Session 5 Control and Diagnostic Systems in Marine Applications PDF

Control and Diagmostic Systems in Marine
Applications
Dr Christian Poensgen, Dr. Mathias Moser
MAN Diesel & Turbo Dr. Christian Poensgen 13. International AVL Powertrain Diagnostic Symposium  26.06.2018 < 1 >
MAN Large Engine Portfolio
VW – MAN from 30 kW to 84280 kW
2 Stroke Engines
MDT S35ME-B9 MDT K98 ME-C
3.200 kW 84 280 kW
4 Stroke Medium Speed Engines

MDT 5L16/24 MDT 20V 45/60
500 kW 26 000 kW
4 Stroke High Speed Engine

MTB 12VD28 MDT 20V 28/33
1 324 kW 10.000 kW
VW SDI 1,9 MTB 12V D28 MDT 20V 171 MDT 20V 45/60 MDT K98 ME-C
430 MC
30 kW 1 324 kW 4 700 kW 26 000 kW 84 280 kW
Two Stroke New Engine Development
Continous Development of Engine Platform
The engine programme is defined by different engine technology

platforms, which can be combined in different combinations
Platforms
G, S, L, K engines
Mechanical bore 30-98 cm, stroke
MC-C, ME-C, ME-B,

Control ME-GI, ME-LGI, MC-S
Mark 7, 8, 9
Performance process parameters
(mep, pmax, pscav)
IMO NOX Tier 0, 1, 2, 3

Emissions IMO SOX, PM
HFO, MDO,
Fuel natural gas, biofuel
Variation of Fuels
LNG LPG CNG Biogas/biodiesel Hydrogen
Methanol & DME HFO Distillate Fuels Battery Emulsions
Four Stroke Product Portfolio
Small Bore 16/24

HFO
21/31 6-9L  All engines for powerplant applications
27/38 6-9L Dual Fuel
Gas
175D D7
with thermodynamic variants
12V/16V/20V
- 2 power versions
V28/33 12V/16V/20V
V12-V20 - net electricity generation
32/40 32/40 6-9L 12V –18V
32/40 G 6L/ 9L V12 /,V18 - combined cycle (CC)
32/44 K 6-10L V12-V20 - combined heat power (CHP)
32/44 32/44 CR 6-10L 12V - V20V
32/44 CR TS 12V / 20V + optimised for various climat zones
35/44 DF 6-10L 12V –20V
35/44 G 12V / 20V
35/44 G TS 12V / 20V  All Marine applications with
48/60 48/60 CR 6-9L
6-9L –18V
12VV12-V18 - Tier III ready with SCR Operation
48/60 CR TS 12V –18V
51/60DF 6-9L 12V –18V
51/60G 12V –18V  All CR Marine applications with power
51/60G TS 12V –18V
management options
45/60 45/60 6-9L6-9L 12V/14V / 20V
V12-V18
0 5000 10000 15000 20000 25000 30000

kW
Four Stroke Engine Combusion Processes
Diesel – Gas – Dual Fuel
Diesel Gas (SI) Dual Fuel
Diesel: Compression ignition

Spark ignition / scavenged pre- Diffusion controlled combustion
Compression ignition chamber Gas: Compression ignition
Diffusion controlled combustion Premixed combustion Premixed combustion
MAN Diesel & Turbo Dr. Christian Poensgen 

13. International AVL Powertrain Diagnostic Symposium  26.06.2018 < 6 >
Instrumentation of a 4x/60 DF Engine
Engine Sensor Bill of Material (partial)
Cylinder specific Equipment
• Gas System
gas injection 12 magnetic valves
ACC 12 300 bar pressure sensors
 CR Main Injection
rail pressure after pump 6 pressure sensor
fuel temperature after pump 6 temperature sensors
injector valves 12 magnetic valves
leakage flow 12 magnetic valves
leakage pumps & injectors 6 magnetic valves
 CR Pilot Injection (analog CR main injection)
 Cylinder Head
exhaust temperature 24 temperature sensors
In total about 200+ sensors and magnetic valves are Crank Case Surveillance
splash oil temperature 12 temperature sensors
controlling the engine and can be used for condition main bearing 16 temperature sensors
monitoring oil mist detector 4 Opacity sensors
Adaptive Combustion Control
With ACC
Without ACC
Figure 7b: Effect of the ACC Control on knocking intensity
Overall Solution
Parameters to be measured and calculated based

on cylinder pressure and crank angle
• knocking detection
• Calculate pmi (mean effective pressure)
• detection of misfiring
• max firing pressure
• combustion curve (SoC, CoC, DoC)
• air fuel ratio
• combustion temperature
• determination of NOx
SoC start of combustion
CoC centre of combustion
DoC duration of combustion
VPX cylinder pressure variance
over time
PGV pilot gas valve
PFO pilot fuel oil
SaCoS 5000 – the Way to Modular and Flexible
Building Kits for HW / SW / Fct.
Flexible Applications
in line with the engine market requirements
SaCoS 5000 Full, LTS, XS
HW-Building Kit SW-Building Kit Fct.-Building Kit
Development of a modular Realisation of a SW building Development of a function

