the unit connects the grounding of the
power plug to the housing. This must not be removed.

Safety Notice/Internet threats

Do not ever connect the system KiBox directly to the Internet. It should always be
operated behind a firewall and/or a router, which shields the system from direct access
from the Internet. The router and the firewall are not included in the KiBox system. The
KiBox system is therefore not specifically protected against attacks from the Internet.

1.2.3 Transport and Storage


If the unit is transported or stored for any time, then the following safety precautions
must be taken:
 The ambient temperature must be between -30 ° C and 70 ° C.
 All connections must be covered with a non-shorting dust cap.
 Make sure that no dirt can enter the unit.
 The environment should be as dry and free of vibration as possible.
 Store the unit so that neither the front nor the back plate experiences pressure.
 As long as the device is not used, it should be stored in the original packaging.

1.2.4 Disposal Instructions


Electronic equipment may not be disposed of with household waste. Please contact
your Kistler sales representative for the disposal of the device.

1.3 Delivery, Accessories and Spare Parts

Please check your order immediately upon receipt of the delivery to


make sure that the delivery and the parts delivered are complete and
correct.

KiBox To Go Set - Type 2893AK1

The delivery of this set includes the following items:

Article Description Amount


number/
Model

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Introduction

2893A121 KiBox To Go - Basic Unit 1

5700A27 Blank front plate 7TEx106, 5mm 0 to 4

5.211.569 Gigabit Ethernet Switch 1

5.590.314 Supply cable to switch, 2m length 1

1200A117A1 Ethernet cable, 1-1, 1m length 1

1200A117A5 Ethernet cable, 1-1, 5m length 1

1200A125A5 Ethernet cable, crossed, length 5m 1

7.620.433 Supply cable to KiBox, open, length 2m 1

5781A4 Mains adapter with country-specific cable plug ( incl. 1


banana-jacks for supply of ethernet switch); max.
150W

5.510.416 D-Sub 25-pin connector with terminals 1

5.511.427 Fischer Triax plug (pos.) 1

7.643.034 User Manual and CD-ROM with KiBoxCockpit software 1

Z16687 Country-specific power cable 2-pole with protective 1


conductor

Crank Angle Adapter Set - Type 2619A11

2619A1 Crank angle adapter (reverb/inductive) 1

5.211.559 Wall bracket kit including mounting screws 1

1200A107A2 Cable for crank angle sensor, length 2m 2

1200A109A5 Connection cable between 2619A1 and KiBox, length 1


5m

Accessories:

5064C11 2-channel charge amplifier optional

5064C12 2-channel PiezoSmart charge amplifier optional

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

4665B1 2-channel piezoresistive amplifier optional

1987BN7 PiezoSmart extension cable, length 7 m optional

1987BN0.5 PiezoSmart extension cable, length 0.5 m optional

1200A107A5 Cable for crank angle sensor, length 5m optional

1200A109A2 Connection cable between 2619A1 and KiBox, length optional


2m

2105... AC/DC miniature current clamp optional

1603BN0,5 BNC sensor extension cable, length 0.5 m optional

1603BN7 BNC sensor extension cable, length 7 m optional

To order items without a specified item number, please contact your Kistler
representative.

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Hardware And System Overview

2. Hardware And System Overview


In addition to the system overview of KiBox To Go in this chapter, particularly detailed
information about the individual hardware components and their measurement ranges
will be specified. Communication regarding the various connectors, switches, displays,
and the most important technical details about the components and their functions are
presented here.

2.1 System Overview

The KiBox can be used either as a single system (standalone operation) or in


combination with an application system (network operation) on the internal
combustion engine.
By means of cylinder pressure sensors, current probes, and if necessary, additional
sensors, the important results of variables on the engine will be measured. With the
help of the crank angle adapter, through which the signal of the pulse wheel sensor
(inductive or hall) the current crank angle position for the motor control is provided,
the measured variables of the resolved crank angle is included in the KiBox. This then
provides the data if desired to the KiBoxCockpit software on the PC. Because the PC is
also used as an interface to the engine application system, the data identified by the
KiBox can also be transmitted to the application software (e.g. INCA). Thus, the
applicator receives both indicated variables and engine control variables synchronously
in a measurement file, making the subsequent analysis greatly simplified.

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

2.2 Hardware

2.2.1 KiBox To Go Type 2893 Terminals, Display and Controls

Front side:

Figure 1: Hardware, front view KiBox

Error LED/Red

Indicates whether an error has occurred during the operation.

Status: on: a system error has occurred in the KiBox


off: KiBox runs without error

Note: see Chapter Troubleshooting

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Hardware And System Overview

Operating LED/Green

Shows the readiness status of the KiBox.

Status: on: the system is active (e.g. during a measurement)


off: the system is idle
fast flashing: USB-Writing is active

Note: The system is idle, for example, during configuration.


Even without a connection to the PC, the KiBox can be
active.
During a firmware update, the error and operating LEDs
will blink.

Power button Button with light/green

For manual switching on and off of the KiBox without the use of the automatic
on-off function of the KiBoxCockpit. Switch on by briefly pressing the button on
and turn off by pressing the button for about 5 seconds.

Status: on: Button glows


off: Button is dark (standby mode)

Note: It is advisable to control the KiBox with the convenient


automatic on and off switch of the KiBoxCockpit.

Analog In 8 units, BNC (differential inputs)

Connection to preferred measuring devices possible

Technical data:  Input voltage range -10V ... 10V


 ADC resolution 16 bit
 ADC sampling rate 1.25 MHz per channel
 Bandwidth 100 kHz
 Raw Data Filter: Oversampling and anti-
aliasing filter

Memory 1 USB unit

Local measurement data storage via USB flash drive or hard disc drive (FAT32
formatted).

Digital In 1 D-sub 25pin unit

Connection of digital signals (input low level: <1V, high level: >4.5V, max ±30V)

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Crank Angle 1 1 unit crank angle adapter for Kistler Type 2619

Connection of the crank angle signal from crank angle adapter Type 2619.

Crank Angle 2 1 unit for optical crank angle encoder

Connection of the crank angle signals from the optical crank angle encoder. The
following types are supported:

 Kistler Type 2614A


 AVL type 365/720
 AVL Type 365/360)
 Encoder with 1200 pulses per 360 °CA
 Encoder with 600 pulses per 360 °CA

Current Clamp 2 units BNC for current clamp

Connection of current probes (Kistler Type 2105, Fluke Type 80i-110s) for
detection of the injection signal.

Technical data:  Input voltage range of-1V ... +1V


 ADC resolution 12 bit
 ADC sampling rate 2.5 MHz

Plug in position for 4 units


measuring amplifier

Slot for Kistler measurement amplifier. The following types are supported:

 Kistler Type 5064B1 ...or 5064C


 Kistler Type 4665B

Note: The amplifier modules can only be an alternative, not used


in parallel with the analog inputs. The KiBoxCockpit is
used to determine if the voltage input or the input signal
via the amplifier is used.
The analog outputs on the amplifier Type 5064/4665...
can be used as needed to supply the appropriate voltage
signal to another application.

The output signal of the 5064…/4665 is routed internally in the KiBox


To Go and has NOT to be connected to the KiBox via the 8 analog
inputs above.

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Hardware And System Overview

Note the numbering of the measurement amplifier plug slots.


Top left No. 1, top right No. 2, bottom left No. 3, bottom right No. 4.
The number of the slot together with the designation of the input signal
on the amplifier shows the full channel name in the KiBoxCockpit: 1A,
1B, 2A, ... 4B

Of the total of 8 signal inputs per channel, only either the analog input
(top) or the equivalent amplifier input can be used.

Back side:

Figure 2: Hardware, back view KiBo

CAN 2 pieces CAN interfaces (SubD 9 pin)

CAN interface for output of calculated combustion analysis parameters via a


CAN-Bus.

Digital Out 1 digital output unit (25 pin SubD)

Output of digital signals.

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

RS-232S 1 serial port (9 pin SubD) unit

RS-232 interface for serial test bench connection.

Ethernet 1 unit 1000 Base-T with green and orange LED


1000/100/10

Standard connection of the KiBox-PC connection.

Status: Green on: Connection between KiBox and PC made.


Green off: Hardware connection is not available.
Orange blinking: current data transfer
Orange off: currently no data transfer

Ethernet 100/10 1 unit 100 Base-T with green and orange LED

Inactive

Equipment tag 1 piece

Shows the main characteristics of this KiBox To Go (type, serial number, power
source, ...). Please always keep this information handy in case of a support or
warranty request.

Ground 1 unit grounded terminal

Shows the main characteristics of this KiBox To Go (type, serial number, power
source, ...). Please always keep this information handy in case of a support or
warranty request.

Power 1 unit

Fuse 1 flat fuse 15A (58V)

Securing the KiBox To Go to ensure the voltage supply.

Remark The standard blade fuse itself can be replaced with the

same type fuse as needed.

2.2.2 Crank Angle Adapter Type 2619 Function

Short Description

The crank angle adapter is the connecting link between the vehicle's crank angle
sensor (hall or inductive) and the KiBox Crank Angle 1 connection. It converts the
analog signals of the crank angle transmitter from the hall or inductive sensor in a

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Hardware And System Overview

uniquely evaluable, digital LVDS pulse sequence at, which is then used in the KiBox for
calculating solid angle measurement data. The power supply and configuration of the
adapter takes place via the KiBox.

Key features of the crank angle adapter Kistler type 2619 at a glance:

 Sensor types: Pulse wheel sensor hall or inductive


 0V ... 5V input voltage range of hall sensor, activation threshold of 2.4V
 -100V ... 100V input voltage range of inductive sensor, activation threshold of
0.45V
 -200V ... 200V overload range
 Signal sequence: 12-1, 12-3, 20-2, 24-1, 24-2, 30-2, 36-1, 36-2, 36+1, 60-1,
60-2, 60-4, 90-1, 120-1, 120-2, 36-2-2, 36-2-2 (asymmetric 22+2+10+2), 60-
1-1, 60-2-2, 60+1+1,
36-2-2-2, 60-1-1-1, 60-2-2-2
Note: For more than one gap, they must be arranged symmetrically.

The crank angle adapter is specifically designed for use in the car and for installation
in the engine room. Here the vehicle specific crank angle sensor signal of the hall or
inductive sensors, required from the ECU (engine control unit), can be tapped and
attached on the three-pin plug of the crank angle adapter 2619A11 (connection:
"sensor"). The communication takes place between the crank angle adapter and the
KiBox via the 14 pin Crank Angle 1 interface. The following figures show the necessary
connection schemes for the corresponding hall and inductive sensors in the vehicle.

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

Figure 3: Connection chart for inductive sensors

Figure 4: Connection chart for hall sensors

2.2.3 Optical Crank Angle Encoder


Detailed information about optical encoders and their various connection types, please
refer to the corresponding data from the different manufacturers.

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Installation

3. Installation
The following chapters will guide you through the installation of the KiBoxCockpit
software and hardware measurement setup.

3.1 System Requirements

To ensure the reliable operation of the KiBox system, the following minimum
requirements of the PC must be met:

Processor : 2 GHz (Dual Core)

RAM : 3 GB (recommended: 4 GB)

Hard disk space : 1 GB (installed)

5 GB (data storage)

Ethernet : 1 Gb

Operating system : Windows XP® (min SP2) / Windows Vista® / Windows 7® /


Windows 8/8.1® / Windows 10®

Please make sure your Windows user account has sufficient rights (such as changing
the firewall settings).

3.2 Hardware Installation

This chapter describes the design of the hardware in the vehicle.

It is important to strictly ensure that neither the installation of KiBox To


Go in the vehicle itself, nor through any cables or mounting aids impair
the assessment of the traffic situation or the operation of the vehicle.

Isolate the metal contacts of the electrodes


Please assure that all metallic contacts (plugs, etc.) in the measuring
chain do not come in contact with the vehicle mass and that the plugs
do not touch each other.
Isolate plug connections and other metal parts of the measuring chains

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

(especially in the engine compartment).


Please use only the one-side shielded Ethernet cable supplied with the
Kistler KiBox To Go. These are perfectly matched for use as a mobile
application in the vehicle. Connect the insulated side of the cable (plug
entirely of plastic, without metal parts) to the KiBox side and not to the
Notebook side.
Otherwise, a noticeable degradation of signal quality with negative
influences on the measurement results may have to be taken into
account.

For supplying various equipment specifically associated with engine


start and engine stop measurements, a separate measuring battery or
an alternative voltage source should be included. The vehicle's battery is
usually not suitable for these two uses.

For the installation of sensors, cables, and other components of the


measuring chains, use the separate booklet entitled "Sensor Mounting
Instructions". Note also the additional data sheets.
For a selection of appropriate sensors and cables, contact your Kistler
distributor.

Recommendations for the placement of the KiBox To Go in the vehicle

Due to its compact size and diverse mounting options, the KiBox To Go may be placed
in various locations in the test vehicle:
 Trunk (with mounting straps, etc.)
 Foot space between the front seats and rear seats
 Rear seat (easy fastening with seat belts)
 Cab (trucks)
 Iso-Fix attachment (accessory is being planned)

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Installation

Figure 5: Proposed placement in the vehicle: Trunk (left), foot space in front of the rear seat
(center), rear seat (right)

In addition to the proper placement and attachment options in each


vehicle, the specific measurements for positioning the KiBox To Go is
crucial.
The basic idea is to make sure that there is sufficient access to the
wiring, the power button, and the visibility of the LEDs.

3.2.1 Measurement Setup With Access To An Application System


The figure below shows the schematic measurement setup of the hardware in the
vehicle with the connection to the application system. Therefor a Gigabit Ethernet
switch is required (included). It connects the PC, the KiBox and the interface of the
application system via the yellow Ethernet cables.

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

Figure 6: Schematic measurement setup with access to application system

3.2.2 Measurement Setup Without Connection To An Application System


To use the KiBox in a standalone operation without connection to an application
system, it must be connected as shown in the following figure by a crossed Ethernet
cable (included, red).

Modern network cards automatically switch to "cross connect" and will


therefore usually also work with the yellow, not crossed Ethernet cables.

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Installation

Figure 7: Schematic measurement setup for standalone operation

3.3 Software Installation And Configuration

Use of the KiBox To Go requires the previous installation of the software KiBoxCockpit
and other components (such as additional drivers, etc.) on a notebook. Furthermore, a
functioning Ethernet connection for communication is required. The following sections
provide further guidance to both the software installation and the subsequent
configuration of the software and network settings.

3.3.1 Installing The KiBoxCockpit Software

Software at a glance:

The accompanying CD includes the following software:

KiBoxCockpit: Graphical User Interface (operating software) of KiBox

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KiBox® To Go, Type 2893A… with KiBox®Cockpit V3.0

KiBox INCA Interface between KiBoxCockpit and application system INCA from
driver: ETAS, necessary for the integration of the hardware component
"KiBox" in INCA; for standalone operation this is not necessary

IFile Converter: Allows the conversion of KiBox measurement files (*. open) to
IFiles

MDF converter: Allows the conversion of KiBox measurement files (*. open) into
MDF files(*. DAT).

Matlab PlugIn: Allows to open KiBox measurement files (*. open) in Matlab
directly.

Remote Client Demo software including MS Visual Studio project so that the
KiBoxCockpit Remote API can be visualized on another PC via
TCP/IP network connections.

Testbed DCOM Interface which enables the KiBox to be connected to test benches
driver using the DCOM protocol

Also available on the CD under the heading "Documentation - KiBoxCockpit" are the
following documents:
 Instruction Manual for KiBox To Go
 Quick Guide to KiBox To Go
 Readme files
 Sensor Mounting Instructions

Installation:

1. Insert the CD into the drive. If the installation application does not start automatically,
start the application "KiBoxToGoSetup.exe" on the CD.
2. Select the desired installation language

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Installation

3. Overview of the components that will be installed with KiBoxCockpit; continue with
"Install" button
4. Selecting the installation method: "Measurement Installation" or "Office Installation"

5. Set paths for the installation files and user files (such as parameter files, etc.). Individual
installation components may be added or unselected.

6. When "Measurement installation" is selected, all INCA installations on the PC are shown.
The user must then select the version of INCA in which the KiBox is to be used (it is not
currently possible to select multiple versions. To work in KiBox with another version of
INCA, KiBoxCockpit must be re-installed or changed).

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7. Starting the Installation


As well as the installation folder the path "...\KistlerData" is automatically suggested
as the default directory for the storage of different user files. If this directory is a
network drive, or if the KiBox is used by multiple users on the same computer, it is
recommended that the user directory is set to a folder to which all users will have
local access. The following folders are created automatically in the selected
directory at the first program startup.
 Data
 DriverSettings
 Event Handler
 Layout
 Parameter
 Template
 UserSettings

In the "EventHandler", subfolders are created and designated, which can


be used for all the events that occur during the use of the KiBox
system. Programs can be stored (*. exe, *.cmd, *.bat) in any of these
folders. Should any one of the relevant events occur, then these
programs run automatically.

3.3.2 Configuration
The communication between the KiBox To Go and the KiBoxCockpit (Notebook) will
take place over a Gigabit Ethernet connection. This connection must be configured
accordingly. This is done by comparing the IP addresses between KiBox To Go, and the
notebook. If required, the IP address of KiBox To Go can be changed.

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Installation

3.3.2.1 Ethernet Settings On The Notebook Operating System And In The


KiBoxCockpit

The Ethernet configuration of the notebook operating system is set under "Control
Panel - Network Connections - LAN connection". In the context menu of the LAN
connection used, "Properties" of the Internet Protocol (TCP/IP) must be selected within
the "General" tab. The "Properties" button then leads to the input mask of the IP
configuration of the operating system.
The KiBoxCockpit Ethernet settings can be adapted with the active KiBox as follows:

Example Configuration standalone operation and local vehicle network:

Notebook KiBox

IP Address 192.168.0.101 192.168.0.100

Subnet Mask 255.255.255.0 255.255.255.0

Default Gateway no entry 192.168.0.254

The KiBox system is delivered with the standard IP 192.168.0.100. In order to be able
to connect directly, the address of the Gigabit Ethernet card on the notebook must be
set to the value of 192.168.0.101. The subnet mask of KiBox and the notebook must
match. The default gateway of the KiBox must be set to the IP 192.168.0.254.
Generally speaking, the KiBox and the notebook must use the same network segment,
but set to a different IP.

Example configuration corporate network:

The notebook and the KiBox can be alternatively connected through a switch to a
corporate network. It should be noted, that in this case, the company-specific network
settings are standard.

The company specific network settings may fundamentally differ. A


generally valid configuration can therefore not be specified.
Please contact your network administrator for detailed settings of the
allowed IP range (IP address, subnet masks and default gateway).

3.3.2.2 Energy Management

In general, mobile computers have an energy manager, which should extend the
duration of battery operation. Please make sure you use an energy scheme that allows
for the maximum processor and fan performance.

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3.3.2.3 Speaker

The KiBoxCockpit software has an audio feedback that can give you helpful feedback
information. Please make sure your speakers are turned on with sufficient volume.

3.4 First Connection

When you first launch the KiBoxCockpit the default IP settings are preconditioned. If
default setting is not the case the IP configuration must be adjusted. This can be done
via the menu "View - Search KiBox" (or press F3) in the menu bar. Then select the IP
address found with "Apply". Alternatively, you can also enter the IP address of KiBox by
hand. If necessary, the KiBox IP address can be changed by pressing the "Edit" button.

Figure 8: First connection: KiBox search

After confirming with "OK", the KiBoxCockpit will try to connect with the hardware.
With the proper IP configuration, the message "KiBox Online" will appear in the status
bar and be announced on the speakers.

Figure 9: Connection status in the status bar

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4. Parameterization of KiBoxCockpit

4.1 User Interface Design

Figure 10: Design of the KiBoxCockpit user interface

In the figure above, the individual components of the user interface are graphically
highlighted. Basically it consists of the following five general components:
 Menu Bar
 Symbol bar
 Navigation Bar
 Status Bar
 Dialogue field
 Message Window

Particular attention should be paid to the color of the displayed


channels in the dialog box. Vector variables (e.g. cylinder pressure
curve PCYL) are orange and scalar parameters (e.g. maximum cylinder
pressure value PMAX) are highlighted in green.

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Depending on the user level setting, the icon is shown in different


places on the user interface. This indicates a hidden functionality which
can be seen when the user level is switched to Expert (Menu – Tools –
Options – User level tab).

4.2 Important Notices

4.2.1 Mental Concept, Basic Settings and Input Errors


The following conceptual approach is realized in the KiBoxCockpit Software:
The administrator (usually a measurements technician/engineer familiar with
indication measurements) prepares a template file with all the basic settings (file
extension *. kit). This is done in the password protected administration level (factory
delivered password: "kibox").
The applicator now uses this template, parameterizes it for custom use and saves it as
a parameter file (file extension *.kip).
First load the DefaultTemplate.kit via "File - Open template". Navigate via "View -
parameter" (or press the F11 function key) to display the parameter editor. The
parameters are arranged vertically from top to bottom. The signal flow always runs
horizontally from left to right.

To validate the input in an input field, you must first exit the input box
(e.g. by pressing the TAB key or by clicking in another field)

Input errors:

In the event of an incorrect input, a red exclamation mark appears next to the
appropriate input box. Move the cursor over this red exclamation mark and you get a
text message.

Figure 11: Note to incorrect input

Decimal seperator:

The KiBoxCockpit software uses the default decimal seperator setting of the operating
system. Please note that incorrect use of decimal and thousands separators may lead
to incorrect entries that are not recognized by the software. The following example
illustrates this:

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Figure 12: Correct use of the decimal separator

4.2.2 Shortcuts
Using a mouse during mobile use in vehicles is very difficult. For this reason, the ability
to control the KiBoxCockpit was made possible primarily with the keyboard. An
overview of all the additional Windows standard shortcuts is available at the end of this
chapter (or in the KiBoxCockpit by pressing the "Ctrl" + "F1").
By pressing "Alt", under each menu name in the menu bar an underlined letter appears
(example "D" in the File menu). With the key combination of "Alt" + "D" the "File" menu
opens.
By pressing the "Alt" key, however, only the File menu is selected but not opened.
Using the cursor arrow keys any menu and each menu item, respectively, and its sub-
points can be marked and opened with "Enter".

Figure 13: Menu bar after activation of the key control by the "Alt" key

List of available keyboard shortcuts:

A. Main features

Key/Key Function Additional Declaration


Combination

F2 Parameter Check -

Menu "Extras" > Menu points "Options" >


F3 KiBox search
Register "KiBox" (device in the network)

F4 Phase switch Changes the assignment of high-and low-

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pressure phase in a four-stroke engine.

Start May need to first check a parameter to be


F5
measurement carried out.

Triggers a manual capture according to the


F6 or space bar Capture settings below the navigation button "data
storage".

After a measuring stop, the data in the


Stop
F7 storage ring can be saved if necessary as an
measurement
*.open file.

Maximize/minimi
The message window is maximized or
F8 ze message
minimized at the lower edge of the screen
window

TDC
determination
F9 -
from cylinder
pressure

Start TDC
determination Only in the "TDC" dialog, Register "from
Space bar
from cylinder cylinder pressure" active.
pressure

Skip to the next Only in the "TDC" dialog, Register "from


Ctrl + Arrow right cycle of the TDC cylinder pressure" active. After successful
determination TDC determination.

Skip to the
Only in the "TDC" dialog, Register "from
previous cycle of
Ctrl + left arrow cylinder pressure" active. After successful
the TDC
TDC determination.
determination

Only in the "TDC" dialog, Register "from


Delete marked
Del cylinder pressure" active. After successful
cycle
TDC determination.

F10 Open Data File ... Only for *.open files.

Parameter (Editor) If the parameters are already visible, any re-


F11
open pressing of F11, terminates the editor.

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Only after measurement stop active. Opens


F12 Store data...
dialog to save data as an *.open file.

Opens the HTML Help with the list of


Ctrl + F1 Shortcuts View
available keyboard shortcuts

Saves altered parameters to the existing file


Ctrl + S Save parameters
name.

Open parameter Opens the dialog to open a *.kip parameter


Ctrl + O
... file

B. chart functions

Key/Key Function Additional Declaration


Combination

Ctrl + Page Up Go to the next tab -

Go to the
Ctrl + Page Down Only active in the "data display" registers.
previous tab

Go directly to a
1 to 9 With "1", the first register is activated.
specific tab

Jump to the Only active "After measuring stop" or in an


Ctrl + left arrow
previous cycle opened *.open-file (data player)

Jump to the next Only active "After measuring stop" or in an


Ctrl + Arrow right
cycle opened *.open-file (data player)

Jump to the first Only active "After measuring stop" or in an


Ctrl + up arrow
cycle opened *.open-file (data player)

Only active "After measuring stop" or in an


Ctrl + down arrow Jump to last cycle
opened *.open-file (data player)

Zoom -
"View" menu> menu item "Zoom" or via
Ctrl + A automatically
symbol bar. Only for each active chart.
scale

"View" menu> menu item "Zoom" or via


Ctrl + Q Zoom - enlarge
symbol bar. Only for each active chart.

