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Changchun, China, September 20-22, 2018 and Modeling
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IFAC PapersOnLine 51-31 (2018) 549–552
Mega
Mega knock
knock detection
detection and
and inhibition
inhibition
Mega knock
system detection
for turbo and
GDI inhibition
engine
Mega knock
system detection
for turbo and
GDI inhibition
engine
system for turbo GDI engine
system for turbo GDI engine
Xin Zhou ∗∗ Baiyu Xin ∗∗ Jialing Li ∗∗ Pengyuan Sun ∗∗
Xin Zhou ∗∗ Baiyu Xin ∗∗ Jialing Li ∗∗ Pengyuan Sun ∗∗
Xin Zhou ∗ Baiyu Xin ∗ Jialing Li ∗ Pengyuan Sun ∗
∗ Xin Zhou Baiyu of Xin Jialing Li Pengyuan Sun
∗ General R&D
∗ General R&D Institute
Institute of China China FAW
FAW Co., Co., Ltd, Ltd, Changchun,
Changchun, Jilin, Jilin,
∗
General R&D
P.R.
P.R. Institute
China
China of China
(e-mail:
(e-mail: FAW Co., Ltd, Changchun, Jilin,
zhouxin1@faw.com.cn).
zhouxin1@faw.com.cn).
General R&D
P.R.Institute of China
China (e-mail: FAW Co., Ltd, Changchun, Jilin,
zhouxin1@faw.com.cn).
P.R. China (e-mail: zhouxin1@faw.com.cn).
Abstract: Mega
Abstract: Mega knock knock is is anan inevitable
inevitable and and destructive
destructive combustion combustion phenomenonphenomenon in in gasoline
gasoline
Abstract:
engine,
engine, and
and Mega
the
the knock isof
tendency
tendency of an
mega
megainevitable
knock
knock and destructive
occurring
occurring in
in GDI
GDI combustion
turbocharged
turbocharged phenomenon
engine
engine is
is in gasoline
more
more serious
serious
Abstract:
engine,
than other Mega
andengine. knock
the tendency
So in isofan
order megainevitable
to knock the
protect andengine,
destructive
occurring ina GDI
system combustion
turbocharged
which can phenomenon
enginemega
detect is morein gasoline
knockserious
and
than
engine, other engine.
andengine. So
the tendency in order
of megato protect
knock the engine,
occurring a system which can detect mega knock and
than
inhibit other
the occurrence So inoforder to protect
consecutive megathe engine,isinaproposed
knock GDI
system turbocharged
which
in thiscan engine
detect
paper. is more
mega
Firstly, knock
the serious
and
knock
inhibit
than the engine.
occurrence So inof consecutive mega knock is aproposed in this paper. Firstly, the knock
sensorother
inhibit
sensor
the occurrence
signal
signal is translated
is translated oforder
to the
to
to protect
consecutive
the mega
integral
integral
the engine,
knock
value,
value, and
and
is it
it
system
proposed
is identified
is
which
identified in this can
that
that
detect
paper.
whether
whether
mega
Firstly, knock
aa mega
mega and
the knock
inhibit
sensor
has the
signal
happened occurrence
is translated
based on of consecutive
the to the
integral mega
integral
value. knock
value, and
Finally, is proposed
it
some is identified
methods in this
that
such paper.
whether
as Firstly,
fuel a the knock
mega
enrichment knock
knock
will
has happened
sensor signal based
isbased on thetointegral
translated theinintegralvalue.value,
Finally,
and some methods such
itexperiment
is identified that asas fuel enrichment
whether a mega will
knock
has
be happened
taken to inhibit on the
mega knock integral the value.
next Finally,
cycle. The some methodsresults such of fuel
HIL enrichment
verify that will
this
be
has taken
happenedto inhibit
based mega knock
on knock
the in
integral the next cycle. The experiment results of HIL verify that this
be taken
system to detect
can inhibit mega
mega knock in thevalue.
occurrence Finally,
nextaccurately,
cycle. The some methods
experiment
and it such by
results
is indicated
indicated as fuel
ofthe enrichment
HILthermodynamics
verify that this will
system
be taken can
to detect
inhibit mega
mega knock
knock occurrence
in the nextaccurately,
cycle. The and it
experiment is results byofthe HILthermodynamics
verify that this
system
theorem that can detect
that the mega
the inhibit knock
inhibit strategy occurrence
strategy is accurately,
is reasonable.
reasonable. and it is indicated by the thermodynamics
theorem
system
theoremcan thatdetect mega knock
the inhibit strategy occurrence accurately, and it is indicated by the thermodynamics
is reasonable.
© 2018, IFAC
theorem that (International Federation
the inhibit strategy is of Automatic Control) Hosting by Elsevier Ltd. All rights reserved.
reasonable.