H/WI building kit kit for firmware and systems building kit
 capability of fast  efficient use of system  efficient use of system

development of additional resources resources
control units for further engine simple application simple application
applications development development
strong improvement of quality strong improvement of quality
reduction of testing
Methods & Tools

Data management and Tools have been developed.  single source of truth, and improvements
in traceability, development efficiency, maintenance and commissioning
Modular Hardware Building Kit
Modulare Functional Housings Control Devices

Hardware H/WPackage
CPU Temp. Modul 4 Connector
DI (digital input)
AI (analog input) Power output 5 Connector
TI Temperatur
FI Frequenz Input Module 6 Connector
CO Current out
Control Module
IO Injector out 7 Connector
Knock Control
DO digital out
AO analog out Injection Control ICM
PO Power out
PS Power supl. Extension Board ICM R
CAN
RS485 Gateway Com. GCM
Ethernet
USB Display DMS
The modular hardware building kit allows to develop quickly further applications
such the control units are scalable
Functions Building Kit
Framework Top Level Integration Engine Product

Functions Framework Components Functions Lines
Functions
FWF 1 TFWF 1 IC 1 EF 1 PL 1
IC 2 EF 2 PL 2
FWF 2 TFWF 2
IC 3 EF 3 PL 3
FWF 3 TFWF 3
IC 4 EF 4 PL 4
FWF 4 TFWF 4
IC 5 EF 5 PL 5
FWF 5 TFWF 5
IC 6 EF 6 PL 6
FWF 6 TFWF 6
IC 7 EF 7 PL 7
FWF 7 TFWF 7
: : :
: :
: : :
: :
: : :
: :
IC n EF n PL n
FWF n TFWF n
The software function building kit allows short development times to handle all
engine variants to fulfil customer requirements
Data Management Flow
Full round-trip data flow with PREEvision as Data Backbone
create
harmonized
data
persist
Engineers 1 connect
Engineers data
data
6 Business
Business Data
Analyse datadata for
Data Analysts
create
analyze product Analyst
for business
harmonized business
development
data 2 developlment
persist
data
configuration
configure
production
load correct
data
3 software
produce engine and
with correct
softwaredata
& data
Bill-of-
Analyse data for Data
Data Backbone
Backbone Bill of
Material
analyze engineering
product
data for product Material
optimization + service
improvement
5
secure transmission
4 of software and
safe & secure
transmission
of software
data
and data
Technical
TechnicalData Web
Connection
Data Analysts
Analyst
Condition Based Maintenance
Condition Monitoring + Diagnostics
Customer Uncompressed live

MDT
data algorithms More data bases
 Stationary Point  combine OS data with
EDSdetection
/ EDS NG PrimeServ LabServer
data etc. OSWeb
Value Creation & Data Stream
Data Logger VPN Client & Internet VPN Data- Viewer

Site Data
CBM
Firewall Gateway & ware- (& Analyser)

Firewall house
Algorithms
 Maintenance Indicator,
TC cleaning etc.
PrimeServ
CBM provides an added value to each step of data processing.
On Line Ship Surveillance
7000 channels
monitored
200 Sensors in the
engine Room
2 GB data storage
every day
20 GB data
transmission
every day
2800 Sensors wired to

the vessel‘s main
control system
Ship motion data

aquired with 20Hz
Source https://worldmaritimenews.com/
Roll Out of a new Satellite Network
- 40 Satellites launched in 2017

- 35 Satellites planned for launch in 2018
Carrier Type Falcon provided by Space X
Bandwidth for Marine download 1,4 Mbit/s
upload approx. 528 Mbit/s
Possibility of satellited to satellite communication to allow
contact to any ground station around the globe
Polar orbit – (connection at angles lager 9° above horizon)
Remote controlled unmanned shipping

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Control and Diagmostic Systems in Marine

Dr Christian Poensgen, Dr. Mathias Moser

4 Stroke Medium Speed Engines

4 Stroke High Speed Engine

30 kW 1 324 kW 4 700 kW 26 000 kW 84 280 kW

The engine programme is defined by different engine technology

MC-C, ME-C, ME-B,

IMO NOX Tier 0, 1, 2, 3

LNG LPG CNG Biogas/biodiesel Hydrogen

Methanol & DME HFO Distillate Fuels Battery Emulsions

Small Bore 16/24

0 5000 10000 15000 20000 25000 30000

Diesel Gas (SI) Dual Fuel

Diesel: Compression ignition

MAN Diesel & Turbo Dr. Christian Poensgen 

Engine Sensor Bill of Material (partial)

Cylinder specific Equipment

 CR Pilot Injection (analog CR main injection)

Figure 7b: Effect of the ACC Control on knocking intensity

Parameters to be measured and calculated based

HW-Building Kit SW-Building Kit Fct.-Building Kit

Development of a modular Realisation of a SW building Development of a function

 capability of fast  efficient use of system  efficient use of system

Methods & Tools

Modulare Functional Housings Control Devices

Framework Top Level Integration Engine Product

Customer Uncompressed live

Data Logger VPN Client & Internet VPN Data- Viewer

Firewall Gateway & ware- (& Analyser)

CBM provides an added value to each step of data processing.

2800 Sensors wired to

Ship motion data

- 40 Satellites launched in 2017

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