Ctrl + E Zoom - reduce "View" menu> menu item "Zoom" or via

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symbol bar. Only for each active chart.

Zoom - enlarge "View" menu> menu item "Zoom" or via


Ctrl + W
range symbol bar. Only for each active chart.

Zoom - move "View" menu> menu item "Zoom" or via


Ctrl + D
curves symbol bar. Only for each active chart.

4.3 Administration

Settings are made in the administration area. In the daily operation normally there is
no (or no longer) need to change (e.g. measuring principle of a sensor, signal names
used, definition of calculations, etc.). These settings are protected with the default
password "kibox".
The change of the default password is made in the password entry field under "View -
Enter admin password" by pressing the "Change" button. You must then type in both
the old password and then twice the new password.

To ensure the comparability of results from different measurements,


the settings in the administration level should not be changed very
often. The unintentional overwriting of the settings in the
administration area is prevented by password protection.

In the section signals, all signal types are defined, which will later be available for a
measurement. In addition to the types of signals, the associated calculations for each
signal type must also be defined.

Just prior to the administration defined calculations to one type of


signal, these can also be used and evaluated in the further sequence.

By right-clicking on the words "Signal Type" and selecting "Signal Type add", new types
of signals can be defined.
To add a new calculation, you must click on the right mouse button on the lettering of
a defined signal type and select the choice of "Add Calculation". "Delete" with the
option of the command from the context menu (right click on the type of signal or
calculation), to delete signal types or calculations.
In the "Channels" area, the physical input channels can be divided into any number of
virtual channels.

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Moving average:

The moving average is used to smooth out the raw signal before the calculation of the
result. This kind of averaging is used mainly for dynamic analysis of measured values.
The moving average is defined with the specification of a range over which the
averaging will take place each time. This +/- °CA value is indicated in most
calculations. If the value is set to +/-0 °CA, there is no moving averaging.

4.3.1 Administration - Signal Types

In the DefaultTemplate.kit all possible signal types and calculations are


already added and provided with default settings. For each particular
application, this must always be checked and updated if necessary.

Pressing the "Reset" button will return the default settings for the
currently selected signal type or the calculation, even if there was
previously no entry.

4.3.1.1 Cylinder Pressure

Figure 14: Administration: Signal type cylinder pressure

No. Designation Description

Filtering of the signal with frequency depending on the


mounting type of the sensor (direct installation, spark plugs or
Filter setting:
glow plug adapter).
Input range: From, 5, 10, 20, 25, 30, 35, 40 kHz

Central definition of the signal name without the cylinder


number. It appears every time you use the signal and it can only
Signal Name:
be changed in the administration area.
Example: PCYL

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4.3.1.2 Digital Signal

Figure 15: Administration: Signal type digital signal

No. Designation Description

see Cylinder pressure


Signal Name:
Example: DIN

4.3.1.3 Eccentric Angle

Figure 16: Administration: Signal type eccentric angle

No. Designation Description

see cylinder pressure


Signal Name:
Example: AVF_EA

For usage of eccentric angle signal in alternative volume function, the


calculator average must be added here.

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Parameterization of KiBoxCockpit

4.3.1.4 Exhaust Pressure

Figure 17: Administration: Signal type exhaust pressure

No. Designation Description

see cylinder pressure


Signal Name:
Example: PEX

4.3.1.5 Ignition Pulse

Figure 18: Administration: Signal type ignition pulse

No. Designation Description

Channel
see injection pulse
selection:

see cylinder pressure


Signal Name:
Example: IGN

Edge
Input range: rising edge, falling edge
selection:

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Display
see injection pulse
range:

Threshold for
Determines the threshold that has to be exceeded by the signal
detection of
to detect the ignition signal
ignition
Input range: +1 V to -1 V
timing:

Threshold for Determines the threshold to which the signal should decrease
detection of after crossing the threshold so that the ignition timing is
ignition detected
timing: Input range: +1 V to -1 V

Generally the thresholds can be on the same level. But if there are
disturbances on the signal, it can make sense to adjust threshold on
a high level and threshold on a low level.

4.3.1.6 Ignition Pulse Digital

Figure 19: Administration: Signal type ignition pulse digital

No. Designation Description

see Cylinder pressure


Signal type:
Example: IGND

4.3.1.7 Injection Pressure

Figure 20: Administration: Signal type injection pressure

No. Designation Description

see cylinder pressure


Signal Name:
Example: PINJ

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4.3.1.8 Injection Pulse

Figure 21: Administration: Signal type injection pulse

No. Designation Description

Selection of current clamp connection channel for signal


Channel
visualization.
selection:
Input range: 1, 2

see cylinder pressure


Signal Name:
Example: INJ

Type: Input range: Magnet injector, Piezo electric injector

This selection sets the display range of the x-axis of the


Display
oscilloscope shown.
range:
Input range: 1 to 500 ms

Threshold for
Determines the threshold that the signal must exceed so the
detection of
digital conversion recognizes the start of the injection.
start of
Input range: +1 V to -1 V
injection:

Threshold for Determines the threshold that the signal should drop after
detection of crossing the threshold of the start of injection so that the digital
the end of conversion recognizes the end of injection.
injection: Input range: +1 V to -1 V

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The definition of the thresholds has to be done by shifting the


respective horizontal cursors in the oscilloscope.

4.3.1.9 Injection Pulse Digital

Figure 22: Administration: Signal type injection pulse digital

No. Designation Description

see Cylinder pressure


Signal type:
Example: INJD

4.3.1.10 Intake Pressure

Figure 23: Administration: Signal type intake pressure

No. Designation Description

see cylinder pressure


Signal Name:
Example: PIN

4.3.1.11 Torque

Figure 24: Administration: Signal type torque

No. Designation Description

see cylinder pressure


Signal Name:
Example: TORQUE

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Parameterization of KiBoxCockpit

4.3.1.12 Universal

Figure 25: Administration: Signal type universal

No. Designation Description

see cylinder pressure


Signal Name:
Example: UNI

4.3.1.13 Crank Angle

Figure 26: Administration: Signal type crank angle with adapter

The high sampling rate of the KiBox makes it possible to measure angle marks with an
angle resolution of 0.1 °CA up to 15 624.9 rpm

Kistler crank angle adapter

No. Designation Description

Selects the encoder type used to detect movement of the


Encoder type: crankshaft.
Input range: Hall, inductive

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No. Designation Description

Number of pulses by the present encoder. This is directly


dependent on the pulse wheel geometry.
Input range: 12-1, 12-3, 20-2, 24-1, 24-2, 30-2, 36-1, 36-2,
36+1,
Number of
60-1, 60-2, 60-4, 90-1, 120-1, 120-2, 36-2-2, 36-2-2
angle marks:
(asymmetrical 22+2+10+2), 60-1-1, 60-2-2, 60+1+1, 36-2-
2-2, 60-1-1-1, 60-2-2-2
Note: For more than one gap, they must be arranged
symmetrically, except 36-2-2.

Inversion of the logical signal (required by a few pulse wheels);


the physical polarity can only be changed at the electrical
connection. This must be chosen so that the measured signal
Polarity:
sequence matches the illustration (shown below the
oscilloscope).
Input range: Signal inversion, no signal inversion

Manual input of the delay time of the vehicle's crank angle


sensor. This depends on the manufacturer and is required for
Delay time: the time compensation of the crank angle measurement chain.
Input range: 0s to 60s
Example: 7 s (hall); 22 s (inductive)

For the detection of the crank angle and engine speed, the falling
slopes of the encoder are used

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Parameterization of KiBoxCockpit

Figure 27: Administration: Signal type crank angle with optical encoder

Optical crank angle encoder

No. Designation Description

Input range: Kistler 2614B/C, AVL 365/720, 365/360 AVL,


Encoder type:
1200 Imp, 600 Imp

Number of
Number of angle marks of the selected transmitter type.
angle marks:

Display of the relevant edge of the angle mark signal.


Active Edge:
(No choice)

Edge of Display of the relevant edge of the trigger mark signal.


trigger pulse: (No choice)

Display of the number of angle marks currently recorded by the


No. of pulses
system. This must match the amount already specified by the
detected:
encoder type.

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4.3.2 Administration - Calculations

In the DefaultTemplate.kit all possible signal types and calculations are


already added and provided with default settings. These must be
updated for each particular application case.

Pressing the "Reset" button will return the default settings for the
currently selected signal type and calculation, even if there had
previously been no entry.

4.3.2.1 CDM and Trigger

Figure 28: Administration: Calculation of CDM and Trigger

No. Designation Description

Detected crank angle(degree) marks


Result name:
Example: CDM

Detected / determined Trigger


Result name:
Example: TRIG

4.3.2.2 Cycle Number

Reflects the incremental cycle number that is incremented at the end of a cycle from
the reference cylinder (at +360 °CA) to "1". It can be used mainly for navigation in the
measurement files.

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Figure 29: Administration: Calculation of cycle number

No. Designation Description

Cycle number [-]


Result name:
Example: CYCLE

4.3.2.3 Digital State and Position

Figure 30: Administration: calculation of digital state and position

No. Designation Description

Logical value
Result name:
Example: DIN_STATE

Position of the digital transition (°CA)


Result name:
Example: ADIN_TRANS

4.3.2.4 Heat Release

The calculation of the heat release is performed without taking into account the wall
heat losses and with a constant polytropic exponent  (input value "calculation: Zero
point correction ").

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Figure 31: Administration: Calculation of heat release

No. Designation Description

Location of the start of combustion


Result name:
Example: AI05

Location of a user-defined conversion (mass fraction burned)


Result name:
Example: AI10

Location of the 50% conversion (mass fraction burned)


Result name:
Example: AI50

Mean value of the location of 50% conversion


Result name:
Example: AI50_AVG

Standard variation of the location of 50% conversion


Result name:
Example: AI50_STD

Location of the end of combustion


Result name:
Example: AI90

Combustion duration as the difference between start and end of


Result name: combustion
Example: BD

Integral heat release


Result name:
Example: I

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No. Designation Description

Value of the maximum conversion


Result name:
Example: QMAX

Location of the maximum conversion


Result name:
Example: AQMAX

Heat release
Result name:
Example: Q

Settings:

No. Designation Description

Calculation Input range: 0.5, 1 °CA


resolution: Example: 1 °CA

Moving
see above
average:

Calculation Input range: -59 to 179°CA (start value is less than end value!)
window: Example: -30 °CA (start)/90 °CA (end)

Definition of the conversion of start and end of combustion, as


well as an user-defined conversion.
Integral heat
Input range: 0 to 100%
release:
Example:5% (start of combustion)/ 10% (user-defined
conversion)/ 90% (end of combustion)

Statistics
see the indicated mean effective pressure
window:

Selecting a calculation method


Algorithm:
Input range: 1. law of thermodynamics, Rassweiler

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4.3.2.5 Ignition Timing

Figure 32: Administration: Calculation of ignition timing

No. Designation Description

Location of the ignition time [°CA]


Result name:
Example: AIGN

Calculation
Input range: 0.1 °CA (fix)
solution:

Calculation Input range: -90 to 60 °CA (start value is less than end value!)
window: Example: -60 °CA (start)/40°CA (end)

4.3.2.6 Indicated Mean Effective Pressure

This calculation determines the indicated mean effective pressure, whose shares in the
high-pressure and gas exchange area as well as some of the related statistical values.

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Figure 33: Administration: Calculation of mean effective pressure

No. Designation Description

Indicated mean effective pressure (IMEP)


Result name:
Example: IMEPN

Gross IMEP for 4-stroke engines


Result name:
Example: IMEPH

Average value of the IMEP over a certain number of cycles


Result name:
Example: IMEPN_AVG

Standard deviation of the IMEP over a certain number of cycles


Result name:
Example: IMEPN_STD

Variant coefficient of the IMEP over a certain number of cycles


Result name:
Example: IMEPN_COV

Pumping loop of the IMEP for 4-stroke engines


Result name:
Example: IMEPL

Average value of gross IMEP for 4-stroke engines over a certain


Result name: number of cycles
Example: IMEPH_AVG

Standard deviation of the gross IMEP for 4-stroke engines over


Result name: a certain number of cycles
Example: IMEPH_STD

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No. Designation Description

Variant coefficient of the gross IMEP for 4-stroke engines over a


Result name: certain number of cycles
Example: IMEPH_COV

Torque calculated from the indicated mean effective pressure


Result name:
Example: TRQIMEP

Settings:

No. Designation Description

Calculation Performed crank angle resolution for the calculation of the IMEP.
resolution: Input range: 0.1; 0.2; 0.5; 1 °CA

Moving
see above
average:

Number of cycles with which the calculation of the statistical


signals of the indicated mean effective pressure is performed. If
the number of available cycles in the measurement is smaller
Statistic
than the number in the statistics window, all available cycles are
window:
included in the statistical analysis.
Input range: 5 to 500 cycles
Example: 30 cycles

The calculation method for determining calculation ranges of


IMEPH and IMEPL is selected here
Algorithm:
Input range: BDC-BDC method, pV diagram intersection point
method

Crank angle range for which the indicated mean effective


Calculation
pressure is calculated.
window:
Input range: –360 to 360 °CA, –540 to 180 °CA

The IMEP result to be used to calculate the indicated torque is


Torque based
selected here.
on:
Input range: IMEP net (total), IMEP gross

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4.3.2.7 Injection Timing Diesel

This calculation reflects the injection timing and duration of each number of injection
for diesel engines, including pre-, main- and post-injections. The number of pre- and
post-injections are numbered beginning with "1" and each attached to the calculation
names (..._#). As the main-injection, the longest injection process is defined.

Figure 34: Administration: Calculation of injection timing diesel

No. Designation Description

Location of the start of pre-injection [°CA]


Result name:
Example: INJ_PRE_S

Duration of injection [°CA]


Result name:
Example: INJ_PRE_D

Location of the start of the main injection [°CA]


Result name:
Example: INJ_MAIN_S

Duration of main-injection [°CA]


Result name:
Example: INJ_MAIN_D

Location of the start of the post-injection [°CA]


Result name:
Example: INJ_POST_S

Duration of the post-injection [°CA]


Result name:
Example: INJ_POST_D

Settings:

No. Designation Description

Calculation Input range: 0.1 °CA (fix)

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resolution:

Calculation
see injection timing gasoline
window:

Defines the counting sequence to be listed in the pre-and post-


injections.
Pre injection
Input range: 1-2-3-M-1-2-3, 3-2-1-M-1-2-3 (M stands for
numbering:
main-inj.)
Example: 1-2-3-M-1-2-3

Maximum no Determines the maximum expected number of pre-and post-


of pre/post- injections.
injections to Input range: 0 to 5 (pre-injections), 0 to 4 (post-injections)
be detected: Example: 2 (pre-injections), 1 (post-injection)

4.3.2.8 Injection Timing Gasoline

This calculation gives the injection timings and durations of each number of injections
for gasoline engines. The number of injections depends on the signal automatically
detected (max 10) numbered beginning with "1" and each attached to the calculation
name (..._#).

Figure 35: Administration: Calculation of injection timing gasoline

No. Designation Description

Location of the start of injection [°CA]


Result name:
Example: INJ_SOI

Duration of injection [°CA]


Result name:
Example: INJ_DU

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No. Designation Description

Duration of injection [s]


Result name:
Example: INJ_TI

Settings:

No. Designation Description

Calculation
Input range: 0.1 °CA (fix)
resolution:

Input range: -719.9 to 359.9 °CA (start value is less than end
Calculation value, with overlapping cycles of injection time detection the
window: range may not exceed a total of 720 °CA!)
Example: -360 °CA (start)/359.9 °CA (end)

Determines the maximum amount of expected injections per


Number of
combustion cycle.
expected
Input range: 0 to 10
injections:
Example: 10

4.3.2.9 Knocking

Figure 36: Administration: Calculation of knocking

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No. Designation Description

Knock frequency: displays the percentage of all observed cycles


Result name: in which knocks were detected.
Example: KFRQ

Knock peak: displays the maximum value of the high-pass


Result name: filtered pressure signal.
Example: KPEAK

Knock ratio: displays the ratio of the integrals of the high-pass-


filtered cylinder pressure profile in the area after "PMAX+Offset"
Result name: and before "PMAX+Offset" ("knock integral"/"reference
integral").
Example: KRAT

Knocking integrated: the high-pass-filtered cylinder pressure


Result name: profile after PMAX+Offset ("knock integral")
Example: KINT

Statistical knock amplitude after exclusion of anomalies for the


Result name: cycles observed.
Example: KPEAK_STAT

Settings:

No. Designation Description

Resolution of the crank angle that will be used to perform the


Calculation
calculation.
resolution:
Setting range: 0.1 °CA (fixed)

Rolling
see above
average:

Specifies the range around the max. pressure, including offset,


in which knock detection takes place.
Input range before max. pressure: 10 to 60 °CA
Calculation
Input range after max. pressure: 10 to 100 °CA
window:
Offset input range: -10 to 10 °CA ("-" corresponds with before
max. pressure)
Example: 30 °CA (before)/30 °CA (after)/-4 °CA (offset)

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No. Designation Description

Detection Determination of the detection method.


method: Input range: Siemens VDO (temporarily fixed)

Determines the sensitivity of knock detection. This value is


compared with the knock ratio (KRAT) to determine whether the
analyzed cycle is detected as knocking or not. This value
Knock factor:
therefore influences the knock frequency (KFRQ).
Input range: 1.01 to 3
Example: 1.5

Specifies the number of cycles in which knock frequency is


Statistic determined.
window: Input range: 20 to 2000 cycles
Example: 50 cycles

Specifies the percentage threshold used to exclude anomalies in


Knock peak knock peak statistics.
statistic E.g. 98% of 100 cycles observed: This means that the two cycles
threshold: with the highest KPEAK values will be excluded and the third
highest KPEAK value will be given as the KPEAKSTAT result.

For more information on knocking detection algorithm: see Knocking in the Appendix.

4.3.2.10 Maximum

This calculation enables a determination of the maximum value of a signal and its
crank angle position within a cycle.

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Figure 37: Administration: Calculation of maximum

No. Designation Description

Result name: Location of the maximum in the crank angle range

Result name: Value of the maximum

Result name: Average of maximum value

Result name: Standard deviation of maximum value

Result name: Coefficient of variation of maximum value

Result name: Average of location of the maximum

Result name: Standard deviation of the location of maximum

Settings:

No. Designation Description

Calculation Input range: 0.1, 0.2, 0.5 and 1 °CA


resolution: Example: 0.1 °CA

Moving
see above
average:

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No. Designation Description

Specifies the area in which the calculation of the maximum


takes place.
Calculation
Input range: -359.5 to 359.4 °CA (start value is less than end
window:
value!)
Example: -30 °CA (start) / 60 °CA (end)

Number of cycle count for statistical calculations of maximum.


In case of a smaller number of available cycles than setup in
Statistic statistic window, all cycles of the measurement are used for the
window: statistic calculation.
Input range: 5 to 500 cycles
Example: 30 cycles

4.3.2.11 Maximum Rise

Figure 38: Administration: Calculation of maximum rise

No. Designation Description

Maximum rise per degree crank angle


Result name:
Example: RMAX

Maximum rise per unit time


Result name:
Example: RMAXT

Crank angle location of the maximum rise


Result name:
Example: ARMAX

Vectorial sequence of the first derivative of the signal after the


Result name: crank angle
Example: PCYL_DER

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Settings:

No. Designation Description

Resolution of the crank angle at which the calculation is


Calculation
performed.
resolution:
Input range: 0.1 ° CA (fix)

Moving
see above
average:

Input range: -359.5 to 359.4 °CA (start value is less than end
Calculation
value!)
window:
Example: -30 °CA (start) / 60 °CA (end)

4.3.2.12 Mean Value

Figure 39: Administration: Calculation of mean value

No. Designation Description

Result name: Mean value

Settings:

No. Designation Description

Calculation
Input range: 0.1 °CA (fix)
resolution:

Input range: -360 to 359.9 °CA (start value is less than end
Calculation
value!)
window:
Example: -185 °CA (start)/-175 °CA (end)

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4.3.2.13 Noise

Figure 40: Administration: Calculation of noise

No. Designation Description

Noise: overall noise levels according to third-octave analysis.


Result name:
Example: CNL

Noise (CAV): the filtered value that shows the transfer of


Result name: combustion chamber pressure to airborne sound pressure.
Example: CNLCAV

Noise (dBA): the value filtered in accordance with the


Result name: sensitivity of the human ear.
Example: CNLA

Noise (CAV+A, dBA): combination of both filters.


Stands for the actual volume, which can be measured on the
Result name:
acoustic test bench using a microphone.
Example: CNLCAVA

Calculation Entry field for the structure damping alongside the relevant
table: third-octave center frequency.

Calculation
Input range: 0.1 °CA (fixed)
resolution:

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The noise calculator is intended primarily for tests carried out on diesel
engines.
The CNLA calculation is only used to provide a complete overview and
will therefore not give any results that can be used in practice.

Further information in Appendix.

4.3.2.14 Speed

Figure 41: Administration: Calculation of speed

No. Designation Description

Speed average per combustion cycle [e.g. rpm]


Result name:
Example: SPEED_AVG

crank angle resolved speed [e.g. rpm]


Result name:
Example: SPEED_HIRES

4.3.2.15 Zero point correction

When using piezo electric pressure sensors, the activation of a zero point correction is
absolutely necessary. The KiBoxCockpit provides three possible variants of the zero
point correction.
 Thermodynamic
 Intake pressure reference sensor
 Static value

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Figure 42: Administration: Calculation of zero point correction

No. Designation Description

Offset value of the change of the signal sequence, which is


Result name: performed by the zero point correction.
Example: PCYL_OFFS

Thermodynamic settings:

A basic distinction in the thermodynamic zero point correction is made between


gasoline and diesel engines. Detailed information on the thermodynamic zero point
correction can be found in the appendix. (Chapter: Thermodynamic zero point
correction)

No. Designation Description

Determination of the left support point


1st reference
Input range: -356 To 355.9 °CA
location:
Example: -100 °CA

2nd Determination of the right support point


reference Input range: -356 To 355.9 °CA
location Example: -65 °CA

Entry of the present polytropic exponent of the cylinder charge


Polytropic in the analysis area.
exponent: Input range: 1.25 to 1.5
Example: 1.33 for gasoline engine / 1.37 for diesel engine

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No. Designation Description

Smoothing (see Chapter: Administration)


Moving
Input range: ± 0 to ± 5 °CA
average:
Example: ± 4 °CA

Reference sensor intake pressure settings:

No. Designation Description

Crank angle position at which a comparison with the signal of


the reference pressure sensor should be made.
Location:
Input range: -355 To 354.9 ° CA
Example: -175 ° CA

Moving
see above
average:

Static value settings:

No. Designation Description

Crank angle position at which a comparison with the assumed


constant value should be made.
Location:
Input range: -355 To 354.9 °CA
Example: -175 °CA

Moving
see above
average:

4.3.3 User Formula


With the help of the User Formula, the calculations implemented standard in the
Cockpit can be extended to meet user requirements. The user has the option of
creating his own calculations and, for example, displaying them in the measurement
environment and saving them in the open-file.
A new formula can be created by right-clicking the "Formulas" node and selecting "Add
Formula" (see Figure 43). By default, a new formula with the name "Formula1" is added.

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Figure 43: Administration: User Formula

No. Name Description

Formula Definition of the formula name. Formula name "Formula1" is


Name: created by default.

The user has the option of storing a description for the formula.
Description: This allows for a quick overview of the calculation processes of
the formula.

Under "Formula inputs" the name of the input variables can be


freely defined for the calculation window. These input variables
are assigned a scalar or vector signal at a later point in time in
Formula the "Signals" tab, for example, Pmax or Pcyl (see chapter
Inputs: 4.5.10).

By activating "Previous Cycle", the user can use the input signal
of the previous cycle for the calculation.

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No. Name Description

Definition of the variables that are used in the calculation


window.
A distinction is made here between the two data types "integer"
(whole number) and "number" (floating point number). Under
the "Size" column, the number of elements and, thus, the size of
Formula the vector is defined. In the "Value" column, the variables are
Variables: assigned an initial value. For a variable with a number of
elements greater than 1, the values are assigned in the
calculation window (for further information, see chapter 4.3.3.1.
The "Formula Variables" are global variables. If the value of
these variables is changed in the calculation window , this
value is then available in the next cycle.

The output variables (result variables) can be defined under


"Formula Output". Select here between the "Scalar" and "Vector"
types. Under "Output Name", the names are specified that are
used in the calculation window as result variables. In the second
column, "Default Signal Name", the user can specify the
Formula designation of the calculated signals. The signal then appears in
Output: the measurement environment and in the open-file under this
name. The "Output Name" and the "Default Signal Name" must
not be the same.