Keywords: GDI
Keywords: GDI engine,
engine, Mega
Mega knock,
knock, Detection
Detection method,
method, Inhibit Inhibit strategy,
strategy, HIL HIL test
test
Keywords: GDI engine, Mega knock, Detection method, Inhibit strategy, HIL test
Keywords: GDI engine, Mega knock, Detection method, Inhibit strategy, HIL test
1. INTRODUCTION
1. INTRODUCTION and
and inhibition
inhibition system system is is indispensable
indispensable for for the
the turbo
turbo GDI GDI
1. INTRODUCTION and
engine.
engine. inhibition system is indispensable for the turbo GDI
GDI 1. INTRODUCTION and inhibition system is indispensable for the turbo GDI
GDI turbocharged
turbocharged engine engine is is of
of high
high thermal
thermal efficiency,
efficiency, high high engine.
The traditional
GDI
torque turbocharged
and low engine
fuel is of
consumption, high thermal
so it hasefficiency,
become high
the The
the engine. traditional method method of of mega
mega knock knock detection
detection is is to
to
torque
GDI and low fuel
turbocharged consumption,
engine is of high so it has
thermal becomehigh
efficiency, The
judge traditional
whether method
the voltage of mega
value knock
of detection
knock sensor ishas
to
torque
research and
focus lowof fuel
the consumption,
world’s major so it has become
automotive companiesthe judgeThe traditional whether the
methodvoltage value
of mega of
knock knock sensor
detection has
isthis
to
researchand
torque focus lowof fuel
the world’s
consumption,major automotive
so it has companies
become the judge
exceeded whether
the the
threshold voltagevalue. value
But of
the knock
accuracy sensorof has
research
recent focus
in recent yearsof(Zoubir,
the world’s
(Zoubir, 1995;major
Attard automotive
and Toulson,
Toulson, companies
2010). judge exceeded the threshold
whether the voltage value.value
But of theknock
accuracy sensorof this
has
in
research years
focus of the 1995;
world’s Attard
major and
automotive 2010).
companies exceeded
method is the threshold
influenced by value.
the But
noise the accuracy
interference, and of this
there
in recent years
However,
However, under(Zoubir,
under the
the working 1995; condition
working Attard and
condition of Toulson,
of low
low speed
speed2010).
and
and method
exceeded isthe influenced
threshold by value.
the noise Butinterference,
the accuracy andofthere
this
in recent
However,
heavy load,years
under
the (Zoubir,
the working
turbocharged 1995; GDIAttard
condition and
engine Toulson,
ofislowpronespeed
to and method
2010).
have needs
needs
method
aa is
large
large
is
influenced
number
number
influenced
by
of
of
by
the noise
calibration
calibration
the noise
interference,
work
work under
under
interference,
and there
different
different
and there
heavy load, the turbocharged GDI engine is prone to have
and needsworking a large
conditionsnumber to of done.
calibration work under different
However,
heavy load,
an abnormal
abnormal under
the the working
turbocharged
combustion condition
GDI
phenomenon engine ofislow
which is speed
prone to have
extremely working
needs aandconditions
large number to be
be
of done.
In
In order
calibration order to
to improve
work improve
under
the
the ac-
differentac-
an
heavy load, combustion
the turbocharged phenomenon
GDI engine which
is is
prone extremely
to have working
curacy conditions
reduce to
the be done.
workload In oforder to improve
calibration, a the ac-
detection
an abnormal
harmful to thecombustion
engine – phenomenon
Mega knock. which is extremely curacy
working and reduce
conditions the
to workload
be done. In of calibration,
order to a
improve detection
the ac-
harmful to the engine – Mega knock.
an abnormal
harmful to the combustion
engine – Mega knock. which is extremely curacy
phenomenon method
method
curacy
and
and
which
which reduce
reduce
the workload
contains
contains
the
bandpass
bandpass
workload
of calibration,
of
filter
filter and
calibration,
a detection
and integrator
integrator
a detection
is
is
Mega
harmful knock
to theusually
engine occurs
– Mega before
knock. the spark
Mega knock usually occurs before the spark ignition, and proposed ignition, and method
proposed which
in
in this
this contains
paper.
paper. bandpass filter and integrator is
Mega
its knock usually
maximum pressure occurs
in the before
cylinder theis spark
far ignition,
higher than and
the method
proposed which
in this contains
paper. bandpass filter and integrator is
its maximum pressureoccursin the cylinder theis spark
far higher than the It
Mega
its knock
maximum
normal
normal
usually in thebefore
pressurepressure.
combustion
combustion pressure. cylinder
What is
What is far
ignition,
higher
more
more than and
unfortunate
unfortunate It has
the proposed has aa long in this
long time
time for
for the
paper. the research
research of of knock
knock mechanism.