In addition, the default unit of the output variables can be set in


"Formula Output".

Special text editor that the user can use to implement his
Calculation calculation. The already defined input variables, formula
window: variables and output variables can be used here. The formula
syntax is explained in chapter 4.3.3.1.

With the "Validate" button, the formula can be verified before it


Validate: is added in the "Signals" tab. Syntax errors are displayed in a
message window.

The formula can be exported by right-clicking on the formula name in the structure
tree . In this way the formula can, on the one hand, be stored separately and, on the
other hand, imported into a different kip file with little effort. This is performed by
right-clicking on the "Formulas" node and then selecting "Import Formula".

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The change in the unit for the output variables may affect the calculated
values. (See chapter 4.3.3.1).

In the calculation window, the decimal places of a decimal number are


always separated by a decimal point in accordance with the formula
syntax. In the "Formula Variables" area, this is dependent on the
number format that is set in the Cockpit. In the German number
system, the decimal number is separated by a comma.

Protecting the User Formula


In the password-protected Administration area, the content of a formula and, thus, the
know-how, can be protected. The password is specific to each parameter file here and
can be changed as explained in chapter 4.3.

4.3.3.1 Formula-Syntax

The formula syntax of the User Formula is based on the Matlab programming language
and was developed to give the user the opportunity to create special, engine-specific
calculations and signals. It is noted here that the scope of functions already
implemented in the User Formula does not correspond to the scope available in
Matlab. All functions of the User Formula are shown in the table below. It can be seen
here that self-developed functions were also integrated in order to improve the
handling of the programming.
The calculations of the User Formulas are performed in the same way as the default
calculators in the KiBox. This has the great advantage that the user-specific User
Formula calculations are also real-time capable.
A created User Formula can be assigned to any cylinder or to the engine on the
"Signals" tab. Any signal that is allocated to a cylinder or the engine can then be used
as input variable for the User Formula (see chapter 4.5.10). A calculation over all
cylinders is not possible (e.g., engine average). This can, however, easily be realized in
post-processing or in application software, such as Inca.

As with the calculation of the calculators implemented standard (e.g.,


heat release), the calculation of the User Formula takes place on the
KiBox to enable real-time capability. Thus, the computing performance
is dependent on the overall parameterization and the operating point. A
parameterization that is too computationally intensive may therefore
cause the KiBox to enter an unstable state. As a result, it is not possible
to guarantee that every algorithm can be implemented in the User
Formula.

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Within the scope of a service offering, Kistler offers support in the


writing of code, development of algorithms or the performance
optimization of existing codes. For further information, please contact
the local Kistler sales staff.

Variables
In principle, all variables are to be handled as vectors, which can be assigned different
sizes. In the case of the "Formula inputs" variables, the size is dependent on the signal
that is assigned to these variables. In the case of a result, such as Pmax, the vector has
the size 1 and is addressed with index 1. If the input signal is a vector signal, the size
is dependent on the calculation window and the computing resolution. If, for example,
the heat release with a computing resolution of 0.5°CA and a calculation window of
30°CA before TDC to 90°CA after TDC is used as input variable, this vector has a size of
240, since the heat release has this number of values per cycle (one value from -30°CA
to +90°CA every 0.5°CA). If the value of the heat release is to be read out at position
0°CA, index 61 must thus be addressed.

The size of the "Formula Variables" is defined by the user as described in chapter
4.3.3. To point to a specific vector position, the position is written in parenthesis after
the variable. If the third element (third index) of the variable "Var" is to be five, it can
be written in the calculation window as follows:
Var(3) = 5;

Units
In the calculation window, the calculation is always performed in the Si system of units.
If, for example, the maximum pressure (Pmax) is used in the calculation window as
input signal, it is considered in pascal. Assuming this lies in the considered cycle at 80
bar, calculations are then performed with 80 ∗ 105 Pa. If 10 bar is to be added to the
result Pmax, 10 ∗ 105 must thus be added to this signal.
If no unit "-" is defined for the "Output variable", the output value is given in the
corresponding Si unit. In the above example, this would be 9,000,000. It would,
however, make sense here to set the "Pressure" unit. In this case, the value of the
output variable is converted to the given unit set by the user under Layout properties.
The layout properties can be found in the Cockpit under "Edit" -> "Layout properties" -
> "Units" (see Figure 44). In this example, the "Pressure" unit is set to bar, whereby the
output variable in the above example was divided by 105 , with 90 bar thus appearing
as the result.

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Figure 44: Layout properties (definition of units)

Syntax
Described in the following is the syntax of the User Formula, which was implemented
on the basis of Matlab.

Arithmetic operators Calculation functions


Addition + Square root sqrt(x)
Subtraction - Exponential function exp(x)
Multiplication * Logarithm (natural) log(x)
Division / Base 10 logarithm Log10(x)
Equal sign = Trigonometric sin(x), cos(x),
function tan(x)
Parenthesis () Modulo mod(x,y)
Power of ^ Absolute value abs(x)
𝝅 pi Rounding round(x)
Greater / less than sign > / <
Greater or equal / >= /
less or equal <=

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Control structures
For loop for i=1:10
Do something;
end
If instruction if logical expression
Do something;
end
If/Else instruction if logical expression
Do something;
else logical expression
Do something;
end
If/ElseIf/Else instruction if logical expression
Do something;
elseif logical expression
Do something;
else logical expression
Do something;
end

Switch-Case instruction switch variable


case variable value 1
Do something;
case variable value 2
Do something;
otherwise
Do something;
end
While loop while logical expression
Do something;
end
Element at position i (first index begins x(i)
with 1)

Manipulate element at position i x(i) = 10;

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Functions
Specifies the cycle number current_cycle()
Outputs the cylinder number assigned cyl_number()
to the calculator
Specifies the rotational speed speed()
Angle-based functions (in rad)
Time-angle relationship atr(x)
 returns the TimeSampleNumber for
each angle
 Example: After downsampling the
AnalogIn inputs, their sampling rate is
1
312500 , whereby 312500
𝑠
TimeSampleNumbers per second are
assigned

Comment: Together with the


"TimeSamplingRate" constant (see
below), the time can thereby be
determined at any crank angle.
Specifies the displacement of the cyl_displacement(eccentric angle) /
cylinder as a function of the eccentric cyl_displacement()
angle in 𝑚 . 3

If no eccentric angle is specified, the


calculation is performed without taking
it into account.
Specifies the displacement of the eng_displacement(eccentric angle) /
engine as a function of the eccentric eng_displacement()
angle in 𝑚 . 3

If no eccentric angle is specified, the


calculation is performed without taking
it into account.
Cylinder volume at point x vol(x, eccentric angle) / vol(x)
(x is an angle in rad)
If no eccentric angle is specified, the
calculation is performed without taking
it into account.
Derivative of the cylinder volume at vol_der(x, eccentric angle) / vol_der(x)
point x.
If no eccentric angle is specified, the
calculation is performed without taking
it into account.

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Constants
Converts an angle in units of degrees Deg2Rad
to rad
Converts an angle in units of rad to Rad2Deg
degrees
Specifies the sampling rate (e.g., TimeSamplingRate
1
Analog In = 3125000 )
𝑠
Specifies the length of a vector in x.Length
indices.

Example: If input variable "x" is


assigned cylinder pressure from -
360°CA to +360°CA, the length of this
vector is 7200 indices. As a result, the
cylinder pressure has a resolution of
0.1°CA.
Specifies the resolution of a vector in x.Resolution
rad
Specifies the start value of a vector in x.Start
rad
Specifies the index of a vector x at x.convertToIndex(y)
crank angle position y.
Returns the crank angle (in rad) of a x.convertToRad(y)
vector x at index position y.

Engine constants
Specifies the cylinder bore in meters BORE
Specifies the conrod length in meters CONROD
Specifies the number of strokes (2 or ENG_TYPE
4)
Specifies the number of cylinders NUM_CYLS
Specifies the cylinder number of the REF_CYL_NUMBER
reference cylinder
Specifies the stroke STROKE
Engine constants (cylinder-related)
Specifies the compression ratio of COMP_RATIO(x)
cylinder x
Specifies the crank offset of cylinder x CRANK_OFFSET(x)
Specifies the firing distance of cylinder FIRING_DIST(x)
x relative to the previously ignited
cylinder

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Specifies the firing distance of cylinder FIRING_DIST_REFCYL(x)


x relative to the reference cylinder
Specifies the firing order of cylinder x FIRING_ORDER(x)
Specifies the piston pin offset of PIN_OFFSET(x)
cylinder x

The "Formula Inputs" signal inputs are generally addressed with a one-
based vector syntax. Scalar signal inputs (results) are considered to be
vectors of length 1. With vectorial input signals, there are
correspondingly more indices. The cylinder pressure with a resolution
of 0.1°CA and a representation range of ±360°CA thus has 7200
indices. The number of indices of a vector is, thus, dependent on the
resolution and the representation range (note multi-cylinder function!).

Note that the User Formula calculates using the generally valid
international system of units (SI units). If no unit "-" is specified under
Default Units, the output is then in SI units (e.g. rad , Pa,…). If a unit is
selected, a conversion of the SI unit to the units set under "Edit" ->
"Layout properties" -> "Units" is performed.

The formula created under "Administration" is then assigned to either a cylinder or to


the engine in the "Signals" tab. At this point, the "Formula Inputs" of the User Formulas
likewise allocated a signal. The corresponding procedure is described in chapter
4.5.10. A number of examples intended to provide better understanding of the
implementation of a User Formula can be found in the appendix in chapter 9.8.

4.3.4 Administration – Channels


In the "Channels" area, the physical channels that are actually available can be divided
into virtual channels. It is therefore possible to deconstruct a multiplexed signal
containing information from several cylinders in one physical channel into its original
component parts within the system. This signal can then be assigned to the
corresponding cylinder as an individual signal for the measurement.

Example 1:
An intake manifold pressure signal recorded by a sensor in the manifold. It contains
information for all of the cylinders connected to the manifold. When an intake pressure
signal is used to correct the zero point of a cylinder pressure signal, however, only the
range of the intake pressure signal used for the zero point correction (e.g., –175 °CA)
is important. It is therefore enough to subdivide the intake pressure signal into the
relevant number of cylinders, assign the respective range to the corresponding cylinder
as an intake pressure signal, and carry out the zero point correction with this.

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Example 2:
The signal from a current probe, which encompasses several control lines for different
injectors and therefore outputs their drive current profile as a signal. This type of
signal can also be subdivided into virtual ranges again as the combined cylinders (if
the cylinders have been combined intelligently in a probe) are only injected in certain
ranges (e.g., –180 °CA to 180 °CA). A corresponding signal section (virtual signal) can
be implemented for injection timing calculations (when connected to a current probe
input) or to evaluate the current signal profile (when connected to an analogIn) for all
cylinders included in this signal.

Example 3:
Combining a cylinder pressure signal from several cylinders in one signal. This can
then be divided into the corresponding ranges in which combustion takes place in the
respective cylinder and used as a virtual cylinder pressure signal in the system. As a
result, all calculations in the KiBox which do not require the full combustion cycle, such
as the indexed mean effective pressure, are available. This means that knocking, for
example, can be analyzed or the PMAX can be monitored, even for more than 8
cylinders.

Configuring Virtual Channels

Figure 45: Administration - Channels: Configuration overview

The tree structure under "Administration – Channels" displays all of the available
physical signal input channels in the KiBox hardware. It is divided up into the 8 analog
and 8 digital inputs, and the 2 current probes.
Each of these channels can be subdivided into any number of virtual channels. The
ranges can be selected at will and can even overlap one another if necessary. Each
divided range, i.e, virtual channel, must be defined with a start and an end in the angle
range and must be given a channel name. The start and end must be between –
720 °CA and +720 °CA. The limits can be a maximum of 720 °CA apart, which

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corresponds to the complete physical signal. The angle position refers to the TDC
which has already been set and which, in turn, refers to the reference cylinder.

Oscilloscope

The oscilloscope is used to help with configuration and marks the start and the end of
each configured virtual channel with a vertical green line.
In the oscilloscope, signals can only be displayed after the engine parameters have
been entered.
For physical signals connected to one of the two current probe inputs, it is possible to
select whether the digitalized injection or ignition pulse signals or the analog input
signal is displayed in the oscilloscope. However, the x-axis is only available in °CA for
the digitalized signals. If the digitalization is not activated for the preview in the
oscilloscope ("Off" selected), the physical input signal is only available on a time basis –
it is only present so that the physical signal can be checked. The green limit lines are
not displayed. The digitalized signals can only be displayed in a useful way after the
thresholds have been configured in "Administration – Injection and ignition pulse
signal types".
For physical signals connected to an analogIn or an amplifier, it is possible to choose
between the amplifier input or connection to the TopConnector ("Top connection"
active) for the preview.
Physical signals on one of the digital inputs can be inverted in the preview.
If no cylinder pressure signals have been configured previously, a phase shift may need
to be carried out to ensure that the angles are assigned correctly (with the F4 button or
the icon in the tool bar).

Virtual Signals

All of the configured virtual signals/channels under "Administration – Channels" are


available as individual, independent channels in the "Signals" area. They can then be
freely assigned to the corresponding cylinders here.

To get a better overview of the signal configuration under Signals, we


recommend using the corresponding cylinder number in the name
when defining the virtual signal.

If a physical signal is not connected to a TopConnector but to an


internal plugged amplifier, all virtual channels derived from this must
have the same sensor settings. These are configured in the "Signals"
area.

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A configuration example for a real application – the division of two current probe
signals for injection timing calculations for a four-cylinder engine – can be found in
the Appendix under Configuration Example for Using Virtual Channels.

4.4 Engine

Figure 46: User interface of navigation button engine

Engine type:

No. Designation Description

Any assigned engine name


Engine name:
Example: KiBoxDemo

Description of the number of strokes per combustion process


Engine type: Input range: 2-stroke, 4-stroke
Example: 4-stroke

Specifying the type of engine


Fuel: Input range: Gasoline/CNG/LPG, Diesel
Example: Diesel

Specifying the total number of cylinders in the engine (not just


the number of cylinders indicated)
Number of
Input range: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, 16, 18, 20,
cylinders:
22, 24
Example: 4

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No. Designation Description

Selection of the reference cylinder, to which other specifications


Reference are referred (e.g. firing order, TDC position ,...).
cylinder: Input range: 1 to number of cylinders
Example: 1

Geometry:

The definitions of the following quantities can be extracted from the drawing on the
right side of the interface.

No. Designation Description

Double crank length


Stroke s: Input range: any [mm]
Example: 82 mm

Input of the hole diameter of the cylinder bore


Bore d: Input range: any [mm]
Example: 73.70 mm

Indication of the conrod length


Conrod
Input range: any [mm]
length l:
Example: 126.8 mm

Specification for the offsetting of the piston pin to piston


Piston pin center plane for each cylinder
offset e: Input range: 0 to half the bore diameter [mm]
Example: 0 mm

Specifies offset from crankshaft axis to the cylinder axis per


cylinder
Crank offset f:
Input range: any [mm]
Example: 0

Specification of the compression ratio (epsilon) per cylinder


Compression
Input range: 5 to 20 (gasoline), 10 to 30 (diesel); [-]
ratio:
Example: 17.2

Entering the firing order starting with the reference cylinder


Firing order: Input range: 1 to cylinder number
Example: 1-3-4-2

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No. Designation Description

Specification of the TDC crank angle offset relative to the


immediately previous firing cylinder (reference cylinder = 0 is
TDC interval: set fixed)
Input range: 0 To 719.9 °CA
Example: 0-180-180-180

Display of calculated displacement from the geometric


Calculated specification of the reference cylinder and the total engine
displacement: (used for checking the entries made).
Example: 0.350 l (reference cylinder), 1.399 l (total engine)

Alternative Volume Function (AVF):

An alternative volume function can be used in the "Expert" user level (Options: User
Level). This function is primarily intended for the use of engines that are able to vary
compression ratio whilst in operation using a control variable (e.g. an eccentric angle).
However, a completely free volume geometry can also be used. Doing so will require
ASCII files that show the characteristic diagrams for both the volume function and the
correction angles for position-based results (e.g. 50% offset position) depending on
the crankshaft and the adjustment parameter (eccentric angle).

Figure 47: Expert Level: alternative volume function

No. Designation Description

Use
alternative
Check box to activate the use of the alternative volume function
volume
function:

Load volume
Opens window to browse to volume ASCII file
ASCII file:

Load offset
Opens window to browse to offset ASCII file
ASCII file:

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No. Designation Description

Eccentric
angle, Manual entry of the eccentric angle (° eccentric angle)
constant:

The most up-to-date eccentric angle is taken from the


Eccentric
AVF_EA_AVG result. This will only be possible if the eccentric
angle, from
signal and the average value calculation are activated under
signal:
both Administration and Signals.

Cylinder
displacement, Manual entry of a constant cylinder displacement [cm³]
constant:

Cylinder
The cylinder displacement is calculated according to the volume
displacement,
function in use at the time.
calculated:

The ASCII files for the volume function and the offset characteristic diagram must be
configured as follows:
The first column must contain at least the crank angle reference points -360 °CA to
359.9 °CA (increment of 0.1 °CA).
The first row must include the used eccentric angle reference points, between 0° and
180°. An increment of no less than 5° and no greater than 180° will be accepted here. A
first value of 0° and a last of 180° is not necessary.
The volume must be entered in cm³ and the offset in °CA.
The decimal separator must be used according to the KiBox Cockpit language setting,
as with other entries.
The system applies linear interpolation between the given reference points. If the
signal value for the eccentric angle is outside the reference points, the volume or offset
function of the lowest resp. highest given angle is used when using the eccentric angle
from the signal.
Otherwise, the relevant volume function is taken from the table during a cycle in real-
time, depending on the contiguous eccentric angle (manually entered or taken from
signal), and is used directly in calculations. The appropriate offset value is added for
position-related results.

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Figure 48: Example for volume asii file

4.5 Signals

Here you define which types of signals are picked up from the "Administration" and
recognized as actual signals to the available hardware channels. A distinction is made
among the assignments "cylinder" and "motor".
The heading "cylinder" can be defined in accordance with the multiple assignments of
cylinders in "Administration". All types of cylinder signals are built exactly the same,
but can be configured individually. The name is set at the administration level. There
are all signal types may be defined in the administration level.

Signals can only be added that have already been defined in


"Administration".

Signal types can be added to the same cylinder several times. An


additional capital letter is then attached to the signal for unique
identification.
Example: PCYL_1, PCYL_A_1, PCYL_B_1

Signals that generally apply to the entire engine, are usually assigned to the engine
(e.g.: SPEED_AVG, CYCLE)

Using Virtual Channels

When virtual channels are used as a signal, all of the calculations


defined in the "Administration" area are also carried out for the virtual
channel. The calculation ranges must be adjusted to the ranges
available in the virtual signal in the "Administration" area.

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Channel Selection

The channel must be selected for every signal to be recorded. The option to do this is
available in every signal type dialog. All virtual channels are available. By default, every
physical channel under "Administration – Channels" is pre-configured as a virtual
channel for the entire combustion cycle (–360 ° to +360 °CA).
In every drop-down menu, all signals that are suitable for the respective signal are
provided. Channels highlighted in gray are already in use in the system. To help the
user, the name, physical connection, and available configured range is displayed for
every channel provided.

Figure 49: Channel selection (AnalogIn, Current probe, DigitalIn)

Figure 50: Selecting divided virtual channels

Method:

By right clicking on the heading "cylinder" or "engine", a context sensitive menu is


opened, in which the signals can be added and deleted.
Some settings are hidden for a better overview. They are made visible by pressing the
button . After entries have been made, they can once again be hidden by pressing
the button .

4.5.1 Signal: Cylinder Pressure


Using these settings, based on the definitions of the administration, the ready defined
signal and its calculated results are returned. These are visible in the "signal pool 'on
the right side of the respective user interface.

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Figure 51: Signal: Cylinder pressure top connectors

Settings:

No. Designation Description

Selection of the channel connecting the corresponding cylinder


pressure sensor (number: Slot number, letter: Channel of the
Channel:
amplifier).
Input range: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B

Selection of the type of connection of the cylinder pressure


signal to the KiBox.
Connector:
Input range: Top connectors (Analog In, Time Compensation: 2
microseconds), Amplifier (time compensation: 0 microseconds)

Depending on the type of connection of the cylinder pressure signal, the further
necessary settings of the signal type vary.

Option: Top connectors

No. Designation Description

Input for the calibration factor for converting the voltage signal
Sensitivity: received from the sensor signal into a pressure value.
Input range: any [bar / V]

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No. Designation Description

Specifying an offset value which should be added to the signal


Offset: after converting to bar.
Input range: any [bar]

Designated type of sensor used.


Type:
Input range: any

Serial
Input range: any
number:

Mounting of the sensor used. The selection enables the filter


defined in the "Administration" area to the selected mounting.
Installation:
The group delay of the filter is fully compensated.
Input range: Direct mounting, spark plug, glow plug adapter

Option: Amplifier

Figure 52: Signal: Cylinder pressure amplifier input

No. Designation Description:

Selection of the type of sensor used


Sensor:
Input range: TEDS sensor, Non-TEDS sensor

Specifying the type of sensor used (only active if "Non-TEDS


Type: sensor" is chosen)
Input range: any

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No. Designation Description:

The serial number of the sensor used (only active if "Non-TEDS


SN: sensor" is chosen)
Input range: any

Mounting of the sensor used. The selection enables the filter


Installation: defined in the "Administration" area to the selected mounting.
Input range: Direct mounting, spark plug, glow plug adapter

Input of the sensitivity (necessary if you select "Non-TEDS


sensor"; after activating "manual input" the declaration is also
Sensitivity:
possible when using a TEDS sensor)
Input range: any [pC / bar]

Selection of the charge amplifier type


Type:
Input range: 5064B / 5064C

Enter the maximum expected cylinder pressure to set the


Range: measuring range of the charge amplifier.
Input range: any [bar]

Other settings:

No. Designation Description

All defined processes are available in the administration level.


Zero The use of a reference sensor signal is only possible in
Correction: connection with at least one definition of "intake pressure"
under the signals of the corresponding cylinder.

Transmission of the signal and all the calculations on the signal


Signal Pool: pool. (informative display of values defined in the
"Administration" area)

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Expert Mode:

The voltage range for the charge amplifier output can be modified in the Expert User
level.

Figure 53: Signal: cylinder pressure, Expert level:

Amplifier A selection can be made between -8V…+10V (standard)


output range: and 0V…+10V

4.5.2 Signal: Digital Signal, Injection Pulse Digital, Ignition Pulse Digital
This type of signal makes it possible to record digital signals (TTL: >4,5V high, <1V
low level). These signals are then transmitted, either by ECU or statically from a test
bench, in order to activate injectors or ignition, for example.

Figure 54: Signal: Digital Signal, Injection Pulse Digital, Ignition Pulse Digital

Settings:

No. Designation Description

Selecting the digital input of the relevant signal.


Channel:
Input range: DI1, DI2, DI3, DI4, DI5, DI6, DI7, DI8

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No. Designation Description

Inverted: Inverts the incoming digital signal

Signal pool: See Cylinder pressure

In order to prevent damage to the KiBox, the permissible voltage range


(max. ±30 V) must always be verified when using digital signals.

4.5.3 Signal: Eccentric Angle


This type of signal can detect an adjustment parameter on the engine (e.g. eccentric
angle for adjusting the compression ratio), which has an effect on the engine geometry
and therefore on the volume function.

Figure 55: Signal: Eccentric angle

Settings:

No. Designation Description:

Selection of the analog input of the corresponding torque


Channel: signal.
Input range: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B

Filter Selection of the filter frequency to be used.


frequency: Input range: Off, 5, 10, 15, 20, 25, 30, 35, 40 [kHz]

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No. Designation Description:

Signal Pool: see cylinder pressure

Sensitivity: Input range: any [°/V]

Offset value to be added to the converted signal.


Offset:
Input range: any [°]

Type: Input range: any

Serial
Input range: any
number:

4.5.4 Signal: Injection Pressure

Figure 56: Signal: Injection pressure top connector

Settings:

No. Designation Description:

Selection of the connector of the corresponding injection


Channel: pressure sensor.
Input range: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B

Selection of connection type of the injection pressure signal to


the KiBox.
Connector:
Input range: Top connectors (analog in), amplifier input
(inactive)

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Option: Top connectors

No. Designation Description

Input of the calibration factor for converting the voltage signal


Sensitivity: received from the sensor signal into a pressure value.
Input range: any [bar / V]

Specifying an offset value which should be added to the signal


Offset: after converting to bar.
Input range: any [bar]

Designated type of sensor used.


Type:
Input range: any

Serial
Input range: any
number:

Other settings

No. Designation Description

Select the desired frequency with which the injection pressure


Filter
signal should be filtered.
frequency:
Input range: From, 5, 10, 20, 25, 30, 35, 40 kHz

Realtime
see injection pulse
Oscilloscope:

Signal Pool: see cylinder pressure

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Option: Amplifier

Figure 57: Signal: Injection pressure amplifier input

No. Designation Description:

The type of sensor used is selected here


Sensor:
Input range: TEDS sensor, non-Kistler TEDS

Specifies the type of sensor used (only possible when "non-


Type: Kistler TEDS" is selected)
Input range: Any

Specifies the serial number of the sensor used (only possible


SN: when "non-Kistler TEDS" is selected)
Input range: Any

The sensor measuring range is entered here (required when


"non-Kistler TEDS" is selected, also possible when using a TEDS
Range:
sensor when "manual input" is selected)
Input range: Any [bar]

The reference current used for the sensor is entered here


(required when "non-Kistler TEDS" is selected, also possible
Ref. current:
when using a TEDS sensor when "manual input" is selected)
Input range: 1, 4 [mA]

The sensitivity of the sensor is entered here (required when


"non-Kistler TEDS" is selected, also possible when using a TEDS
Sensitivity:
sensor when "manual input" is selected)
Input range: Any [mV / (mA*bar)]

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No. Designation Description:

The sensor offset in the zero point is entered here (bridge


ZMO: voltage of the sensor in a vacuum)
Input range: Any [mV]

The type of amplifier used is selected here


Type:
Input range: 4665B

The zero point offset of the output signal when the


Output amplification factor is adjusted automatically to increase the
offset: measurement resolution.
Input range: 0, –8, –10 V

An offset is entered here to correct the signal (e.g., in the event


Offset
of a thermal load)
correction:
Input range: Any [bar]

Expert View:

With the Expert user level, additional settings can be used.

Figure 58: Signals: Injection pressure – Expert level

No. Designation Description:

The option to correct a systematic error of the sensor. The


corresponding value can be taken from the calibration sheet
Terminal
(mostly only required and available for injection pressure
linearity:
sensors).
Input range: –3 to +3 [%FS]

The digital temperature compensation can be


Temp. comp.:
activated/deactivated if the connected sensor supports this.

Other settings

No. Designation Description

Select the desired frequency with which the injection pressure


Filter
signal should be filtered.
frequency:
Input range: From, 5, 10, 20, 25, 30, 35, 40 kHz

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No. Designation Description:

Realtime
see injection pulse
Oscilloscope:

Signal Pool: see cylinder pressure

4.5.5 Signal: Injection/Ignition Pulse

Figure 59: Signal: Injection / Ignition pulse

No. Designation Description:

Selection of the channel connecting the corresponding current


Channel: probe.
Input range: 1, 2

Control of the connected signal. The display can be stopped by


Real-Time
clicking the stop icon at the bottom right border of the
Oscilloscope:
oscilloscope. All zooming functions are supported.

Signal Pool: see cylinder pressure

The setting of the oscilloscope display area has no influence on the


subsequent measurement.

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4.5.6 Signal: Intake Pressure/ Exhaust Pressure

Figure 60: Signal: Intake pressure

Settings:

The parameterization of the intake pressure or the exhaust pressure is analogous to


that of the injection pressure. For the intake pressure an additional setting of using a
zero point correction is needed.

No. Designation Description:

Definition of the zero point correction, which is to be used for


Zero this intake pressure signal. Defining the process of the zero
correction: point correction by a constant value is available in
"Administration".

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4.5.7 Signal: Torque


This type of signal can be assigned either to the individual cylinders or the entire
engine.

Figure 61: Signal: Torque

Settings:

No. Designation Description:

Selection of the analog input of the corresponding torque


Channel: signal.
Input range: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B

Filter Selection of the filter frequency to be used.


frequency: Input range: Off, 5, 10, 15, 20, 25, 30, 35, 40 [kHz]

Signal Pool: see cylinder pressure

Sensitivity: Input range: any [Nm/V]

Offset value in Nm to be added to the converted signal.


Offset:
Input range: any [Nm]

Type: Input range: any

Serial
Input range: any
number:

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4.5.8 Signal: Universal

Figure 62: Signal: Universal

No. Designation Description:

Selection of the analog input of the corresponding signal.


Channel:
Input range: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B

Enter the unit of the universal signal.


Unit:
Input range: A, bar, °C, dB, J, m, N, V, W

Sensitivity: Input range: any [selected unit / V]

Specifying an offset value which should be added to the


Offset: converted signal.
Input range: any [unit selected]

Filter Selection of the filter frequency to be used.


frequency: Input range: Off, 5, 10, 15, 20, 25, 30, 35, 40 [kHz]

Realtime
see injection pressure
oscilloscope:

Signal Pool: see cylinder pressure

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4.5.9 Signal: Crank Angle


In the area signal crank angle, no adjustments are necessary. These are fully defined in
the administration section. All existing fields around are display only fields.

Figure 63: Signal: Crank angle

No. Designation Description:

Display of currently counted pulses by the pulse wheel sensor.


Number of
In case of multiple triggers (gaps / additionally teeth), for every
pulses
range between the triggers, the detected pulses will be
detected:
displayed separately.

Signal Pool: see cylinder pressure

4.5.10 Signal: User Formula


Right-click on the respective section and select the "Add Formula" command to add
formulas both to the cylinders as well as to the engine. It is possible to assign all
signals that are calculated under this cylinder or engine to the "Formula Inputs" input
variables of the User Formula. The output variables (Formula Output) that are
calculated in the User Formula can then be used in the accustomed manner in the
statistic, diagrams and data output.

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Figure 64: Signals: Formula

No. Name Description

After adding the formula, it appears under the selected heading


Menu: (here: Cylinder 1) with the formula name assigned in
Administration

Shown in the signal pool are all signals and calculations that
result from the signals and formulas that were assigned to the
Signal pool:
heading (here: Cylinder 1). These can be used as input signals
for the User Formula.

The "Input Signals" area is divided into three columns:

Input Name: Here, the names of the input variables used in the
formula are stored automatically.
Input Signals: Signal: Here, the user can use drag & drop to insert the input
signal from the signal pool .

Type: Under "Type" the structure of the input signal is defined


automatically (scalar or vector)

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No. Designation Description:

In the "Output Signals" area, the signal calculated in the User


Formula is characterized.

Output Name and Signal Name: These two fields are


automatically filled according to the names defined by the user
in Administration. The signal name can, however, be changed
Output here again.
Signals:
Unit: Here, the user can define the unit of the output signal

From … To °CA: Definition of the range in which a vector signal


is to be displayed.

Resolution: Here, the resolution with which the output signal is


to be returned can be entered.

The setting of the output variables affects the number of indices of the
vector. This must be taken into account when implementing the User
Formula. An example can be found in the appendix in chapter 9.8.2.

The unit used in the Output Signals area affects the size of the
calculated value or signal (see chapter 4.3.3.1).

Explained in the appendix by way of an example is the implementation of a User


Formula, from the creation in the Administration area to the integration of the formula
in the "Signals" area. (chapter 9.8).

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4.6 Statistic: General Statistical Calculations From Results

The "Statistics" area is used to configure general statistics parameters from the
existing results. This means that predominantly statistical evaluations can be carried
out for results which are not a predefined part of a calculation (e.g., IMEPL_AVG).

Figure 65: Configuration for calculating general statistics results

Approach:
All available results can be moved from the signal pool to the table area at will using
drag and drop. Next, the number of cycles needed for the statistical calculation and
the statistical values for the respective result must be selected. The following statistical
values can be selected: Average, minimum, maximum, standard deviation, and
coefficient of variation. As soon as a statistical value is selected, the corresponding
result appears in the signal pool of the statistical results on the right. These signals are
subsequently available and can be used in all areas of the KiBoxCockpit in the same
way as the normal results (e.g., for displaying and outputting data, etc.).

The general statistical calculations can also be applied to results that


have already been statistically determined, such as PMAX, whereby a
PMAX_MAX calculation is enabled, for example.

4.7 TDC: Determine The Position Of Top Dead Center

In this section, the settings and the actual implementation of the determination of the
top dead center (TDC) can be made. These always refer to the reference cylinder. Three
types for determining the TDC are available:
 Direct input of the differential angle (if it is already known)
 Transient determination from cylinder pressure(the differential angle must be
determined)
As a basis for further steps in connection with the TDC, the loss angle has to be
specified . Background information can be found under thermodynamic loss angle
in the appendix.

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 Transient determination with capacitive TDC probe

The determination of the TDC, can only take place in the non-fired
engine operation of good quality. Therefore, the reference cylinder
must be in coasting mode during the TDC-determination. This can
occur when driving downhill without pressing the accelerator, or by
disabling the injection at the reference cylinder.
If the TDC position of this engine is already known, it can also be
entered manually.

The angle difference found is only a relative angle and therefore cannot
be transferred to other systems or other measurement systems.

All angle input for the parameterization in the KiBoxCockpit (calculation


window, measuring points, etc.) always refer to the above method
determined TDC position of the reference cylinder. The TDC position of
the reference cylinder is fixed at 0° CA.

To ensure quality, the raw data used for TDC-finding can be saved as a
measurement file (*.open) (no zero-point corrected values).

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Figure 66: TDC: Current values

Current Values:

No. Designation Description:

Display of previously determined, or the specific input of the


TDC shift:
angular offset of the reference cylinder to TDC.

The smaller the value displayed, the more accurate the


Deviation:
calculated differential angle.

Due to different algorithms, only differential angles that have been


determined previously with the KiBox can be entered. When used in the
KiBox, a differential angle determined in another system can cause the
TDC to be assigned incorrectly.

Procedure for transient TDC determination from the cylinder pressure:

1. User input of the loss angle and the number of cycles to be used for determining
the TDC
2. Start TDC-determination (in coasting mode!): Cycles are recorded and mapped
3. If necessary, manually delete bad cycles
4. Display of the retrieved TDC position: calculated differential angle [°CA], and its
deviation [°CA]
5. Accept calculated TDC position

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Figure 67: TDC: From cylinder pressure

From cylinder pressure:

No. Designation Description:

Pressure Selection of pressure signal in case of more than one cylinder


signal: pressure signal for the reference cylinder.

Input of the thermodynamic loss angle


Loss angle:
Input range: any [°CA]

Start: Starts the TDC determination

Number of cycles that are evaluated to determine TDC


Number of
Input range: 5 to 50 cycles
cycles:
Example: 10 cycles

By pressing the Save button, the raw data of the TDC


determination is saved for quality assurance as an *.open File.
Save:
The choice of the location to save to results in the subsequent
dialog.

Current TDC
Display of the TDC-shift based on the last TDC-determination
shift:

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No. Designation Description:

By clicking on this button, the cursor changes to the selection


Delete bad mode. Thus, individual cycles in the display can be selected and
curves: deleted with a mouse click or the selection buttons. The
selected cycle is shown in white and bold.

With the selection buttons "next" and "prev" you can jump back
next and and forth between the individual cycles, select unsuitable cycles
prev. button: and then delete them. A selected cycle is shown in white and
bold.

Displays the differential angle determined by previous TDC


TDC shift:
calculation

Shows the quality of the previously determined differential


Deviation: angle. The smaller the value displayed, the more precise the
differential angle determined.

Absolute TDC
Calculated interval (angular ignition space) to reference cylinder
interval:

Relative TDC Calculated interval (angular ignition space) to previously ignited


interval: cylinder

By pressing this button, the TDC position found for the


Save new
reference cylinder is saved and applied for further calculations
TDC shift:
and evaluations.

Save new By pressing this button, the calculated angular ignition spacings
firing are transferred to the angular ignition spacing table in the
intervals: "Engine" area.

All recorded cycles of cylinder pressure curves will be displayed


Diagram:
in the diagram. Individual cycles can be deleted if necessary.

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Enter the loss angle (see Appendix: Thermodynamic loss angle) exactly
for the condition of where you want to later carry out the TDC-
determination, i.e., engine operating temperature, desired rotational
speed, and the position of the throttle (if present). Note that the testing
of the loss angle is very often used with a fully opened throttle and
switched off injection. But this is often not possible in the vehicle. The
loss angle for operation with the throttle closed is usually about 0.1 to
0.5 °CA greater than that for the operating point with fully opened
throttle.

Make sure that the rotational speed change is as small as possible


throughout the operation! This can be achieved most simply by a
descent in an appropriate gear.

If individual cycles with combustion are visible in the chart, you should
delete them from the calculation.

Figure 68: TDC: With capacitive TDC probe

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With Capacitive TDC Probe:

No. Designation Description:

Type of The type of probe used is selected here


probe: Input range: AVL 428, Kistler 2629

The channel to which the probe signal is physically connected is


Channel: selected here
Input range: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B

The cylinder in which the probe is mounted


Cylinder:
Input range: 1, …, n

The number of cycles evaluated to determine the TDC


Number of
Input range: 5 to 50 cycles
cycles:
Example: 10 cycles

Start: Starts the TDC determination

Pressing the Save button saves the raw data of the TDC
Save: determination as an *.open file for quality assurance. It is
possible to select where this should be saved in the next dialog.

Current TDC Displays the previous differential angle determined by a TDC


Shift: calculation

Clicking this button changes the cursor to selection mode. As a


result, individual cycles on the display can be selected and then
Delete:
deleted by clicking the selection buttons. The selected cycle is
displayed in white, bold font.

With the "forward" and "back" selection buttons, it is possible to


Forward and switch between the individual cycles. Unsuitable cycles can be
back button: selected and deleted. A selected cycle is displayed in white, bold
font.

Displays the differential angle determined by previous TDC


New TDC shift
calculation

Shows the quality of the previously determined differential


New TDC shift
angle. The smaller the value displayed, the more precise the
deviation:
differential angle determined.

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No. Designation Description:

By pressing this button, the new TDC shift is saved and applied
Apply:
for further calculations and evaluations.

All recorded cycles of cylinder pressure curves will be displayed


Diagram:
in the diagram. Individual cycles can be deleted if necessary.

4.8 Diagrams

In "Diagrams" is defined which of the signals and calculated results are presented on
the display while measuring.

For diagrams, only signals and results can be selected, that previously
were defined in the settings of the navigation button "signals". A signal
may then only be defined there if the desired signal type and the
corresponding calculations have been previously defined in the
"Administration".

Figure 69: Diagrams: Configurations dialog, starting position

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Area A (overview display types)

Overview of the available display types for data visualization. There are charts of signal
processes based on crank angle or time, pV-charts (linear, logarithmic), bar charts,
tables, and trend graphs available for results.

Area B (display selection)

Area with the selection of displays for data visualization.

Area C (signal pool)

Signal pool with the display of all available signals and calculations that can be added
to a display element of area B (activated by click) and by using drag and drop.

Method for the configuration of diagrams:

1. By using drag and drop, the desired display type from the area A can be place in
area B.
2. The desired signals and calculations elements seen in the C area of the signal pool,
can be place with drag and drop into the currently selected (highlighted in gray)
display element.
3. The display choices can be individually customized by adding, deleting or moving
displays, signals, or calculations.

A total choice of five different display types is available:

Angle / Time signals This type of display presents signals and results as
vectors (highlighted in orange). All curves have the
same x-axis (crank angle, respect. time) and per
unit of its own y-axis.

pV diagram The display type presents cylinder pressure signals


(highlighted in orange) as a pV chart with linear
scale.

Log pV diagram The display type presents cylinder pressure signals


as a pV chart with logarithmic scale.

Bar chart for This display type provides results that are in the
cyclic results form of scalar values (highlighted in light green),
as a bar. All values per chart must have the same
physical unit. Therefore, if necessary, several bar
graphs should be defined.

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Table for cyclic results Any results (shaded light green) can be displayed
in a table.

Trend diagram for cyclic Any results (shaded light green) can be shown in
results the trend chart as a trend indicator.

Statistics Chart The statistics chart provides the statistical analysis


of any result (shaded light green) and appears as a
combination of a bar chart and a table.

The X-Y diagram can be used to compare any


results with one another. For one result on the x-
X-Y diagram
axis, any number of results can be displayed on
the y-axis.

All values that can be calculated and thus also displayed are divided into two
categories:

Signals as curves (vectors) Signals (orange background) are available as vectors and
are shown as curves.
Example: Cylinder pressure, intake pressure, exhaust
pressure, ...

Results as values (scalars) Results calculated using a calculator (shown in light


green) exist as single data values for each cycle and are
also displayed as such. The same applies for results
configured in the general "Statistics" area (shown in dark
green).

Example: Indicated mean effective pressure, maximum


pressure, etc.

Operating parameters (text Operating parameters (shown in blue) which are


or individual values transferred once per data file as text or numerical values
when connected to a test bench. However, these are only
available to view offline (see Visualization Of
Measurement Data With KiBoxCockpit) in the saved open
data file and to display in the diagram type table.

Example: OP_P01

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The multiple use of a display type is possible and is performed by


repeatedly pulling in a display type in the B area. By dividing the data
displayed on different graphs, the overview visibility can be improved.

In the data pool, only those signals and calculations are displayed that
match a selected (highlighted dark gray) display in the B area. If no
display is selected, then the data pool (Area C), also shows no visible
signals or calculations. If a signal or a calculation from the data pool is
moved into a display, this element will disappear from the data pool of
the corresponding display.

The deletion of an existing display in area B is executed by right-


clicking in the appropriate display and the option "delete chart".
The removal of existing signals or calculations from a display in area B
is performed by the "replacement", i.e. moving back of each signal and
the respective result in the data pool. This is done using drag & drop
from area B to area C.
In short:
- Created displays cannot be moved, but ONLY deleted.
- Signals and calculations can only be moved, but NOT be deleted!

Statistics Chart

Figure 70: Statistics Chart

In Figure 70 a demonstration view of a configured statistic chart can be seen. In the


upper half the statistic bar chart of the result AI50 for 4 cylinders is displayed. There
the characteristic points of maximum (Max), minimum (Min) as well as the standard
deviation (Std) around the mean value (Mean) are available and will additionally be
displayed as value in the table below.

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All this and also further statistical values like 3 times of standard deviation, coefficient
of variation, median, minimum in % and maximum in % can be activated/deactivated in
the context menu by the user for the visualization in the table.
The statistical analysis is based on the amount of cycles, which can be configured by
“history length” in the context menu, too. The current value of history length is
displayed in the top left cell of the table.
In one statistics chart only values with the same unit are accepted.

X-Y Diagram:

Figure 71: X-Y diagram configuration

As with other types of diagram, the X-Y diagram can be configured with the required
results using drag and drop. However, the diagram window is split into two sections: y
(top) and x (bottom). Placing results deliberately in one of the two sections can have an
impact on the axis assignment. While only one result (from one cylinder) is possible for
the basis, the x-axis, the y-axis can be assigned any number of results from any
cylinders. The assignment, which is the basis of the signals, can also be adjusted in the
online display by right-clicking "Select signal on x-axis". The number of cycles for
which value pairs are displayed by the diagram is also set in the "Statistics window"
context menu in online mode.

Creating and modifying individual registers for the data display:

To support the clarity and the work process, various tabs can be defined in the data
view and for each one of these tabs, a separate display configuration can be created. In
an active measurement, you can easily switch back and forth between different data
displays with a single button (number of the tab).
Tabs can be added to, removed or renamed. By right-clicking on a tab, the appropriate
context menu is invoked. See figure below.

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Figure 72: Data Display: Edit tabs

Any number of registers with display configurations can be created .


The system load does not increase, because only the currently
displayed tab is actively provided with measured data. The same name
may be given to a tab more than once. For the tab names any arbitrary
ASCII characters are available.

4.9 Data Output

In connection with the navigation button "Data Output", three things are defined.
Firstly it must be determined which channels (measurement data) for a measurement
event are actually stored and which channels are used for CAN-output. Then there is
the possibility of selecting which measurement events are to be included in your
measurement projects. Furthermore, information such as name or file path of the
measurement data of the particular events should be entered.
The sections in the user interface are:
 Channels
 Events
 Data File

4.9.1 Channels: Data File (.open), Data File (MDF4) , CAN Output and
Limit Monitoring

Signals and calculated results can only be selected for the data output,
if they were previously defined in the settings of the navigation button
"signals". A signal may only be selected under the navigation button
"Signals" when the desired signal type and the corresponding
calculations have been previously defined in the "Administration"
section.

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Data File (.open):

Figure 73: Data Output: Channels Data file (.open)

Area A (signal pool)

Data pool with the display of all possible signals and calculations that can be added to
the data storage in the area B.

Area B (data storage)

Area with the selection of signals and calculations which should be considered when
storing data.

Procedure:

With the help of drag & drop move the desired signals and calculations from the area A
into the area B.

If a signal or a result is moved into the data storage pool from the
signal pool, these elements disappear.

By using the two arrow buttons between the areas A and B, all results
can be moved together from one to the other side.

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Moving the signal name means a shift of the signal for all the cylinders.
Upon detection of the corresponding cylinder symbol before the signal
name, only the signal for the selected cylinder is moved.

The removal of existing signals or calculations from the area B is


performed by the "replacement" of the existing signal or calculation in
the respective signal pool. This is done with drag & drop from Area B to
Area A.
In short:
- Signals and calculations can only be moved here, but will NOT be
deleted!

If a signal is deleted under the "Administration" or "Signals", and later


re-inserted, it must then be re-added in the "Data Output".

Data file (MDF4):

Local data storage can be configured here. Depending on the actual configuration, all
measurement signals can be continuously saved onto a Flash or HDD data storage
device connected to the front of the KiBox via USB. This data streaming is only limited
by the storage capacity of the external storage device. To this end, it is possible to
limit the volume of data stored, by storing only the required resolution of the relevant
signal, thereby saving storage capacity.
The local data storage can also be used in standalone mode, without the need for a
connection to the KiBox Cockpit. The MDF recording function must only be activated
once, and starts as soon as the KiBox is switched to measurement mode. Measurement
mode is activated as soon as the KiBox is switched on (no PC connection necessary),
provided that the KiBox has been fully configured.
The MDF setup is configured similarly to the diagram selection setup.

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Figure 74: MDF configuration overview

Area A (configurable signal groups):

Overview of configurable signal groups. Vector signals, digital signals and scalar
signals can be selected.

Area B (displays the selected signal groups):

Area with the relevant selection of signal groups and respective signals.

Area C (signal pool):

Signal pool displaying all of the signals and results available for the signal groups
entered/selected in area B. These can be dragged and dropped into the signal group.

Configuration procedure:

1. The required signal group can be dragged and dropped from area A to area B.
Alternatively, signal groups can be moved by clicking on the button.
2. The required signals and calculations, visible in area C of the signal pool, can be
dragged into the selected signal group (shaded gray).
3. Data reduction can be applied or modified using the settings at the bottom of the
selected signal group.
4. It is also possible to add or remove entire signal groups or individual signals from
here at a later date.

5. MDF data can be written by pressing the button on the toolbar. This process can
be activated or deactivated directly from the configuration mode or from the
measurement mode. However, data is only recorded while in measurement mode. At
the start of each measurement procedure, a new MDF file is created, which contains
the relevant measurement start time in the file name.

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Vector Signal Group

Figure 75: Vector signal group settings

No. Designation Description:

Edit: Opens Data reduction settings window.

Settings for general window area. Entry field for start of the
Resolution: window and end of the window, as well as a drop-down menu
for the resolution of the window area.

Use high Activates a second window area that can be used for a higher
resolution: resolution in the area around the TDC, for example.

Digital Signal Group

Digital signals can only be entered onto the MDF file via this signal group. Data
reduction is not necessary here as the digital signals only take up a small amount of
data.

Scalar Signal Group

Data can also be reduced in the scalar signal group. The highest resolution is "1 cycle",
which means that every cycle is stored. The lowest resolution, "100 cycles", means that
only every 100th cycle will be stored.

It is possible to allocate different signals of the same type (e.g. PCYL1


and PCYL2) to two identical but differently configured groups, thereby
creating different resolutions for the two signals.

To ensure that the evaluation tools run effectively, the result files will
automatically be split into files of approx. 1 GB in the case of long-term
measurements.

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Streaming data files take the ASAM-standardized MDF4.0 format.


However, it should be possible to open the files with any offline tool that
supports MDF4.

If the MDF streaming is used with two cascaded KiBoxes it is necessary


to synchronize the two MDF-files offline

CAN Output:

The representation of the user interface is dependent on the selected user-level


(settings in menu "Extras - Options"). There is a distinction between
"beginner/advanced" and "expert".
The settings for "beginner" or "advanced" are usually enough to configure the CAN
output. If, however, special demands on the CAN frames must be made (e.g. for rapid
prototyping), these can be configured in the "expert" view.

Area A (signal pool)

Data pool with the display of all possible results that can be added to the CAN output
in B.

Area B (data storage)

Area with the selection of calculations, which will be issued by CAN.

Procedure:

With the help of drag & drop, move the desired signals and calculations from the area
A into the area B. Distribution/ field size for results can are made by KiBoxCockpit and
cannot be edited at this user level.

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Figure 76: Data output: CAN output (view: beginner / advanced)

Figure 77: Data storage: CAN output Detail view

No. Designation Description:

Baud rate: Input range: 125, 250, 500, 1000 [kBd]

Imports an existing CANdb-File (*.dbc) (previously created with


Import:
KiBoxCockpit)

Export: Exports the CAN-output definition to a CANdb-File (*.dbc).

Switch to detailed view (display only) that provides further


Details / Edit
information of the CAN output. Once the detailed view is active,
View
the button changes to "Edit View" and refers back to it.

Refresh units Performs an update of all units.

In the expert setting, the individual parameters of the editing view, which otherwise
appear only in the detailed view can also be changed.

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Figure 78: Data output: Experts view CAN output

No. Designation Description:

Sets the priority of the frames. Low ID's have higher priority.
CAN ID
Input range: any beginning with 2

Maximum value of the output result (influences transmission


Maximum
resolution)

Minimum value of the output result (influences transmission


Minimum:
resolution)

By moving the mouse pointer on the red triangle, the detail


Features:
settings of each size are presented tabular.

The default setting is 1. When using multiple KiBoxes, these


System
should be adjusted to ensure that there are no duplicated CAN
message ID:
IDs in the CAN Bus.

For each CAN frame, 8 bytes (standard frame) are available for user
data. These are shown here in columns (1 byte per column). The more
bytes available for a result, thus the finer the resolution is of the value
in the CAN output. These can be resized by dragging the horizontal
margin of the result.

If the entire data used capacity (8 bytes) for transmission of a result is


not required, each CAN frame can be inserted in a plurality of results of
the same cylinder (e.g. PMAX_1, APMAX_1 ,...) or the total engine (e.g.
SPEED, CYCLE.. ).
The fewer CAN frames defined, the higher the transmission speed can
be.

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Besides the System Service Message Frame (update frequency 0,2Hz)


there will not be transferred any combustion analysis results to the Can
bus in case of engine speed=0 or a non detected crank angle signal.

Further action and the involvement of the KiBox CAN output in other measuring
systems is described in the chapter Integration into external application systems.

Limit Monitoring:

This area is where the limit monitoring is configured. This configuration makes it
possible to monitor existing measurement results. If a result reaches or exceeds the
limit defined here, the system can respond in 2 different ways, which can be selected
here. One option is to activate a digital output signal. The second option is to trigger a
capture.
The configuration process is as follows:

Figure 79: Data output: Limit Monitoring

No. Designation Description

Error Bit Duration of error bit Digital Out 01 as soon as one of the
DO01 configured conditions has been exceeded.
Duration: Input range: any natural number(s)

Enable: Enables limit monitoring to be carried out for each result.

Defines the logical condition of the limit monitoring process for


Logical
each result.
operator:
Input range: =, != , <, >

Entry field for the limit


Limit:
Input range: any (unit will depend on result)

The limit value is only triggered once the number of event


Event
cycles within the specified number of total cycles (sliding
cycles… of
window) has been reached.
total cycles:
Input range: 1 to any natural number (cycles)

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No. Designation Description

Selection of the digital output to be activated when the limit for


Output: each result is exceeded.
Input range: -, DigitalOut 2 to 8

Duration: Duration of the selected DigitalOut (6 options).

Logical Logical connective of two cases of limit monitoring.


connective: Input range: OR, AND

Configuration:

1. Drag and drop the required result from area A to area B.


2. When adding multiple limit monitoring values, always check the connective. The OR
connective is selected as default.
3. In order to trigger a capture when a limit is exceeded, the event entitled Limit
Monitoring must be activated under Data Output — Events, and the cycles that took
place before and after the event occurred must be given. The capturing is triggered
by the error bit.

As soon as a condition is met, the relevant DigitalOut is activated.


However, the error bit is only activated when all the conditions have
been met (i.e. when all sub-conditions have been met in the case of
AND connectives).

Test Bed

This area is used to configure the test bench interface on which all signals to be
transferred to the test bench are defined.
Every result, even results from selected cylinders, can be moved from the signal pool
to the table using drag and drop so that it can be output. When it is subsequently
linked up, the test bench then receives the results with the name provided in the alias
and the suffix configured in the table above. Both the alias and the suffix can be
parametrized at will. This means that they can be transferred conveniently to test
bench variables that have already been pre-configured. The following types of transfer
can be selected for a result:
1. Current value: "Online" transfer – the information is transmitted continuously in
measuring mode at a frequency specified by the test bench (approx. 10 Hz).
2. Last value: Transfers the last value from the previous single measurement
(procedural measurement).

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3. Average: Transfers the average value from the previous single measurement
(procedural measurement).
4. Minimum: Transfers the minimum value from the previous single measurement
(procedural measurement).
5. Standard deviation: Transfers the standard deviation from the previous single
measurement (procedural measurement).

Figure 80: Test bed data output

Provided that the test bench automation system supports this, two
types of transfer (e.g., current value and average) can be transferred
with the same suffix (or without a suffix) if the alias is the same. This
means that it is not necessary to assign additional test bench variables.

By right clicking and choosing “remove” on an already configured test bed output
result, it will be removed from data output.

4.9.2 Events
In this section, which events lead to a data storage are defined. In addition, you specify
the amount of data to be stored before and after each event.
The following events are available:
 Manual Capture
 Engine start capture
 Engine stop capture
 Remote Capture
 Limit Monitoring

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Figure 81: Data output: Events

No. Designation Description

Settings for the data storage as well as both the number of


Manual
cycles before (left input field) and after (right field) the event to
Capture
"Manual Capture".
(always
Input range: 0 to 2000 cycles ( 0 to 500 cycles with additional
active):
time data)

Engine start Settings for the data storage, both of the period before, and the
capture number of cycles after the beginning of the event "Engine Start".
(optional): Input range: 1 to 30 s; 0 to 500 cycles

Engine stop Settings for the data storage, both the number of cycles before,
capture and of the period after the beginning of the event "Engine Stop".
(optional) Input range: 0 to 500 cycles; 1 to 30 s

Capture activated by the remote system (e.g. INCA).


Settings: see manual Capture
Remote
Tip: The capture command will be delayed caused by the remote
Capture:
mode. Therefore it is helpful to increase the cycle count of the
prehistory.

Limit Capture process triggered, Limit Monitoring error bit. Settings:


Monitoring: see manual capture

Time data Additional storage of time data in measurement file (optional —


(optional): if engine start-and-stop capture is inactive).

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4.9.3 Data File


The settings are again divided into the three different capture types:
 Manual Capture
 Engine start capture
 Engine stop capture
 Remote Capture
 Limit Monitoring

Figure 82: Data output: Data File

No. Description

Storage of data files (*. open) for all capture types in the same path.

Storage of data files (*. open) for all capture types with the same file prefix.

Enter the storage location.

Specifying the desired file name.

Select whether to append to the file name, the index number or the exact time
of the capture event.

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4.10 Parameter Check

The navigation button "Parameter Check" performs the automatic validity check after
the parameterization of KiBoxCockpit is completed. It will be checked on the basis of
different criteria, whether all inputs are in range, whether all necessary adjustments
have been made, and whether the connection to the KiBox is working properly.

Figure 83: Parameter Check

The result of the parameter check can either be displayed as "check completed" or with
a different system status. This reference to such text notes give clear instructions on
what needs to be corrected in order to achieve a successful configuration.

The text between the two colons "::" in this case indicates the exact
path of a faulty configuration. Navigate to the appropriate dialog in the
KiBoxCockpit and make the corrections noted, until the check of the
parameters of the system status: "check completed" is displayed.

Without the system status after the parameter check as "Check


completed," a measurement is not possible.

4.11 Hardware

In the "Hardware" tab, it is possible, on the one hand, to prepare the kip-file for a
cascaded parameterization by selecting "Use cascaded KiBox" and, on the other hand,
to freely select the point of time of the timestamp.

4.11.1 Timestamp
In Figure 84 it can be seen that the time in °CA in which the timestamp is to be set can
be freely selected in the work cycle. This enables optimum synchronization of the
engine control-device data and the KiBox data. By default, the timestamp is set to the
end of a combustion cycle (359.9°CA).

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4.11.2 Cascading
It is possible to cascade two KiBoxes in order to obtain a channel expansion to 16
analog channel inputs, 14 digital channel inputs and 4 current-clamp channel inputs.
For this purpose, a new "Hardware" tab was implemented in the Cockpit (see Figure
84). If the check mark for "Use cascaded KiBox" is set here, 16 AnalogIn channels, 4
current clamp channels and 14 DigitalIn channels can now be configured in the
following tab "Administration". The Digital Out 8 channel of the master KiBox and the
Digital In 8 channels of the master and slave KiBox are, however, needed for the
synchronization of the two KiBoxes and, as a result, should not be changed.

Figure 84: New tab "Hardware"

Once the ranges of all channels have been defined in the "Administration" tab, they can
be assigned to the respective cylinder or to the engine under "Signals" (see figure
below). The signals can now be used in "Diagrams" and "Data Output" in the
accustomed manner.

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Figure 85: Range settings of the channels under "Administration" (left) and subsequent cylinder
assignment in the signal level (right)

For faster parameterization, it can be helpful to work in offline mode.


This has the advantage that the parameter file is not sent to the KiBox
until a new connection is established. This is easily performed in the
"KiBox" tab -> "Disconnect". As soon as "Switch on" is clicked in this
tab, the KiBox reconnects.

4.11.2.1 Cascading: Hardware setup

In addition to the familiar KiBox setup, two cascaded KiBoxes require an LVDS splitter
box of type 2633A to transmit the crank angle signal to both KiBoxes. For this
purpose, either the engine's own crank angle signal (Hall/inductive sensor) or the
signal of an optical encoder is connected to port "Crank Angle 1" or "Crank Angle 2" of
the splitter box. Inside the splitter box, the signal is duplicated and then sent via two
CA1 cables or two CA2 cables to the two KiBoxes (see Figure 86). It is thereby ensured
that both KiBoxes receive the identical signal.

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Figure 86: LVDS splitter box (type 2633A) at left and synchronization cable at right

By means of the synchronization cable, it is ensured that both KiBoxes always run
simultaneously. This synchronization cable consists of one male and two female 25-
pin Sub-D connectors.
The male Sub-D connection is connected to the digital output of the master KiBox.
Here, a signal is output via DigitalOut 8 which is split at the connector and transmitted
via the two channels to the digital inputs of the master KiBox and the slave KiBox. The
female Sub-D ends are then connected to the two digital inputs of the KiBoxes.
The two KiBoxes can be connected to the PC with the help of the switch included in the
scope of delivery of the KiBox.

4.11.2.2 Cascading: software setup

The network settings are made via the "Tools" tab -> "Options" in the "KiBox" tab. The
IP address of the master KiBox is transferred to the upper field in the accustomed
manner with the "Use" button (see Figure 87).
If a second KiBox is to be cascaded, the check mark for "Cascade" must first be set.
The KiBox that is to be used as a slave can then be clicked (blue background) and
transferred to the lower field using the "Use cascaded" button. A connection is now
established to the two KiBoxes. If the KiBoxes were previously used in non-cascaded
operation, they are rebooted before a connection is established, providing them with
the correct configuration in the process.

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Figure 87: Establishing a connection in cascaded operation

Inca connection: In the Inca network manager, an IP address range is


defined for ETAS hardware. For the KiBox, the last IP address of this
range is always blocked. The IP address of the master KiBox is
automatically set to this end value by Inca as usual. To avoid double
allocation of the IP addresses, it is important to note that the slave
KiBox automatically obtains an IP address that is one higher than that of
the master KiBox.

If the MDF streaming is used with two cascaded KiBoxes it is necessary


to synchronize the two MDF-files offline

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5. Run Measurement
Using the menu item "Measure - Start", the shortcut "F5" or the button , KiBox starts
the continuous measurement. Here, the actual measured data is continuously stored in
a ring buffer. If the amount of data of the current measurement exceeds the size of the
ring buffer, the latest resulting data is still stored. At the same time, however, the
oldest data in the storage ring will be deleted. Thus, even after "measuring stop" the
last measured data is temporarily stored in the storage ring and can be saved manually
when needed.

5.1 Online-View

After the measuring starts, KiBoxCockpit changes to the so-called online view. This
allows for a continuous monitoring of indication values during a test. All signals and
results that were previously defined in the parameter "Diagrams" are visible. Only the
chart properties such as the coloring of the sizes, etc., can be changed in the context
menu (right click) of the corresponding chart.

5.2 Storing Data

Data from an ongoing measurement can be saved by triggering both by the event
"manual capture" (Shortcut: "F6" or "Spacebar") or after stopping the continuous
measurement by the targeted saving in "File - Save Data" (F12). After stopping the
measuring, the KiBoxCockpit changes into the so-called post measurement view. Here,
all data in the storage ring can be considered and saved manually as required. It differs
only from the online view in that charts, displays, etc. can be added to the current
layout, or can be removed and processed. The manual storage process opens the
following dialog.

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Figure 88: Dialogue manual data storage

No. Description:

Storage path of the data file

Name of data file

File type (fixed)

Any comment on the data file

Cycle range of the ring storage, that should be saved.

When activated, time data is stored with

targeted select and deselect of individual signals, in order to reduce the data
file to the signals of interest

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6. Evaluation
KiBoxCockpit in principle offers the possibility of evaluating the created data. For
specific requirements for presentations or further calculations, an offline analysis tool
should be used. The following programs can be used for evaluation of KiBoxCockpit
data files (*.open):
 Turbolab
 Uniplot
 Concerto / Indicom (using Ifile-Converter/Concerto-PlugIn)
 Matlab
 FlexPro
 Diadem
 all programs that can handle ASCII format ( it is not recommended because of large
file size)

6.1 Visualization Of Measurement Data With KiBoxCockpit

Basically, the data visualization between online view, post measurement view and
offline view (viewing of the recently stored data) must be differentiated. So features
such as layout processing only for post measurement and offline view or the "ASCII-
export" are only active for the offline view. To look at data in the offline view, it must
first be opened under the "File - Open data file" (F10) or by of the symbol bar. The
measurement data is then now displayed in a local layout. This means that an accurate
display of the data is loaded, which was set in the parameters during the creation of
the open file. If additions or amendments are now made in the display of data, they
can either override the local layout (File - Save layout), or a new layout can be stored
("File - Save Layout As"). This can also be used for the evaluation of other
measurement files. However, the local layout applies only to the currently loaded test
file. A quick change to other saved layouts and saving the current layout can be done
using the button in the symbol bar.
After opening the display selection on the right side of the screen ( ), analog changes
to the layout can be made as described in the chapter Parameter Diagrams.
The figure below shows a selection of the most important possibilities and actions that
can be used in the offline view.

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Figure 89: User Interface: Visualization of stored data

No. Description

Use the toggle button for "show data file" (offline-view) or "show data"
(online or post measurement view)

Move the display or chart ( a cross cursor will appear near the edge)

New charts to add with drag & drop

Additional signals to add with drag and drop into a chart

Customize the visual appearance of displays and charts


(scale range, graph properties, ...)

Selection tab, Add New Sheet to data display or rename


(via right click on an existing tab)

Data player

Zoom display

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No. Description

Cursor activation

Switching between time and angle data (x-axis)

Save changed layouts quickly, switch between existing layouts

Special features of the data display:

 "Crossed signals" -> is a result or a signal that is not available in the area shown;
this will be shown crossed out in the chart legend
 "No data" -> If no data is available for an illustrated chart, this text appears. This
can especially be the case at the beginning or end of a measurement.
 "Yellow warning triangle" -> appears when during the recording of data, a system
integrity warning is active. If you move the mouse cursor over the triangle, the
cause for the warning is shown.
 automatic switching between time and angle data -> if there is no angle data for a
certain signal but only time data (or vice versa), the display changes automatically in
accordance with the available mode.
To customize the chart options to meet specific requirements, the context menu (right
click) of the chart can be used. The following options usually are available:

Clicking on the edge or corner of the chart:

 Adjust the size and position of a display (drag & drop)

Right-click on the appropriate chart:

 Chart Title
 "Chart characteristics"> font, size, background color, grid color, font color, - Chart
properties, set to default
 Autoscale

Right click on the desired coordinate axis:

 Scale range ...


 Decimal places ...
 Show grid (switch on or off)
 Chart title
 "Chart characteristics"> font, size, background color, grid color, font color, - Chart
properties, set to default
 Autoscale

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Right-click on the appropriate signal in the legend of a chart:

 Signal color
 "Chart characteristics"> font, size, background color, grid color, font color, "Reset
to Defaults"
 Autoscale
 Chart title

The data player is available in the post measurement as well as in the offline view in
the KiBoxCockpit in the lower left corner of the window. This is used to start the
animated display of measurement data. It can be operated much like a music player.

Figure 90: Data player

No. Description

Number of the first cycle (pure display field)

Jump to the first cycle

One cycle back

Play All cycles

One further cycle

Jump to last cycle

Number of the last cycle (pure display field)

currently displayed cycle

Slider to select the desired cycle

The distinction between current and stored data is the possibility


between displaying an ongoing measurement and an open data file
, freely back and forth. The data can also be changed arbitrarily
between the displays of current data after the measurement has
stopped and open data.

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Cursor functions:

For a more precise analysis you can choose between two graph cursor types. The data
cursor for reading certain specific values of signals within a chart, or the difference
cursor which calculates the signal value at the cursor position 2 minus the signal value
at the cursor position 1.
The cursor is activated and deactivated with the button from the symbol bar. In each
chart of "mixed signals" one of the two cursor types are now represented. The
selection and display of the cursor in each chart must be activated by right-clicking
and then the "Show data cursor". By means of another right-clicking in the appropriate
chart and the subsequent selection of "show difference cursor" that is also activated.
The cursors appear as vertical red lines in the chart.
For analog, the current cursor types can be removed by right clicking and disabling
"Show data cursor/show difference cursor".
The table with the cursor values consists of four columns. These list the values of
cursor C1, from cursor C2 and their difference (C2-C1; Warning: Note sign) for all
existing signals in the chart, the crankshaft position and the time.

Figure 91: Data cursor and difference cursor

6.2 Saving, Exporting, and Converting The Measurement Data

Measurement data can be saved, exported, or converted. The original measurement


parameters can be exported from a data file.

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Save data after measure stop:

In the menu "File - Save data", the settings are initially defined in a dialog window, as
the data after measure stop should be stored in a measurement data file (*.open) see
chapter: Start measurement - save data

Export measurement data:

In the menu "File - Export data", all settings are defined in a dialog box, with which the
data from an *.open file containing reduced information content can be exported in a
*. csv file. (Not recommended!)

Figure 92: Settings for exporting data files

No. Description:

Save path of export files

Cycle range to be exported.

Separator
Input range: Comma, semicolon, tab

When activated, the cycle numbers are additionally written into the export file.

Selecting if signals or results should be exported

Targeted calling and deselection of individual signals/results to reduce the


export file to the signals of interest

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Depending on the language of the operating system and the application


software used for further processing (e.g. Microsoft Excel), only one or
the other of the delimiters is correctly detected when you open the *.csv
file. This means that the loaded values are only correctly identified as
separate variables (e.g. in separate columns) if the corresponding
correct delimiter was selected when exporting.

Measurement data conversion:

In the menu "File - convert data" the KiBoxCockpit data files can be converted (*.open)
in the IFILE(*.ifi) or MDF(*.dat) data formats. The selection opens a file browser in
which the converted data file (*.open) is selected. The conversion process is
automatically started. The converted file is saved under the same file path as where the
original data file is located.

Using the EventHandler functionality (Note: EventHandler in chapter


3.3.1) supports an automatic conversion of data immediately after the
storage of a capture. The needed *.exe files are located in the Add On
directory of the KiBoxCockpit installation cd.

Only pre-stored data files (*.open) can be converted. For the conversion
of data from the storage ring, they must first be saved manually.

Exporting information about a data file and parameters from an *.open file

In the menu "File - Data Properties", the properties of an open data files (*.open) can
be called up. In addition, the parameters with which the open data file was created can
be exported in a parameter file (*.kip), can subsequently be loaded and reused.

Matlab Plugin:

The Matlab plugin is a .m-file that facilitates the loading of the open-file signals and
results in Matlab. By default, "openimport.m" is located under path: "C:\Program Files
(x86)\
Kistler\MatLabPlugin". Figure 93 shows the interface that appears after executing the
openimport.m-file. The export of the open-data in Matlab occurs here.

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Figure 93: Exporting the open-data in Matlab

No. Description:

The desired open-file can be loaded under "File".

After loading the open-file in , all values stored in the open-file are
displayed.

Selecting the data to be imported:

- Individual values can be transferred with the single arrow.

- Transfer all values with the double arrow.

After selecting in , the values to be transferred are listed in the "Selected


Data" pool.

With the help of the "Structured import", all open-file values are transferred to
subdirectories in a structured manner.

Use the "Import Data Tracks" button to add the selected data to the workspace
in Matlab; the data can then be used for analysis in Matlab.

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6.3 File Formats

Template (KiBox Template *.kit):

A template (*.kit) does not differ in content from a parameter file (*.kip). Both contain
settings that are configured in KiBoxCockpit. However, they differ in function. The
template (*.kit) should be serve as "pattern files", to be used as a starting point for
measuring tasks. Based on these, individual (done) configured parameter files should
be created. A "default template" including default values is already supplied. These
default values can be called up for configuring via the respective "reset button", i.e.
transferred into the input fields.
If a template is loaded, the KiBox opens the KiBoxCockpit and opens a parameter file
with the template properties and automatically assigns it the name "unnamed.kip".
This should be changed using the "File - save parameters as - parameters".
The template is stored in the directory "... My
Documents\Kistler\KiBoxCockpit\template" under the name "DefaultTemplate.kit".

Parameter file (KiBox parameters *.kip):

Based on the template, the pre-configured parameter file should be individually


created for the appropriate measurement task. It is always stored in the measurement
file, from which it can be extracted again whenever needed.

By this division of template file and parameter file, a valid company-


wide or project-level template can be created, which can then be
customized to the individual circumstances of the actual measurement
environment. Uniform, pre-configured parameter files can then be
developed for a specific measurement task, but which are uniform with
respect to signal names, calculation rules etc.

Layout format (KiBox layout *.kit):

In the layout file, specific layout settings for data visualization can be defined. The
layout of a measurement is always stored within the data file. Additional layout files for
the offline or post measurement view can also be defined.
The following properties are stored in the layout:
 Chart layout
 Color Schemes
 Fonts
 Font Sizes
 Line width of signals

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Measurement data file (*.open):

Basically, the KiBox generates data files of the *.open type.


The following contents is saved in an *.open file:
 Parameter
 Time and angle data
 Layout

Measurement Data File (*.mf4):

Measurement data files with the extension .mf4 are only stored locally in streaming
mode on USB mass storage devices.
The following data is saved to a .mf4 file in a time-based manner only:
 Angle and time data
 Continuous angle track

It is possible to convert KiBox data files (open) into different file formats
(MDF, IFile, ASCII). (see Chapter: Saving, exporting, and converting
measurement data)

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7. Integration Into External Systems


KiBox and KiBoxCockpit are supporting diverse ways to integrate external systems.
Between the following interfaces will be differentiated:

Type: Definition Interface

„Standardized“ communication protocol to


Test bench
connect to common test bench automation RS-232; TCP/IP
interface
systems.
Disclosed software interface to KiBoxCockpit
for each system providing a freely
Remote API Lokal; TCP/IP
programmable interface or an already available
driver.
Simple transfer of the configured results to
CAN external systems which support CAN CAN1
communication.

Depending on the type it is also possible to connect more than one external system.
The Use of the test bench interface or of the remote API supports not only the transfer
of results but also a control of KiBoxCockpit.
This can only be realized by one external system, the master system, at the same time.
In case of master rights for all interface types the chronological order of the
connection build up is significant.
Which connection type is permitted in KiBoxCockpit and if the master rights are
allowed is displayed in the options dialog (tab: remote) of the menu: tools and can
partly be configured. Additionally the permission of a remote capture for each type can
be defined.
Figure 94: Options RemoteFigure 94 shows the dialog of the remote configuration in
KiBoxCockpit. In the Remote access area all installed drivers are listed. Beside the test
bench also the remote server driver is installed by default. According to the installed
features, several additional drivers (e.g. INCA driver) might be listed.
In the lower section of the dialog the interface to the test bench (when using RS-232 to
the left, when using TCP to the right) can be configured.

Changed remote settings might require a KiBox or KiBoxCockpit restart.


The activation or deactivation of master permissions will not be
effective before all remote clients have been reconnected.

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Figure 94: Options Remote

Handling Of The Remoted KiBoxCockpit

Once a remote client has connected to KiBoxCockpit the general remote icon or a
driver specific icon will appear in the status bar. In case of a simultaneous connection
of several remote clients the corresponding amount of icons will be displayed. The first
system which connects in chronological order and has master permissions takes the
control of KiBoxCockpit. The corresponding icon will be highlighted by a blue border.
Individual remote connections can be terminated by right click on the icon.
In general remote operation can be locked or authorized by the button Disable/Enable
Remote Control / which changes its icon depending on the state.

7.1 Application Systems

Especially in connection with the application of all engine control parameters, the
knowledge of values of indication is of enormous importance. There are two
possibilities available for integration into application systems. Optimal support is
provided for users of the INCA application system from the ETAS, CANape from Vector
as well as Vision from ATI. In addition, by means of a CAN-interface, indication values
could also be sent to other application systems by the KiBox.

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7.1.1 ETAS INCA


A prerequisite for integration of the KiBox in INCA is an installed version of the INCA
software (V6 or higher) and the appropriate installed "KiBox INCA driver" (see chapter
3.3.1 Installing The KiBoxCockpit Software).
The advantage of this interface (OHI + ASAP1b) is the time stamping of indication
results, which allows for highly accurate time-synchronized data compilation together
with the ECU measurement data.

7.1.1.1 Configuration

The configuration is divided into the following main steps:


 Connect KiBox
 Configure network manager
 Configure hardware
 Parameterization

When using a Windows 7 operating system, the KiBoxCockpit must be


executed with administrator privileges at each program start up (Right
click on KiBoxCockpit.exe. and "Run as administrator").

INCA from ETAS is a very extensive and complex system. At this point,
it can therefore not be claimed that the following instructions
completely explain how to work with INCA.

Connect KiBox:
 Start KiBoxCockpit
 Wait until the connection has been made according to the previous connection
configuration (chapter: Installation).
 If the KiBox is off, it must be automatically turned on when starting the
KiBoxCockpit through INCA. You can set the switch on option of the KiBox through
INCA in the KiBoxCockpit menu, "Tools - Options - Power Management" tab.

If the automatic switch on of the KiBox at startup is not activated in the


KiBoxCockpit, then the KiBox must already be on when INCA is started.
Otherwise, a timeout error occurs.

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Configure the network manager:


 Start INCA and open the Network Manager ("Tools" menu).

Figure 95: Inca: Network Manager

 Make sure that the automatic settings are disabled. Select your Gigabit Ethernet
card and click "Continue".

Figure 96: Inca: Network Manager IP Configuration

 Set address pool: Enter the range of addresses that should be available to INCA. The
stop address must be chosen so that it matches the KiBox adress (see also
KiBoxCockpit, shortcut F3). Press "Finish". Otherwise, the ETAS Network Manager
changes the IP address of KiBox precisely to the stop address defined here. Then an
automatic restart of the KiBox is necessary (time loss).
 After creating a work environment, open the hardware configuration (HWC, for
example by pressing "Ctrl + F3"). Using the context menu and "Insert" button (or
pressing the "INS") a list opens in which the "Kistler KiBox system" can be selected
(assuming the KiBox INCA driver is installed).

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Figure 97: Inca hardware configuration: Add KiBox

Figure 98: Inca hardware configuration: Add KiBox (2)

The red icon on the hardware configuration, stating "no device


connected," only means that the KiBoxCockpit has not yet been
initialized.

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Parameterization:
 Then you must include a valid KiBox configuration in the INCA database. Highlight
the entry in the hardware device "KiBoxCockpit" and right click on the button below,
"Configure".

Figure 99: Inca hardware configuration: Configure KiBox

 The KiBoxCockpit parameter editor starts. You can now load (for example with "Ctrl
+ O") a valid parameter file (*.kip) as a copy in the INCA environment or configure a
new parameter file.

The window mentioned here with the name "KiBoxCockpit Parameter


Editor" for entering the parameters in the KiBoxCockpit has no menus
(File, Edit, View, ...) and thus differs from the usual standard user
interface. It has a custom symbol bar that is provided with the
additional "Close" button..

 Using the "Close" button, the dialog for setting the parameters of the KiBoxCockpit
under INCA closes. Thus, the parameters are saved as a copy in the INCA database.

Please note that this is done in INCA with a copy of the KiBox parameter
file. If changes are made directly over the KiBoxCockpit, and these are
saved as a parameter file of the same name, the modified parameter file
must be newly reloaded into the INCA hardware configuration.

 With F3 you can now initialize the hardware in INCA. This is done automatically by
opening an experiment. If you want to open your experiment without a KiBox
connection (e.g. at the office), you can either create a copy of your work

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environment and delete the KiBox from the hardware list, or use the toolbar button,
"Experiment without hardware", and open the experiment again.
 In the opened experiment, you can now use as normal variables, the ones that had
been previously provided by the KiBox. Please note that there is a different sampling
rate in the KiBox and in the engine control interface. As a rule, for the variables
from the engine control, only time frames of 10 ms and 100 ms and the
synchronous segment compilation are available (e.g. "synchro" as equivalent to a
four-cylinder four-stroke engine 180°CA). In addition to the two time grids between
10ms and 100ms, in KiBox you can also select between motor and cylinder
synchronous raster.

The available variables are all those that are also available in the signal
pool of the KiBoxCockpit as scalars (e.g. PMAX). Vectors (e.g. PCYL) are
not available.

In KiBox, a so-called cycle counter is provided as a calculation result


(KiBoxCockpit Parameter Editor - Administration - crank angle - cycle
number - default name CYCLE). Please include this variable both in your
INCA experiment as well as your *.open file. The synchronization
between INCA and KiBox data is therefore simplified.

7.1.1.2 Measuring

To perform a measurement, select the menu items "Start measure data


display",respectively, or "Start measure data recording" in the INCA menu
"Measurement". The same actions can also be accessed via the icons on the left side of
the INCA-window "experiment" or via the function keys F11 and F12. The INCA user
interface and remote-controlled KiBoxCockpit now run in parallel and each is
configured to show results in the previously defined tables and charts.

Figure 100: INCA Remote active

In the status bar of the KiBoxCockpit, the INCA icon appears. This
means that the KiBoxCockpit is remotely controlled by INCA. The
remote operation is also indicated by a greatly reduced variety of
menus and icons.

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At the start of the INCA measure data display or recording, in the KiBox
the measurement mode is started, i.e. the online view is started, results
are calculated and transferred to INCA. Once the INCA display or
recording is stopped, then the measuring in the KiBoxCockpit is also
stopped. There, the post measurement view is now active.

It is possible at any time, to trigger a capture process manually in the


KiBoxCockpit. To do this, change to the KiBoxCockpit window during a
running measurement (e.g. "Alt + Tab") and perform a capture (e.g.,
"Space" or "F6").

In INCA under configure recorders> output file, the option for "Wait for
user comment" can be selected. This may result under certain
conditions in INCA-/Hotfix versions that INCA cannot be exited as long
as the measurement mode is running until the user closes the save
dialog. Thereby important data in the ring storage of KiBox can be lost!

KiBox Capture Triggered by INCA Recorder

In INCA version 7.0 and later, a capture can be triggered remotely in the KiBox Cockpit.
For this to occur, an additional recorder must be installed alongside the default
recorder in INCA Experiment. All INCA Experiment variables (of ECU, KiBox or other
hardware) can be selected as the trigger for this recorder. As soon as the recorder
detects an event (several options available), and a measurement is saved in INCA, the
remote capture command is sent to the KiBox Cockpit.
The following settings must be made to allow the KiBox Cockpit to then process the
capture.
 Under the "Remote" tab in the "Options" menu, both the "Enabled" and "Remote
capture" boxes must be checked for the INCA driver. These options are
automatically activated when KiBox Cockpit, including the INCA 7 Driver, is
installed. The "Remote capture" box should not be checked if the capture is not to
be triggered by the INCA recorder. The KiBox Cockpit will need to be restarted if any
changes are made.

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Figure 101: Settings for INCA remote control

 "Remote Capture" must also be activated in the configuration settings under "Data
output — Events" and each cycle number required in the measurement file must be
entered before and after the recorded event.

Figure 102: Settings for remote event recording

Due to the system-dependent delays between the INCA recorder trigger


and the capture command in the KiBox Cockpit, it is a good idea to
increase the cycle number before the event occurs. This will ensure that
the relevant measurement data of the actual event time will also be
stored in the measurement file.

Name transfer

If a trigger is set in INCA (see above) that triggers an INCA measurement and a KiBox
measurement, it is possible beginning with INCA 7.2 to transfer the recorder name
defined in INCA to the Cockpit and to use it as a file name for saving the open-file. As
a result, the INCA dat-file and the open-file have identical names, thereby making the
assignment very simple. This feature can be activated under "Tools"->"Options" in the
"Remote" tab (see figure below). Click on button to open another window .

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Figure 103: Transferring the file name / MDF streaming

If the check box for "Use Recorder File Name for Capture" is activated, the Inca
recorder name is sent to the open-file and stored under this name. Furthermore, the
open-file, like the INCA measurement file, is stored under the path that was defined in
the INCA recorder (see Figure 104)

Figure 104: Identical storage name and storage location

Activating MDF streaming

Beginning with INCA version 7.2, it is possible to switch on MDF streaming in the
Cockpit by activating the default recorder in INCA. This is activated by setting the
check mark for "Auto-activation of MDF streaming" as shown in the upper Figure 103
the filename / MDF streaming”.
If this function is activated, MDF streaming is automatically activated in the KiBox as
soon as the default recorder is activated in INCA.

KiBox capture triggered by INCA:

For INCA version lower than 7.0 there is also a workaround of triggering a capture in
KiBoxCockpit. This is done by using a customized formula. To use this function, the
following installation steps have to be carried out:
 Quit INCA.
 Copy the file "KistlerTrigger.pm" from the "IncaDriver \ KiBoxCapturesByInca" folder
on the installation CD into the target directory
"<ETASData>\INCAX.X\CalculatedSignals\PM\online"

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 Start INCA.
 Define the desired trigger signal in the INCA experiment under "Variables -
define/manage" (Alt Gr+C).

Make sure that the windows environment variable "KIBOXCOCKPIT"


includes the full path to the KiBoxCockpit program. This is generally
guaranteed by the KiBox installer.

With the following example, a unique capture process starts in INCA when the engine
speed value exceeds 4000 rpm.

Figure 105: Example configuration of a variable to trigger a capture by Inca

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As input, all INCA variables (including ECU labels) can be used. The desired monitoring
window is defined with the values "const_low" and "const_high". To save each event of
leaving the monitoring windows in INCA as *.open file, set "const_retrig" = 1. For
"const_retrig" = 0, only the first exceeded threshold is captured since the start of
measuring.

To activate the trigger, you must subscribe to the trigger formula in the
experiment (display or use as a trigger signal in a recorder definition).

7.1.1.3 INCA in combination with other external systems

In case of a combination of INCA with further external systems for KiBoxCockpit


remote operation, it is necessary to ensure which system must have master
permissions.
Generally it is recommended to run INCA with master permissions when the connection
builds up. This can be done by connecting INCA before all the other systems or by
removing master permissions of the other systems in general (Setup of Master
permissions: see chapter 7).
If a specific other external system only runs correctly when master permissions are
allowed, the INCA driver can operate without them, too.
In this case the following KiBoxCockpit control functions of the driver are prohibited:
- Start measurement
- Stop measurement
- Open the KiBoxCockpit parameter editor
- Loading of a KiBox parameter located in the INCA workspace
These functions can only be operated by the master remote system. INCA only has
“listening permissions”. That means only those results which are available in the
parameter file given by the master client will be transferred to INCA. Furthermore the
transfer of KiBox results is independent of the INCA visualization mode but requires a
KiBox measurement already started by the master client.
The user will be informed about the ignored actions in the INCA log window.

In case of an application of KiBox in combination with a test bench


automation system INCA always has to operate in listener mode.

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7.1.2 ATI Vision

Since Vision V3.8 an integration of KiBoxCockpit is available.


Regarding the procedure of purchase, installation and start of operation of the ATI
Vision KiBox driver please contact the ATI Vision customer support.

7.1.3 Vector CANape


Since CANape V11 an integration of KiBoxCockpit is available.
Regarding the procedure of purchase, installation and start of operation of the Vector
CANape KiBox driver please contact the Vector CANape customer support.

7.1.4 Other Application Systems


Specifically for other application systems, the ability of the CAN output is of interest.
The characteristics of the CAN messages are defined in the CANdB files (*.dbc). The
definition and creation of these files is described in Chapter: Parameterization. Data
output, channels.

Configuration of the CAN-monitoring system:

The following necessary configurations are shown as in example in the INCA


measuring system. When using other application systems, please follow the
instructions of the respective publishers. Add the desired DBC file as follows into your
INCA work environment:

Figure 106: Add CAN-DB

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Then in the hardware configuration, add the CAN hardware for CAN monitoring by
automatic search or by pressing "Insert".

Figure 107: Add "CAN-Hardware"

Be careful when configuring your CAN interface that the project CAN baud rate is set to
1 Mbps and the proper CAN port (CAN1/CAN2) was selected.

Figure 108: CAN Configuration

For the connection between KiBox and the CAN monitoring device, a minimum of two-
conductor, twisted pair and shielded cable must be used. For the correct layout, please
refer to the figure below.

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Figure 109: CAN-cable scheme

When you connect the CAN cable, use only the CAN port 1 on the KiBox.
This interface is not internally terminated.

Standalone operation:

As well as the local data storage function, the KiBox can also be used in standalone
mode using the CAN monitoring function. This means that the most recently loaded
parameter file, once correctly configured, will automatically load internally when the
KiBox is started and will activate the CAN output. CAN will then continuously transfer
indexed values (as defined in the chapter entitled Configurations: Data Output,
Channels ). Two temperatures and the watchdog variable (changing the value from 0 to
1 and back in a defined time period) can be read out from the CAN-Bus in order to
check the CAN function, even when the engine is at a standstill.

7.2 Test Bench Automation Systems

The connection to a test bench automation system is possible for all those systems
which support the simple serial protocol (KiBox document: KiBox Testbed
Communication Protocol) or DCOM protocol.
Apart from that a general integration to test bench systems can be done via CAN
monitoring, too. The KiBox supports CAN-Bus speed of 125, 250, 500 and 1000
kBaud.
The triggering of a capture for instance can be done by calling "KiBoxCockpit.exe -

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capture" in an active continuous measurement.


In addition, Kistler offers a comprehensive remote API for a programmable KiBox-
integration into the test bench system for free (the company apicom already
implemented it in Horus).
The procedure and the functionality of the KiBox integration into several common
automation systems will be clarified in the following chapters.

7.2.1 AVL PUMA


Depending on the version of PUMA different interfaces will be available. Earlier versions
only support an RS-232 interface. For newer systems (PUMA Open) the serial interface
for combustion analyzers is not supported any more. That is why the communication
will take place via TCP/IP. But they all must use the simple serial protocol.
The KiBoxCockpit also supports the DCOM interface which can carry out the procedural
measurement and also transfer measured values continuously.

7.2.1.1 Connection via RS-232

As hardware connection a null modem cable (crossed) must be used between the PUMA
interface for a combustion analyzer and the KiBox RS-232 connector (back plane). The
serial interface of the KiBox must be configured, like explained in chapter 7,
corresponding to the one of the automation system. The PUMA setup takes place
analog to the connection of other popular indicating systems.
The following restrictions in configuration and operation of the KiBox have to be
noticed:
- Only procedural measurement, no continuous

The protocol only supports variable names with 8 characters. If the


name of a required result contains more than 8 characters by default,
the alias should be shortened under "Data output – Channels – Test
bench". Example: SPEED_AVG. As this contains 9 characters, this must
be changed to SPEED, for example, so that just SPEED is transmitted.

If the transmitted name should or must be stored under another


NORMNAME, either the alias in "Data output – Channels – Test bench" or
the norm name conversion table in "PAM, INM, Menu: Group" can be
used.

7.2.1.2 Connection via TCP/IP and CDH Block

Since PUMA Open V1.3 the RS-232 interface for combustion analyzers has not been
supported anymore. When using the CDH block the same protocol can operate via
TCP/IP, too. The needed files for an installation in PUMA are located in the AddOn
directory of the KiBoxCockpit installation disc.

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The following steps have to be executed in PUMA for the installation of the KiBox CDH
driver:

1. Copy the following files into PUMA folders:

Filename PUMA folder


KiBox.mdd .\AVL\MDD
KiBox.mlg .\AVL\MLG
KiBox.ico .\AVL\BMP
KiBox.wnd .\AVL\POI\WNDCUST
KiBox.bmp .\AVL\POI\WNDCUST

2. Start PUMA parameter manager PAM and open in your SYS parameter file the
parameter block MDV (Measurement Device).

Figure 110: PUMA SYS

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3. Add a new device

Figure 111: PUMA MDV: New Device

4. PUMA’s Configurable Device Handler Wizard (CDG) will be started. “Next”

Figure 112: PUMA CDH Wizard

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5. Load device description file KiBox.mdd

Figure 113: PUMA: Load KiBox.mdd

6. Select Next in all following dialogs


7. In the last dialog select KiBox.ico file and KiBox.wnd file. Don’t forget to activate
the generation of object support files. Click “Save” button and close the dialog with
the “Finish” button.

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Figure 114: PUMA CDH: Device Properties

8. In the following KiBox device tab pages you can define the name translations and
communication settings. To finish click “OK”.

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Figure 115: PUMA CDH: KiBox Settings

9. In PUMA POI reload the changed SYS parameter file. Open KiBox POI window
KiBox.wnd and control your new KiBox device.

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Figure 116: PUMA CDH: View KiBox.wnd

The delivered Files for the integration of KiBox via CDH block basically
serve as draft. Per default only the common results for maximum 4
cylinders are preconfigured. If any additional results might be required
they can be configured in the CDH wizard.

7.2.1.3 Connection via DCOM

When the DCOM Puma interface is used, the KiBox behaves in the same way as other
popular indicating systems. The test bench automation system must therefore be
configured as described in the instructions for use of indicating systems. The signals
that should be transferred must be configured in the KiBox via "Data output – Channels
– Test bed".
When the DCOM interface is used, the following restrictions apply for the KiBox:
1. Only results (1 value per combustion cycle, e.g., PMAX), but no vectors (complete
signal curve, e.g., PCYL), are available for online measurement data transmission
from the KiBox to the test bench.
2. It is not possible to perform a recalculation using some of the calculators inside the
KiBox after the actual measurement has been carried out and the operating
parameters for the test bench, which were transferred immediately beforehand
(2nd step calculation), have been taken into account.

Commissioning the DCOM

DCOM (Distributed Component Object Model) is a piece of technology from Microsoft


which enables COM technology to be used in a network. Several settings need to be
applied on the operating system (KiBoxCockpit PC and Puma PC) so that DCOM can be
used. If this is not done then the DCOM interface cannot be used.

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There is a tool included in the KiBoxCockpit which can be used to apply all of the
necessary settings automatically. To find this tool, go to the "Tools – Options" menu,
find the "Remote" tab and click on the "..." button in the Testbed DCOM driver line.
When the dialog window opens, select the second tab, "DCOM Register".
The following steps should then be performed consecutively on the KiBoxCockpit PC.
1. Click on the "Enable DCOM" button: To change system settings that are generally
required to use DCOM. In the log window, "Completed successfully" should appear
for the last entry.
2. Click on the "Register" button: To register the KiBoxCockpit software for DCOM. In
the log window, "Completed successfully" should appear again for the last entry.
3. To unregister the KiBoxCockpit software for DCOM (e.g., if other systems need to
communicate via DCOM on the PC), click on the "Unregister" button.
4. Close the window by clicking "Close".

The DCOM interface must also be activated on the client PC (PC test bench
automation). If the supplier of the client system has not provided a tool, the entire
"TestBedDCOMRegisterClient" folder can be copied to the test bench PC from the add-
ons directory on the installation CD. The executable file
"TestBedDCOMConfiguration.exe" can be found under
"..\Driver\TestBedDCOMDriver\Registration". This starts the same dialog window that
is included in the KiBoxCockpit software.
After executing the tool on the client PC (test bench), the following steps should be
carried out.
1. Click on the "Enable DCOM" button: To change system settings that are generally
required to use DCOM. In the log window, "Completed successfully" should appear
for the last entry.
2. Click on the "Register" button: To register the KiBoxCockpit software for DCOM. In
the log window, "Completed successfully" should appear again for the last entry.
3. Click on the "Register Client" button: To carry out the additional registration for the
client PC.
4. Close the window by clicking "Close".

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Figure 117: DCOM registration tool

Saving an Open File

The test bench can specify a number of combustion cycles which should be used for a
measurement point. If this is not the case, the KiBox uses the configured number of
cycles found under "Capture Type Remote Control" in "Data output – Events".
In addition, the test bench can also trigger the process for saving the measurement file
relevant for the last measurement point. The data can be saved in the following ways:
a. The file name is specified by the test bench in conjunction with the save
command (the transfer name is configured in the test bench automation
system)
b. The file name is not specified by the test bench. The KiBox uses the file
name as it is configured by default under "Capture Type Remote
Capture" in "Data output – Data file", including the file suffix.
c. The file name is not specified by the test bench but should be
configured differently to how it is configured in "Data output" (as these
are intended for INCA captures, for example). The intended file name
can be modified by clicking on the "..." button in the Testbed DCOM
driver line in the "Remote" tab in the "Tools – Options" menu. It is also
possible to create the file name using transmitted user variables. To do
this, the user variables to be used must have been transmitted
previously (%Name). The default configuration is
<%TSTSERIES>_<%TSTNAME>_<%BRBLATT>_<%MESPKTNR>. This
indicates a combination made up of four different user variables. If one
of these user variables is not transmitted from the test bench via the
operating parameters, the file name configuration for the KiBox will not
be complete. In this case, the naming method specified in point b is
applied again. If, however, all of the user variables configured here are
transferred from the test bench, the file name is composed of the
relevant transmitted values of the variables. Every variable must be
surrounded by <...>.

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Example: User variables transferred from the test bench:


%TSTSERIES=EngineXY
%TSTNAME=Full load
%BRBLATT=154
%MESPKTNR=8
File name according to save command without name from test bench:
EngineXY_fullload_154_8-01.open (with index as suffix) or
EngineXY_fullload_154_8-14-54-11.open (with time stamp as suffix)

Operating Parameters

The KiBox supports the transfer of test bench information via operating parameters.
An operating parameter can contain information from the test bench. This information
contains three values (name, information, unit) for each measurement point or
measurement file. These three values can contain both numerical values and text
information. The test bench automation system is used to configure which parameters
should be transmitted. A visualization of the operating parameters is only provided
offline in a table for data display purposes. In the signal pool, operating parameters
are shown in blue.
The units of all operating parameters will be transferred automatically by the interface
provided that the test bench automation system is set up correctly. If this is not
possible, the units of the respective operating parameters can also be very easily
adjusted using a default XML file (Configuration.xml). The configuration file can be
found in the user directory under ..\Driversettings\TestBedDCOMDriver (e.g.,
D:\KistlerData\DriverSettings\TestBedDCOMDriver).
The KiBox analyzes the transferred name of the operating parameter, searches for this
name in the list, and then applies the corresponding predefined unit if this is available.
Example:
Extract from Configuration.xml:
<OperatingParameters>
<Parameter id="01">
<name>OP_01</name>
<unit>Nm</unit>
Test bench transfers operating parameter: Name=OP_01 and value=50.
Three values in saved open file: OP_01, 50, Nm

7.2.2 Apicom Horus


For the integration of the KiBox by using the standard interface, please proceed analog
to the integration of any kind of combustion analyzer via serial interface. Additionally
there is a special KiBox driver available.

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7.2.3 D2T Morphe


For the integration of the KiBox by using the standard interface, please proceed analog
to the integration of any kind of combustion analyzer via serial or DCOM interface.

7.2.4 Horiba Stars


For the integration of the KiBox by using the standard interface, please proceed analog
to the integration of any kind of combustion analyzer via serial or DCOM interface.

7.2.5 Troubleshooting of the Test Bench Communication


For the troubleshooting of the test bench communication the file Testbed.log can be
analyzed.
1. Open KiBox device IP address in your favorite web browser. Click on 1st hyperlink
„Application Files“

2. Select the hyperlink “Test Bed Log File”

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3. In the Testbed.log File you can see the ASCII communication between PUMA ( T =
Testbed ) and KiBox ( K = KiBox ). Timestamps are always in UTC. <13><10> are
“end of command” characters (0x0D 0x0A). In case of communication problems
please send this file together with a detailed description to Kistler.

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8. Maintenance and Troubleshooting

8.1 Software Updates

The following firmware updates can be performed:


 Firmware Update for the combustion analysis system (basic unit)
 Firmware Update for the charge amplifier used

Informations about firmware updates are available at www.kistler.com.


The time of delivery latest firmware is on the installation CD in the
package. After installation of KiBoxCockpit the supplied firmware
versions are stored in the "firmware" file of the KiBoxCockpit
installation directory.

Procedure for updating the firmware:

1. Open "Tools - Update" in the KiBoxCockpit.


2. Selecting the module for the firmware update (KiBox or charge amplifier).
3. Use the button "Update", locate the desired firmware file (*. tar) and select it.
4. Execute the update with "Yes". The update progress will display in a status window.
5. Was performed successfully after the update, this is confirmed in a corresponding
information window. "Ok" the window is closed again.
6. Run additional updates (for other components) or close the update manager.

During the entire update the status LEDs for each channel are switched
on and off several times. At the end of the update the system is
automatically switched off and on again.

During the update process may not eliminate the combustion analysis
system or its power supply be interrupted. So pay attention to a stable
power supply (eg, external power supply) during the firmware update.

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8.2 Troubleshooting

The KiBox To Go and the KiBoxCockpit assist the user in operation with various
functions to ensure the flow of information and to resolve problems or errors.
Hardware - KiBox:
Various LED indicators on the combustion analysis system, amplifier modules, crank
angle adapter, current clamp and Gigabit Ethernet switch display the current device
status. Details can be found at the appropriate instructions in the "Hardware and
System Overview".

Software - KiBoxCockpit:

For information and troubleshooting KiBoxCockpit provides the various feedback to


the user. On the one hand, status information is displayed in the status bar. On the
other hand, some messages are acoustic (activate the speaker!) Via voice and / or
generated with the help of pop-up windows.
The following types of messages can be distinguished:
 general status in KiBoxCockpit
 System Integrity Warnings in KiBoxCockpit
 Info (pop-up window with "?" Symbol)
 Error (pop-up window with a red "x" symbol)
 Fatal error (pop-up window with a red "x" symbol)

Please note in each case the exact type of this message and
information. For more information and support, please contact the local
representative of Kistler.

FAQs:
 Two-digit cylinder numbers (eg PCYL_01): Menu: "Edit - Layout Properties - TAB:
Miscellaneous ", then" activate cylinder numbers with two digits. "
 Maximum operating temperature: Mainboard warning at temperatures higher than
55 ° C -> warning, greater than 65 ° C-> Emergency shutdown
 collect log files for troubleshooting: Menu "Help - Log Collector" a connected KiBox
is necessary!

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9. Appendix
In the following sections, detailed and basic information on some of the topics
discussed thus far is given.

9.1 User Interface Design In Detail

9.1.1 Menu Bar


The structure and content of each menu based largely on the commonly used
standards. All menus can be fully operated with the computer keyboard using
shortcuts and the cursor keys.
The following seven menus described are available:

It is important to note that depending on the current system


configuration resp. of the KiBox status, individual entries in the menus
may not be available. Furthermore, the number of available sub-points
at certain points of a menu can also vary.

Menu File

 Open Data File ... F10:


Opens a data file (*. open)

 Store data... F12


Saves the current measurement data of the ring storage in a data file with the extension
*.open.

 Export data:
If a data file (*. open) is open so that the symbol "Saved Data" is activated, the
selection "Export data" opens a dialog, with which a new data file with customized data
can be exported separately into an ASCII file (*. csv).

 Close Data:
If a data file (*. open) is open so that the symbol "Saved Data" is activated, this
data file is hereby closed.

 Convert Data:
Using "convert data", data files (*. open) will be converted into other angle / time-
based formats such as IFILE or MDF.

 Data Properties:
If a data file (*. open) is open, it can access via the corresponding data, various
properties such as capture type, creation date, description, information concerning the
KiBox, the KiBoxCockpit and so on. Also, the original parameter file with which the

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present data was collected is exported.

 Create new parameters:


Creates a new parameter file. Here, a completely empty configuration is loaded.

 Open Template :
Opens a previously created template (*. kit). Start a new parameterization with this
menu item.

 Open Parameter:
Open a previously created parameter file (*. kip).

 Save parameters:
The currently edited parameter file (*. kip) is saved under the current name. The
existing file is overwritten without warning.

 Save the parameters as...:


...Parameter: The currently edited parameter file (*. kip) is saved under a new name.
...Template: The currently edited parameter file (*. kip) is saved as a new template
e.g. for the company standard (KiBox template *.kit).

If since the last save, changes have been made in the parameter file,
this is identified in the title bar of the KiBoxCockpit window by the
name of the parameter file with a "*". For example: .... Kip *

 Save Layout:
Saves the current layout under the name used for the layout already.

 Save Layout As ...:


Saves the current layout under a new name.

 New layout:
Creates a new layout. The now visible empty display window is constructed the same as
the display of stored data and is therefore parameterized analogously.

 Exit:
Finish KiBoxCockpit. Prior to this you will be prompted to save the configuration if it has
not been completely stored.

Menu Edit

 Clear parameters:
By selection all parameters are deleted and there is an empty parameter file (*. kip).

 Clear Layout:
Deletes the currently displayed representation (layout) of stored data. There is then a
new layout without any display data, which can be reconfigured.

 Layout Properties:

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This menu item opens a dialog box with two tabs. The register "units" includes settings
for unit selection for calculations and displays. The tab "Miscellaneous" includes settings to
format the result name. This will determine how accurately the automatically generated
result name of the *.open files should be marked.

Details of the units:

Angle °CA

Current A

Electric charge C

Energy J

Force N

Frequency Hz

Length m

Performance W

Pressure bar, Ps, psi

SPL dB

Temperature: °F, K, °C

Time s

Voltage V

Volume l, m 3

Rotation speed 1/s, rpm, 1/min

Torque Nm

Angle °,rad

Other details:
Selects whether the auto-generated result / signal name in the form
"cylindernumber_name" or "name_cylindernumber" should be created. In addition, the option
can be selected, to represent the cylinder number in two digits.

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If the unit settings are to be made at a certain time, the other settings
in the parameter file that have already been made, the dependent
entries that already exist are automatically converted.

Menu View

 Parameters (F11):
By selecting "parameters" the Parameter Editor view opens. The various settings of the
navigation buttons are visible.

 Check parameters (F2):


This selection changes the the parameter check view. This shows the current system
status on the basis of existing / previously entered parameters.

 Searching KiBox (F3)


Opens the dialog to search for connected devices on the network (alternatively accessible
via: "Tools - Options...- KiBox ").

 Message Window (F8)


Shows or hides the message window at the lower boarder of the screen.

 TDC (F9):
Displays the dialog of TDC-determination (or navigation key "TDC" in the "parameters").

 Enter Admin password:


Opens the dialog to enter or change the administration password.

 Show data:
Change to the view of current data of the ring storage (Online-View, Post measurement
View)

 Show data file:


Change to the view of stored data (Offline View)

 Zoom:
Under the menu item "zoom", all sub-items like "zoom in", "Zoom out","zoom window",
"automatic scaling" and "move curves" are visible and can be selected.

Always only one zoom setting can be active (marked with a tick).
Further details on each zoom options are available in the following
"symbol bar" section.

 Angle data:
Switches the mode to display the data angle based.

 Time data:
Changes the mode to display data on a time base.

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The setting of "time data" or "angle data" is an "either-or choice,"


marked with a tick. The activation of one setting automatically disables
the other.

Menu Measure

 Start (F5)
A measurement is started. Change to Online-View ..

 Stop (F7)
A measurement is stopped. Change to Postmeasurement view.

 Capture (F6)
By "capture", the recording and storage of measurement data while an ongoing
measurement is triggered, depending on the settings under "Data output - events".

 Shift Phase (F4)


Enabling this selection causes a phase shift of the crank angle signal (switch of TDC gas
exchange to TDC firing )

Menu KiBox

 Switch on
KiBox is switched on.

 Switch off
KiBox is switched off.

 Disconnecting
The KiBox can be disconnected from the network via the "Disconnect" button.
Offline operation enables significantly faster parameterization of the kip file. Press
the "Switch on" button to then reconnect the KiBox.

The switch on-off function on KiBoxCockpit only works if at least once


a connection has been made to KiBox.

If the KiBox is manually switched off by the power button, it must be


started again the next time that way.

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Menu Tools

 Updates ...:
Opens the Update Manager. This allows installing firmware updates of KiBox and
amplifiers. The updates will be installed from the appropriate installation folder, or from any
storage medium. Details of the update dialog are explained in chapter maintenance and
troubleshooting.

 Options ...:
By selecting a configuration window opens. It contains the registers "KiBox", "User Level",
"Language",”Remote”, "Power Management", "Warnings" and "Directories".
In the register "KiBox" the Ethernet connection between the computer and combustion
analysis system is configured. Also the inversion of digital out signals is available here.
The different user levels have an impact on the visibility of features in the UI.
Remote Control manages the installed remote drivers. It could be chosen which driver
should be used.
In the language section you can set the language and also country-specific number
formats.
The power management defines if switching on and off the KiBoxCockpit also switches on
and of the KiBox.
As part warnings several security queries in connection with the operation of KiBoxCockpit
are defined.
In Directories the paths are set, in which the whole user directory, templates, parameters,
layouts, and EventHandler data files are located or will be stored.

The settings for language and numerical format will take effect only
after restarting the KiBoxCockpit.

Menu Help

 Content (F1):
The help function is invoked. This is context sensitive and is possible with the key "F1"to
any point in the KiBoxCockpit.

 Hot Keys (Ctrl + F1):


Opens the shortcut chapter in the help.

 kiBox Update Newsletter:


Opens the dialogue for KiBox newsletter registration..

 Kistler on the web:


Opens the Kistler website in your default browser.

 Log directory:
Opens with the help of Explorer, the folder with the log files of the KiBoxCockpit. Here
the problems and errors during operation of the KiBoxCockpit are saved as *.txt files.
These files can be important for Kistler support. The path is usually located: "... \

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ApplicationData \ Kistler \ KiBoxCockpit \ Logs".

 Log Collector:
Support Tools: Enabling the collection of various logs, whereby the support can optionally
be accelerated.

 Log Control:
Support Tools: Settings, what type of information should be logged (changes will take
effect only after restarting KiBoxCockpit)

 System Information:
Opens the Windows system information of the used PC.

 Info
With this selection, the information window with basic information about the currently used
combustion analysis system hardware and software KiBoxCockpit displays. Keep this
information ready when requesting support!

9.1.2 Symbol Bar


Important and frequently used functions from the various menus are summarized in
the symbol bar and can be reached by clicking on its icon. The following functions are
directly available:

Open Data File (F10) Opens an existing data file into the offline view.

Remember: By default, automatically the last used folder is


called.

Open Parameter File


Opens an existing parameter file
(Ctrl + O)

Remember: By default, automatically the last used folder is


called.

Save Data (F12) Saves measurement data into a data file (*.Open)

if no current data in the memory of KiBox are


Disabled
available.

Remember: Current data is only available after a measurement.


An opened data file cannot be saved. Only a
modified layout can be stored in a data file.

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Save Parameters
Saves an existing parameter file
(Ctrl + S)

Disabled if the online-view is active.

Remember: By default, automatically the last used folder is


called.

Start measurement (F5) Starts a measurement, switch to online view

Disabled - if no (or incomplete) parameters were defined


- If there is no connection to KiBox

By starting a measurement, the stored settings


Remember: "Data output - events" are enabled and data
recorded in accordance with the specifications.

Capture (spacebar, F6) Starts a manual capture

Disabled - if the data set is too large for a planned capture


- If there is no connection to KiBox
- If no measurement is active

Previously, continuous measurement must have


Remember:
been started.

Stops the continuous measurement. The


Stop measurement (F7)
KiBoxCockpit changes to postmeasurement view

Disabled when measurement is not active

Remember: An active capture process is still completed even if


the measurement is stopped manually.
The data in the storage ring can be saved manually
(F12).

Shift Phase Manually changing the phase of the TDC

Disabled - If no measurement is active

Show data Switch to online / postmeasurement view

Disabled if no current data in the storage ring are available

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Show data file Change to offline view

Disabled if no data file is open(*. open)

Remember: Stored data is data that is already stored in a file.


An open data file cannot be saved. Only a modified
layout of the display can be stored in the data file.
Data from an open data file can be exported (. Csv)

Opens the Parameter Editor, editing the


Parameters (F11) parameters for a template or parameter files is
possible.

Disabled if a capture process is active

This icon zoom in to a chart. It is activated by the


Zoom in
icon and used by click on a chart.

Remember: This is an "on/off setting," that can be turned on or


off. With the cursor, the appropriate function is
executed on a graph.
Click point on the graph zooms both axes and
represents a new center
Click point on the axis zooms in on just this one
axis.

This icon zooms out to a chart. It is activated by


Zoom out
the icon and used by click on a chart.

Remember: See "Zoom in"

This icon can be a chart zoom in regions. It is


activated by the icon and used by select the
Zoom window
desired range by pressing and holding the mouse
button.

Remember: This is an "on / off setting". With the cursor over


the appropriate graph it is executed on a graph.

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Moves the visible range, respectively. the axis of a


Move curves
chart and show the desired (partial) view.

Remember: This is an "on/off setting," that can be turned on or


off. With the cursor the appropriate function is
executed on a graph.

With this symbol, the axes of all plots are scaled


Autoscale
automatically.

Remember: This is an "on/off setting," that can be turned on or


off. With the cursor over the appropriate function
is executed on a graph.

By enabling the setting "angle data", all elements


are displayed with an abscissa (indicating either
Angle data
the time or angular data) as a function of crank
angle.

Remember: This is an "either / or setting." There can be only


"angle," or "time data" (see below) enabled.

By enabling the setting "time data", all elements


Time data are displayed with an abscissa (indicating either
the time or angle values) as a function of time.

This is an "either / or setting." It can only be


Remember:
activated "angle (see above) or " time data".

Save Layout This icon can save a created layout.

Disabled if no layout is loaded

Select a saved layout, and use it to display the


Select Layout
currently open data.

Disabled If no layout is loaded

MDF Stream Enable/disable of local data storage.

Disabled If there is no connection to KiBox.

/ Remote Access Activation/Deactivation of remote access.

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9.1.3 Navigation Bar


The navigation bar consists of two parts. The navigation buttons are located in the
lower part and serve the coarse navigation. In the upper part houses the navigation
tree, which is used for detailed navigation within a single navigation button.

Figure 118: Construction of the user interface, navigation

The following 8 navigation buttons are available:


 Administration:
As part of the administration settings are to be found in daily operation normally (no
longer) need to be changed. These are settings such as the measurement principle of a
sensor, the signal names used, etc.

 Engine:
At this point, all information required for indication of the used engine is specified. In
addition to the name of the engine used, information must be entered on the points of
engine type, geometry, and firing sequence.

 Signals:
Management of all signals to be used for measurement.

 Statistic:
Configuration of general statistics calculations from any available result.

 TDC:
In the "TDC" the settings and the actual implementation of the determination of top dead
center (TDC) have to be done.

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 Data Display:
In the data display is defined which of the measured signals and the associated
calculations are displayed.

 Data output:
At this point it is determined which of the displayed signals with associated calculations to
be stored. It will also give further details about folder and file extension of the data.

 Parameter Check
Settings and parameters are subjected to a plausibility check. In order to be found
missing, incorrect or implausible configurations and corrected with the necessary assistance.

9.1.4 Status Bar


In the status bar the current state of KiBoxCockpit is shown. This information will be
conveyed to the following areas:
 Connection to KiBox
 Memory status
 Parameter
 System Integrity
 Remote Control Status (INCA, Test bench)

Figure 119: User interface, status bar

9.1.5 Dialogue Field


The various dialog boxes are the actual working areas of the user interface and are
individually marked. Depending on the particular settings required there are different
mapped areas. Basically, the dialogues include schematics, settings, and display
various other information. Special mention are the following components:
 Easy entry text(lowest part)
 Signal flow chain (symbols connected with orange arrows), horizontally from left to
right
 Display oscilloscopes (middle part, black)
 By means of the red dashed, orthogonal line it is possible to displace the shown
signal along the time axis in the oscilloscope. This line and the horizontal, red
dashed line represent a point of intersection, which is allocated on the shown
signal curve.
 Pool with orange signal (vectors) and green (scalar) fields labelled

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The easy entry text gives first information on this dialog and simplifies
the structured work.

9.2 Thermodynamic Zero Point Correction

The method of thermodynamic zero point correction assumes an adiabatic


compression between the nodes  and  2 and a constant polytropic exponent .
From the pressure difference between the two points of the characteristic curve of
compression the absolute pressure level is calculated back by using the polytropic
equation pV = constant and the given .
k

Formal description

averaged pressure

Averaging window (user input)

Reference point 1 (user input)

Reference point 2 (user input)

Polytropic exponent

Volume at reference point 1

Volume at reference point 2

Zero line correction

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9.3 Thermodynamic Loss Angle

As a thermodynamic loss angle is called an offset between the maximum of measured


cylinder pressure curve in coasting mode and the mechanical TDC of the piston. Due to
wall heat losses and leakage the pressure maximum is before the mechanical TDC. The
loss angle decreases when the engine is warm, with increasing speed and lies in
today's engines in a range from 0.5 to about 1.2 °CA at 2500 r / min. Applying the
TDC-determination by cylinder pressure in coasting mode requires the knowledge of
the exact thermodynamic loss angle in the corresponding operating point.

Figure 120: Thermodynamic loss angle

A determination of this loss angle can be made by first carrying out a capacitive TDC-
determination. This determines the mechanical TDC. By a subsequent thermodynamic
TDC-determination with the unfired pressure curve and the indication of a
thermodynamic loss angle of 0 °CA you get the TDC-Offset as result. This Offset
defines the exact thermodynamic loss angle in this operating point.

9.4 Noise

Method: From the complete cycle of each cylinder pressure curve is calculated the
frequency spectrum by using a Fast Fourier Transformation to the base 2. Then the

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resulting sound pressure level of Terz middle frequencies will be totaled. Depending
on the result of the frequency band is first assessed by means of a transfer function
(addition, because of logarithmic).
Table of Terz middle and cutoff frequencies:

Center of [Hz] to [Hz] Structure A_filtered [dB]


frequency Damping [dB]
[Hz]

100 0.01 112 -143 19.1


125 112 141 -137.5 -16.1
160 141 178 -132.4 -13.4
200 178 224 -127.8 -10.9
250 224 282 -122.3 -8.6
315 282 355 -117.2 -6.6
400 355 447 -112.3 -4.8
500 447 562 -108.2 -3.2
630 562 708 -103.8 -1.9
800 708 891 -100 -0.8
1000 891 1122 -96.5 0
1250 1122 1413 -93.3 0.6
1600 1413 1778 -90.8 1
2000 1778 2239 -89.7 1.2
2500 2239 2818 -89.5 1.3
3150 2818 3548 -90.6 1.2
4000 3548 4467 -94.2 1
5000 4467 5623 -99.2 0.5
6300 5623 7079 -105.6 -0.1
8000 7079 8913 -116 -1.1
10000 8913 11220 -127.8 -2.5

9.5 Knocking

The combustion analysis system uses the Siemens-VDO algorithm for calculation of
knocking values.
The advantage of this algorithm is that knocking can be detected within a combustion
cycle. It requires no information from previous cycles.
Approach of the Siemens VDO algorithm:
1. Finding the maximum cylinder pressure:
If you already have a calculation of the maximum cylinder pressure which is inserted
into the administration, this result is used. Otherwise, the calculation is performed
internally with default settings.

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2. Smoothing of the cylinder pressure signal using the input value for the sliding
averaging.
3. Calculation of the high pass filtered signal by subtraction of the raw signal of
cylinder pressure and the smoothed signal.
4. Rectification of the high-pass filtered signal
5. Selection of reference window and knock window depending on settings.
Reference window: Range of input value "before maximum pressure" to value
"Maximum Pressure + Offset"
Knock window: Range of value "maximum pressure+ offset " to value "after
maximum pressure
6. Calculating the knock ratio: Ratio of integral within the range of knock window to
the integral within the range of reference window (knock integral / reference
integral).
A summation of 1.5 for each ratio prevents a divide by zero.

Figure 121: Siemens VDO knock algorithm: Method

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9.6 Digital Channel Pin Assignments

Digital Inputs

Pin assignment: Function Pin Pin


Digital In DI1+ 1
DI2+ 2
DI3+ 3
DI4+ 4
DI5+ 5
DI6+ 6
DI7+ 7
DI8+ 8
n.c 9
n.c. 10
n.c. 11
n.c. 12
n.c. 13
DI1 - 14
DI2 - 15
DI3 - 16
DI4 - 17
DI5 - 18
DI6 - 19
DI7 - 20
DI8 - 21
n.c 22
n.c 23
n.c 24
n.c. 25

The digital inputs are electrically isolated.

Max. input voltage V  30


Input level low V <1
Input level high V > 4,5
Input current mA <8
Voltage between input voltage and casing Vrms < 40

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Digital outputs

Pin assignment: Function Pin Pin


Digital Out DO1_TTL 1
DO3_TTL 2
DO5_TTL 3
DO7_TTL 4
GND_TTL 5
DO1a 6
DO2a 7
DO3a 8
DO4a 9
DO5a 10
DO6a 11
DO7a 12
DO8a 13
DO2_TTL 14
DO4_TTL 15
DO6_TTL 16
DO8_TTL 17
DO1b 18
DO2b 19
DO3b 20
DO4b 21
DO5b 22
DO6b 23
DO7b 24
DO8b 25

The 8 digital outputs are available once as 5V logic signals and once as electrically
isolated PhotoMOS Relay outputs.

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DOx_TTL DOxa/b

The two DOxa/b outputs are symmetrical and interchangeable. The outputs are
passive and can therefore be connected flexibly:

The voltage level can be selected.


Polarity can be selected (pull-up or pull-down resistor).
Multiple outputs can be logically connected to each other (wired or & wired and).
It is possible to switch between AC and DC currents.

Technical data of TTL outputs:

Low level @ 50 µA VDC < 0.1


Low level @ 5 mA VDC < 0.6
High level @ 50 µA VDC > 4.8
High level @ 5 mA VDC > 4.3

Technical data of PhotoMOS-Relay outputs:

Maximum voltage between two output pins VDC < 40


Permanent current load @ 25°C mA <120
Leakage current at switched off state µA < 10
Resistance at switched on state  < 35
Voltage between output and housing Vrms < 40

The outputs are overcurrent (e.g. short-circuit) protected. If the protective circuit was
active, the corresponding output hast to be deactivated before it can be activated
again.

9.7 Configuration Example for Using Virtual Channels

The following example shows the entire configuration of the injection timing
calculation for a four-cylinder engine. Only the two current probe inputs should be
used here. This is only possible if each current probe input contains the injection
information for two signals, i.e., a multiplexed signal. A current probe therefore
encompasses the control lines for the injectors for two cylinders, which ideally have
the largest possible angular ignition spacing.
Example engine:

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4-cylinder diesel
Firing order: 1 – 3 – 4 – 2
Angular ignition spacing: 180 °CA
CurrentProbe 1 is connected to CurrentClamp input 1.
The signal includes injection Cyl 1 and Cyl 4.
CurrentProbe 2 is connected to CurrentClamp input 2.
The signal includes injection Cyl 2 and Cyl 3.
The angular ignition spacing between the two injection processes is 360 °CA in a
physical signal. When dividing into virtual channels, every virtual channel then has 720
°CA/2 = 360 °CA available (entire combustion cycle/number of cylinders included in
the physical signal). The range available for a virtual channel should always be larger
than/equal to the angular ignition spacing of both cylinders included in the physical
signal for the intended measurement. In addition, the signal associated with one of the
two cylinders must remain within the virtual range at all times during the
measurement. Otherwise, the system cannot always assign the injections to the
respective cylinder reliably.
Example: The maximum injection duration (or the difference between the start of the
first injection and the end of the last injection) in the operating range to be measured
for the engine is 200 °CA. A summary of all of the cylinders in a current probe is
therefore not possible as the virtual channels only include 180 °CA (720/4). The four
cylinders must therefore be divided into 2 physical signals!

Configuration in "Administration – Channels":


The entire configuration refers to the reference cylinder, Cylinder 1 in this case.
The approach is described step by step below:
1. "Administration – Injection pulse signal type": Configure the thresholds for the start
and end of both current probe inputs.
2. "Administration – Channels – Current probe –1": Enter the virtual range of the
injection for cylinder 1. The expected injections for this type of engine are between
–180 °CA and +180 °CA.
-> Configuring a virtual signal for the reference cylinder: Start = –180 °CA, end =
+180 °CA and name = INJZ1 (Injection Cylinder 1).
-> Configuring the remaining virtual signals: For all other cylinders, the angular
ignition spacing for the respective cylinder is added on to the range (start and end)
of the reference cylinder. If the total is greater than 720, then 720 °CA must
subsequently be subtracted from both the value for the start and the value for the
end.
For Cylinder 4, the result is as follows: Start = 180 °CA, end = 540 °CA (start =
start for reference cylinder+angular ignition spacing for Cylinders 1 to 4 -> start: –
180 + 360 = 180; end = 180 + 360 = 540); name = INJZ4

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Figure 122: Configuration example for current probe 1

3. "Administration – Channels – Current probe –2":


Cylinder 3: Start: 0 °CA, end = 360 °CA (angular ignition spacing 1 – 3 = 180 ->
start: –180 + 180 = 0; end = 180 + 180 = 360); name = INJZ3
Cylinder 2: Start: 360 °CA, end = 720 °CA (angular ignition spacing 1 – 2 = 540 ->
start: -180 + 540 = 360; end = 180 + 540 = 720); name = INJZ2

Figure 123: Configuration example for current probe

4. "Administration – Injection pulse signal type – Diesel injection timing calculation":


Adjust the calculation range in the calculator on the virtual channel for the
reference cylinder.

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Figure 124: Configuration example for diesel injection timing calculation

5. Signals: Add the relevant virtual signal to each of the four cylinders. When selecting
the channel, the correct virtual channel can now be assigned to the corresponding
cylinder very easily using the defined name. Cylinder 1 = INJZ1, Cylinder 2 = INJZ2,
Cylinder 3 = INJZ3, Cylinder 4 = INJZ4

Figure 125: Configuration example for selecting channels in signals

9.8 Example User Formula

Work with User Formulas is explained in the following chapter using a number of
examples. In the first subchapter 9.8.1, a simple example is presented for a number of
functions that were explained in chapter "Formula syntax" (chapter 4.3.3.1). This is
intended to detail the use of the individual functions.

In the second subchapter 9.8.2, a more complex example of a User Formula is


explained, from the implementation in the Administration area to the integration in the
"Signals" tab to the display in measurement operation.

9.8.1 Simple examples of the User Formula functions


In this subchapter, a number of examples of the functions described in chapter 4.3.3.1
("Formula syntax") are shown. These are also subdivided into "calculation functions",
"control structures", "functions" and "constants".

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Calculation functions:
The left side of Figure 126 shows the implementation of the calculation functions. In
the calculation window, it can be seen at the left that names of the output variables are
described with their indices. These names must match the names defined under
"Output Name" (e.g., root). Because the used output variables are scalars (vectors of
size 1), the index is always 1.
At the right in the calculation window, the actual function can be seen. For example,
sqrt(4) returns the square root of 4. All of the functions are ended with a semicolon.
The "Default Signal Name" in the "Formula Output" area can be freely configured. The
result / signal then appears with this defined name in the measurement (see Figure
126, right). In the case of the square root of 4, the signal name was defined as "Root"
and is equal to 2.

Figure 126: Implementation of the calculation functions (left) and the corresponding result in
measurement operation (right)

In the above example, the assignment of the User Formula was not
explicitly declared under Signals. This is, however, mandatory in order
to depict the User Formula signals in the measurement environment.
For the complete implementation of a User Formula, see chapter 9.8.2.

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Control structures:

Figure 127 shows a corresponding example for the control structures. Two "Formula
Inputs" were defined with the names "IN_PCYL" and "IN_PMAX". At a later point in time,
these input variables will be assigned the cylinder pressure curve (PCYL) or rather the
maximum cylinder pressure (PMAX) in the "Signals" tab. Thus, if "IN_PCYL" or
"IN_PMAX" is used in the programming, input signal PCYL or input result PMAX is used
in this example.
The first example shows a For Loop that adds each value of the cylinder pressure
signal from index 1 to the last index of the signal (x.Length) with the "plus" variable.
The “plus” variable was defined under "Formula Variables" with the value 10*10^5.
Thus, the cylinder pressure curve is increased by 10 bar (10*10^5 pascal). This
calculated signal is output in the measurement environment (Figure 127) in the
progression chart as a red curve.
In the second example "If / else / end", PMAX is used as the input signal. If PMAX is
equal to or less than 85 bar, output variable DIG_ should have the value 1, otherwise 0.
For a PMAX of 94.7 bar in measurement operation (Figure 127, right), the value 0 is
therefore output. The "If / elseif / end" example behaves in a similar way; no further
explanation is therefore provided.
In the bottom example, the use of a switch / case condition is shown. In this example,
a query is performed to determine the case of the calculated variable "DIG_switch" (this
is defined in the example above). With a PMAX of 94.7 bar, case 2 thus occurs. In this
switch / case example, output variable "DIG_switch2" should receive the value 4 for
case 2. This can also be seen in the measurement environment (see Figure 127, right).

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Appendix

Figure 127: Implementation of the control functions (left) and the corresponding result in
measurement operation (right)

The names of the input variables do not need to include the names of
the signals assigned under "Signals". Thus, the name in the example
above does not need to be IN_PCYL or IN_PMAX. This serves the
purpose of clarity only. Also conceivable would be "In1" and "In2" as
well as any other name.

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Function:

The functions are shown in an example in Figure 128. Under "angle based functions", it
can be seen that the TimeSampleNumber is output at 90°CA after TDC and at TDC.
With the help of the sampling rate (TimeSamplingRate), the time in seconds that
elapses between these two points is calculated.
Furthermore, with the help of the "vol()" volume function and a FOR loop, the cylinder
volume can be displayed as a signal on the progression chart (red curve).

Figure 128: Implementation of the functions (left) and the corresponding result (right)

Unlike the angle-based functions, all signals are addressed with


indices.

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Constants:

The use of the constants described in chapter 4.3.3.1 can be seen in Figure 129.

Figure 129: Implementation of the constants (left) and the corresponding result (right)

9.8.2 Example implementation of a more complex User Formula


In the following chapter, the complete implementation of a User Formula will be
explained using a practical example. Here, the ignition signal of all four ignitions was
measured with a current probe and the voltage signal applied to an analog input
(Analog In 3A Top Connector). This signal was divided into four virtual channels and
assigned to the individual cylinders. Refer to Figure 130 to see how the virtual
channels are divided. The virtual channels serve as the input signal of the User Formula
example. For the detailed procedure on creating virtual channels, see chapter 9.7.

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Figure 130: Division of the ignition signal into four virtual channels

In Figure 131, the ignition signal (universal signal - Analog In 3A) over the crank
angles of the four cylinders can be seen. With the help of the User Formula, the
ignition time (falling flank) should now be depicted in the progression chart as a
marking and as a scalar value in the table.

Figure 131: Figure of the ignition signal [V] and pressure signal [bar] over the crank angles

Creating the formula:


To create the formula, a new formula is first added in the "Administration" tab in
"Formulas". In the left part of the figure below, it can be seen that a formula was added
in the "Formulas" heading and it was named "Ignition_Uni". Seen in the left part of the
main window is the formula name, a formula description and the definition of the used
variables.

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Figure 132: Example User Formula

Section 1: The first section of the User Formula is used to search for the falling flank of
the ignition signal. For this purpose, all indices of the input signal are checked for the
IF condition. For this test, the "Leveltobecrossed" variable was defined with size 1 and
value 2.5. The condition is met as soon as the input signal exceeds the value 2.5 and
drops below the value of 2.5 in the next index. This is the index being search for,
which is written as the value in variable IGN_index. Because the input signal is a
multiplexed signal with the resolution 0.1 °CA, which begins at -90°CA and not at -
360°CA as is typical, the missing 2700 ("indices") is added to variable IGN_index. The
value of this variable now corresponds to the index of the falling flank, as if the input
signal was not multiplexed. This leads to easier use and, as a result, can avoid errors.
(Another method is likewise conceivable)

Section 2: The scalar output value (ignition time) is calculated in section 2. Considering
that, with a resolution of 0.1°CA, the signals contain 7200 indices but a combustion
cycle consists of only 720°CA, the indices are multiplied by 0.1. Because the indices
begin with 1 but the combustion cycle begins with -360°CA, 360 must first be
subtracted from variable "IGN_index". Output variable "Out1" now corresponds to the
ignition angle. Because the User Formula calculates with SI units, it is imperative that
the value be converted to rad (even if it is to be output later in crank angles!).

Section 3: In section 3, an output vector "Out2" is calculated. This vector is to display


the value of variable "IgnSignal" at the ignition time and two indices later. All other
indices of vector "Out2" are to have the value 0. A marking for the ignition time is
thereby created in the progression chart.

The user formula is now validated and can then be added to the cylinders on the
"Signals" tab by right-clicking on the choosen cylinder and selecting "Add Formula"
(Figure 133). Use drag & drop in the main window to assign the input signal. In this
example case, the multiplexed universal signal. A unit can now be assigned for both

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output variables. The vectorial output variable is still to be provided with a range and a
resolution. For the example calculation, this must be set as in Figure 133.

Figure 133: Inserting the User Formula and adding the input signal

The "AIGN_Formula" and "Ignition" variables can now be used in the same way as a
result or a vector in the diagrams and data output. The calculated ignition time is
shown in a table in Figure 134. The second output variable calculated in the User
Formula, "Ignition", can also be seen in lower part of the display detail. This is depicted
as a curve and marks the ignition time in the progression chart.

Figure 134: Measurement with the ignition time calculated in the User Formula

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It is conceivable that another approach could be taken to solve the


above example. For sections 1 and 2, the use of the x.convertToRad
function would make sense and would simplify the calculation.

All of the above examples as well as a library of predefined User


Formulas for various applications that expand the scope of the system
can be downloaded free of charge at www.kistler.com/Kibox at the right
in the download area after logging in on the home page.

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List of Illustrations

Figure 1: Hardware, front view KiBox ............................................................................................... 12


Figure 2: Hardware, back view KiBo ................................................................................................. 15
Figure 3: Connection chart for inductive sensors .......................................................................... 18
Figure 4: Connection chart for hall sensors .................................................................................... 18
Figure 5: Proposed placement in the vehicle: Trunk (left), foot space in front of the rear
seat (center), rear seat (right) ...................................................................................... 21
Figure 6: Schematic measurement setup with access to application system............................. 22
Figure 7: Schematic measurement setup for standalone operation ............................................ 23
Figure 8: First connection: KiBox search ......................................................................................... 28
Figure 9: Connection status in the status bar ................................................................................. 28
Figure 10: Design of the KiBoxCockpit user interface ................................................................... 29
Figure 11: Note to incorrect input .................................................................................................... 30
Figure 12: Correct use of the decimal separator ............................................................................ 31
Figure 13: Menu bar after activation of the key control by the "Alt" key .................................... 31
Figure 14: Administration: Signal type cylinder pressure ............................................................. 35
Figure 15: Administration: Signal type digital signal ..................................................................... 36
Figure 16: Administration: Signal type eccentric angle ................................................................. 36
Figure 17: Administration: Signal type exhaust pressure ............................................................. 37
Figure 18: Administration: Signal type ignition pulse ................................................................... 37
Figure 19: Administration: Signal type ignition pulse digital ....................................................... 38
Figure 20: Administration: Signal type injection pressure ............................................................ 38
Figure 21: Administration: Signal type injection pulse ................................................................. 39
Figure 22: Administration: Signal type injection pulse digital ..................................................... 40
Figure 23: Administration: Signal type intake pressure ................................................................ 40
Figure 24: Administration: Signal type torque ................................................................................ 40
Figure 25: Administration: Signal type universal ........................................................................... 41
Figure 26: Administration: Signal type crank angle with adapter ................................................ 41
Figure 27: Administration: Signal type crank angle with optical encoder .................................. 43
Figure 28: Administration: Calculation of CDM and Trigger ........................................................ 44
Figure 29: Administration: Calculation of cycle number ............................................................... 45
Figure 30: Administration: calculation of digital state and position ........................................... 45
Figure 31: Administration: Calculation of heat release ................................................................. 46
Figure 32: Administration: Calculation of ignition timing ............................................................ 48
Figure 33: Administration: Calculation of mean effective pressure ............................................ 49
Figure 34: Administration: Calculation of injection timing diesel ............................................... 51
Figure 35: Administration: Calculation of injection timing gasoline ........................................... 52
Figure 36: Administration: Calculation of knocking ...................................................................... 53
Figure 37: Administration: Calculation of maximum..................................................................... 56

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Figure 38: Administration: Calculation of maximum rise ............................................................. 57


Figure 39: Administration: Calculation of mean value .................................................................. 58
Figure 40: Administration: Calculation of noise ............................................................................. 59
Figure 41: Administration: Calculation of speed ............................................................................ 60
Figure 42: Administration: Calculation of zero point correction ................................................. 61
Figure 43: Administration: User Formula ........................................................................................ 63
Figure 44: Layout properties (definition of units) .......................................................................... 67
Figure 45: Administration - Channels: Configuration overview .................................................. 72
Figure 46: User interface of navigation button engine .................................................................. 74
Figure 47: Expert Level: alternative volume function .................................................................... 76
Figure 48: Example for volume asii file ........................................................................................... 78
Figure 49: Channel selection (AnalogIn, Current probe, DigitalIn) .............................................. 79
Figure 50: Selecting divided virtual channels ................................................................................. 79
Figure 51: Signal: Cylinder pressure top connectors ..................................................................... 80
Figure 52: Signal: Cylinder pressure amplifier input ..................................................................... 81
Figure 53: Signal: cylinder pressure, Expert level: ......................................................................... 83
Figure 54: Signal: Digital Signal, Injection Pulse Digital, Ignition Pulse Digital ......................... 83
Figure 55: Signal: Eccentric angle ..................................................................................................... 84
Figure 56: Signal: Injection pressure top connector ...................................................................... 85
Figure 57: Signal: Injection pressure amplifier input..................................................................... 87
Figure 58: Signals: Injection pressure – Expert level ..................................................................... 88
Figure 59: Signal: Injection / Ignition pulse .................................................................................... 89
Figure 60: Signal: Intake pressure .................................................................................................... 90
Figure 61: Signal: Torque................................................................................................................... 91
Figure 62: Signal: Universal ............................................................................................................... 92
Figure 63: Signal: Crank angle .......................................................................................................... 93
Figure 64: Signals: Formula ............................................................................................................... 94
Figure 65: Configuration for calculating general statistics results .............................................. 96
Figure 66: TDC: Current values ......................................................................................................... 98
Figure 67: TDC: From cylinder pressure .......................................................................................... 99
Figure 68: TDC: With capacitive TDC probe .................................................................................. 101
Figure 69: Diagrams: Configurations dialog, starting position .................................................. 103
Figure 70: Statistics Chart................................................................................................................ 106
Figure 71: X-Y diagram configuration ........................................................................................... 107
Figure 72: Data Display: Edit tabs .................................................................................................. 108
Figure 73: Data Output: Channels Data file (.open) ..................................................................... 109
Figure 74: MDF configuration overview ......................................................................................... 111
Figure 75: Vector signal group settings ........................................................................................ 112
Figure 76: Data output: CAN output (view: beginner / advanced) ............................................ 114
Figure 77: Data storage: CAN output Detail view......................................................................... 114
Figure 78: Data output: Experts view CAN output ...................................................................... 115
Figure 79: Data output: Limit Monitoring ...................................................................................... 116
Figure 80: Test bed data output ..................................................................................................... 118

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Figure 81: Data output: Events ....................................................................................................... 119


Figure 82: Data output: Data File ................................................................................................... 120
Figure 83: Parameter Check ............................................................................................................ 121
Figure 84: New tab "Hardware" ....................................................................................................... 122
Figure 85: Range settings of the channels under "Administration" (left) and subsequent
cylinder assignment in the signal level (right) ........................................................ 123
Figure 86: LVDS splitter box (type 2633A) at left and synchronization cable at right ........... 124
Figure 87: Establishing a connection in cascaded operation ..................................................... 125
Figure 88: Dialogue manual data storage ..................................................................................... 127
Figure 89: User Interface: Visualization of stored data ............................................................... 129
Figure 90: Data player ...................................................................................................................... 131
Figure 91: Data cursor and difference cursor ............................................................................... 132
Figure 92: Settings for exporting data files .................................................................................. 133
Figure 93: Exporting the open-data in Matlab ............................................................................. 135
Figure 94: Options Remote .............................................................................................................. 139
Figure 95: Inca: Network Manager .................................................................................................. 141
Figure 96: Inca: Network Manager IP Configuration .................................................................... 141
Figure 97: Inca hardware configuration: Add KiBox ................................................................... 142
Figure 98: Inca hardware configuration: Add KiBox (2) .............................................................. 142
Figure 99: Inca hardware configuration: Configure KiBox .......................................................... 143
Figure 100: INCA Remote active ..................................................................................................... 144
Figure 101: Settings for INCA remote control .............................................................................. 146
Figure 102: Settings for remote event recording ......................................................................... 146
Figure 103: Transferring the file name / MDF streaming ........................................................... 147
Figure 104: Identical storage name and storage location .......................................................... 147
Figure 105: Example configuration of a variable to trigger a capture by Inca ........................ 148
Figure 106: Add CAN-DB ................................................................................................................. 150
Figure 107: Add "CAN-Hardware" .................................................................................................. 151
Figure 108: CAN Configuration ....................................................................................................... 151
Figure 109: CAN-cable scheme ...................................................................................................... 152
Figure 110: PUMA SYS ...................................................................................................................... 154
Figure 111: PUMA MDV: New Device .............................................................................................. 155
Figure 112: PUMA CDH Wizard ....................................................................................................... 155
Figure 113: PUMA: Load KiBox.mdd ............................................................................................... 156
Figure 114: PUMA CDH: Device Properties .................................................................................... 157
Figure 115: PUMA CDH: KiBox Settings ......................................................................................... 158
Figure 116: PUMA CDH: View KiBox.wnd ...................................................................................... 159
Figure 117: DCOM registration tool ............................................................................................... 161
Figure 118: Construction of the user interface, navigation ........................................................ 177
Figure 119: User interface, status bar ........................................................................................... 178
Figure 120: Thermodynamic loss angle ........................................................................................ 180
Figure 121: Siemens VDO knock algorithm: Method ................................................................... 182
Figure 122: Configuration example for current probe 1 ............................................................ 187

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Figure 123: Configuration example for current probe ................................................................ 187


Figure 124: Configuration example for diesel injection timing calculation ............................. 188
Figure 125: Configuration example for selecting channels in signals ...................................... 188
Figure 126: Implementation of the calculation functions (left) and the corresponding
result in measurement operation (right) .................................................................. 189
Figure 127: Implementation of the control functions (left) and the corresponding result in
measurement operation (right).................................................................................. 191
Figure 128: Implementation of the functions (left) and the corresponding result (right) ...... 192
Figure 129: Implementation of the constants (left) and the corresponding result (right) ..... 193
Figure 130: Division of the ignition signal into four virtual channels ....................................... 194
Figure 131: Figure of the ignition signal [V] and pressure signal [bar] over the crank
angles ............................................................................................................................ 194
Figure 132: Example User Formula ................................................................................................ 195
Figure 133: Inserting the User Formula and adding the input signal ....................................... 196
Figure 134: Measurement with the ignition time calculated in the User Formula .................. 196

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Index
Add CAN-DB ............................................................................................................................... 150
Administration ........................................................................................................................ 34, 62
Administration - Calculations ....................................................................................................... 44
Administration - Signal Types ....................................................................................................... 35
Alternative Volume Function ......................................................................................................... 76
Appendix: ................................................................................................................................... 167
Application Areas Of KiBox.............................................................................................................. 5
Application Systems .................................................................................................................... 139
capture triggered by INCA: .......................................................................................................... 147
CDM and Trigger ........................................................................................................................... 44
Channels: Data File, CAN Output, Limit Monitoring ..................................................................... 108
Configuration ........................................................................................................................ 26, 140
Crank angle ................................................................................................................................... 41
Crank Angle Adapter Type 2619 Function ..................................................................................... 16
Cursor functions: ........................................................................................................................ 132
Cycle Number ................................................................................................................................ 44
Cylinder Pressure .......................................................................................................................... 35
Data File ...................................................................................................................................... 120
Data Output ................................................................................................................................ 108
Delivery, Accessories And Spare Parts ............................................................................................. 8
Diagrams............................................................................................................................. 103, 128
Dialogue Field ............................................................................................................................. 178
Digital Signal ................................................................................................................................. 36
Digital State and Position .............................................................................................................. 45
Disposal Instructions ....................................................................................................................... 8
Eccentric Angle.............................................................................................................................. 36
Energy Management ...................................................................................................................... 27
Engine ........................................................................................................................................... 74
ETAS INCA ................................................................................................................................... 140
Ethernet Settings On The Notebook Operating System And In The KiBoxCockpit .......................... 27
Evaluation ................................................................................................................................... 128
EventHandler ................................................................................................................................. 26
Events ......................................................................................................................................... 118
Exhaust pressure ........................................................................................................................... 37
FAQs ........................................................................................................................................... 166
File Formats ................................................................................................................................ 136
First Connection ............................................................................................................................ 28
For Your Safety ................................................................................................................................ 6
Hardware....................................................................................................................................... 12

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Hardware And System Overview ............................................................................................ 11, 166


Hardware Installation .................................................................................................................... 19
Heat Release.................................................................................................................................. 45
Ignition Digital Signal .................................................................................................................... 38
Ignition Pulse ................................................................................................................................ 37
Ignition timing .............................................................................................................................. 48
Important Notices ..................................................................................................................... 5, 30
INCA Recorder ............................................................................................................................. 145
Indicated Mean Effective Pressure ................................................................................................. 48
Injection Digital Signal .................................................................................................................. 40
Injection Pressure .......................................................................................................................... 38
Injection Pulse ............................................................................................................................... 39
Injection Timing Diesel .................................................................................................................. 51
Injection Timing Gasoline .............................................................................................................. 52
Installation ............................................................................................................................ 19, 140
Installing The KiBoxCockpit Software ............................................................................................ 23
Intake Pressure .............................................................................................................................. 40
Integration Into External Systems ................................................................................................ 138
Introduction .................................................................................................................................... 5
KiBox To Go Type 2893 Terminals, Display And Controls ............................................................ 12
Knocking ......................................................................................................................... 53, 55, 181
Limit Monitoring .......................................................................................................................... 116
Maintenance And Troubleshooting .............................................................................................. 165
Maximum ...................................................................................................................................... 55
Maximum Rise ............................................................................................................................... 57
MDF4 .......................................................................................................................................... 110
Mean Value ................................................................................................................................... 58
Measurement Setup With Access To An Application System .......................................................... 21
Measurement Setup Without Connection To An Application System .............................................. 22
Measuring ................................................................................................................................... 144
Mental Concept, Basic Settings And Input Errors ........................................................................... 30
Menu Bar ..................................................................................................................................... 167
Navigation Bar ............................................................................................................................. 177
Noise ............................................................................................................................... 59, 60, 180
Online-View ................................................................................................................................ 126
Optical Crank Angle Encoder ......................................................................................................... 18
Other Application Systems .................................................................................................. 116, 150
Parameter Check ......................................................................................................................... 121
Parameterization Of KiBoxCockpit ................................................................................................. 29
password....................................................................................................................................... 34
Preface ............................................................................................................................................ 1
rapid prototyping ........................................................................................................................ 113
Run Measurement ....................................................................................................................... 126

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Saving, Exporting, and Converting The Measurement Data ................................................. 132, 137
Shortcuts ....................................................................................................................................... 31
Signal: Crank Angle ....................................................................................................................... 93
Signal: Cylinder Pressure ............................................................................................................... 79
Signal: Digital, Injection digital signal/Ignition digital signal ......................................................... 83
Signal: Eccentric Angle .................................................................................................................. 84
Signal: Injection Pressure .............................................................................................................. 85
Signal: Injection/Ignition Pulse ...................................................................................................... 89
Signal: Intake Pressure/ Exhaust Pressure ..................................................................................... 90
Signal: Torque ............................................................................................................................... 91
Signal: Universal ............................................................................................................................ 92
Signals .......................................................................................................................................... 78
Software Installation And Configuration ................................................................................ 23, 140
Software Updates ........................................................................................................................ 165
Speaker ......................................................................................................................................... 28
Speed ............................................................................................................................................ 60
standalone mode......................................................................................................................... 110
Stand-alone operation ................................................................................................................ 152
Statistical Calculations .................................................................................................................. 96
Status Bar .................................................................................................................................... 178
Storing Data ........................................................................................................................ 126, 133
Symbolbar ................................................................................................................................... 173
System Overview ........................................................................................................................... 11
System Requirements .................................................................................................................... 19
TDC: Determine The Position Of Top Dead Center ........................................................................ 96
Test Bed ...................................................................................................................................... 117
Test Bench Automation Systems .................................................................................................. 152
Thermodynamic Loss Angle .......................................................................................... 96, 101, 180
Thermodynamic Zero Point Correction ........................................................................................ 179
Tips for Using the Manual ............................................................................................................... 6
Torque .......................................................................................................................................... 40
Transport and Storage..................................................................................................................... 8
Troubleshooting .................................................................................................................... 12, 166
Universal ....................................................................................................................................... 41
User Interface Design .................................................................................................................... 29
User Interface Design In Detail .................................................................................................... 167
Visualization Of Measurement Data With KiBoxCockpit ............................................................... 128
Zero point correction .................................................................................................................... 60

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