mechanism.
its maximum
normal
is that pressure
combustion
mega knock in the
pressure.
is cylinder
accompanied What with is far
is more ahigher
large than
unfortunatethe
pressure It has
However,
However, a long time
because
because for
of
of the
the
the research
very
very complex
complexof knock mechanism.
phenomenon
phenomenon of
of
is that mega
normal knock is
combustion accompanied
pressure. What with
is a large
more pressure It
unfortunate has a long
However,
combustion time
because
and manyfor the
of the
other research
very complex
factors, of there
knock mechanism.
phenomenon
are different of
is that mega
oscillation, knock
which is is accompanied
very easy to cause withfatala damage
large pressure
to the combustionbecause
However, and many of theothervery factors,
complex there are different
phenomenon of3
oscillation, which is very easy to cause fatal damage to the combustion and many other factors, there The
are different
is that (Mangeruca
engine mega
oscillation, knock
which is accompanied
is and
very easy to 2003;
Ferrari, cause withfatala damage
Boubai, large2000). the explanations
pressure
toThe explanations
combustion
to
to
and
the
the
many
mechanism
mechanism
other
of
of
factors,
knock.
knock.
there The
are
main
main
different 3
engine (Mangeruca
oscillation, which is and and
very Ferrari,
easynormal 2003;
to 2003;
cause Boubai,
fatal damage 2000). The
the explanations
toThe theories are as tofollows:
the mechanism
”Spontaneous of knock.
combustionThe theory”,
main 3
engine
pressure (Mangeruca
relationship Ferrari,
among Boubai,
combustion, 2000).
common theories are as follows: ”Spontaneous combustion theory”,
pressure(Mangeruca
engine
pressure
knock and and
relationshipand
relationship
mega knockknock
among normal
isFerrari,
among shown 2003;
normal
combustion,
in Fig.
Fig. Boubai,
combustion,
1. 2000). The explanations
common
common theories
”Flame
”Flame are astofollows:
acceleration
acceleration
thetheory”,
mechanism
”Spontaneous
theory”, and of knock.
combustion
and ”Detonation
”Detonation
The mainA-3
theory”,
theory”.
theory”. A-
knock mega is shown in 1. common mong theories
”Flame are as
acceleration follows: ”Spontaneous
theory”, and combustion
”Detonation theory”,
theory”. A-
pressure
knock and relationship
mega knock among
is shown normal combustion,
in Fig. 1. mong the
”Flame the 33 theories, the
the theory
theories, theory”,
acceleration theory and
of spontaneous
spontaneous combustion
of ”Detonation combustion
theory”. A-
knock and mega knock is shown in Fig. 1. mong
is
is widely
widelythe 3 theories,
recognized,
recognized, the theory
because
because of
it spontaneous
can better
it spontaneous combustion
explain
can better explain the
the
mong
is
resultswidelytheof 3 theories,
recognized, the theory
because(Zhen of
it canet better combustion
explain the
results
is widely of various
various
recognized,
experiments
experiments
because (Zhen
it canet
al.,
al., 2012;
better2012; Hamama
Hamama
explain the
results
and
and of
Ferch,
Ferch, various
2015), experiments
and
2015),experiments the (Zhen
necessary
and the necessary et al.,
way
way 2012;
to Hamama
reduce
to reduce the
the
results
and
possibility of
Ferch, various
2015),
of mega andknockthe (Zhen
necessary
is to et
avoid al.,
way
the 2012;
to Hamama
reduce
spontaneous the
possibility
and Ferch, of megaand
2015), knockthe is to avoidway
necessary thetospontaneous
reduce the
possibility
combustion
combustion of
of mega
mixed
of mixed knock
gas.
gas. Now
Now is to
the
the avoid
most
most the
commonly
commonly spontaneous
method
method
possibility
combustion of mega knock is to avoid the spontaneous
is
is to
combustion enrichof
to enrich mixed
the
ofthe
mixed
gas. Now
air-fuel
air-fuel
gas. ratiothe
ratio
Now the
most commonly
(Wang
(Wang and Song,method
and Song,
most commonly
2015).
2015).
method
is to
However,
However, enrich under
underthe air-fuel
some
some ratio
complex
complex (Wang
working
working and Song,
conditions,
conditions, 2015).
such
such
is to enrich
However,
aa measure under
is the good
not air-fuel
some ratioto(Wang
complex
enough working
inhibit and Song,
conditions,
mega knock. 2015).
such
This
measure under
However, is not goodsome enough
complex to working
inhibit mega knock. This
conditions, such
apaper
measure
paper presents
presents is not a good
better
a good enough
inhibition
betterenough
inhibitionto inhibit
strategy
strategy mega knock.
which
which can This
take
can This
take
apaper
measure
different presents is
measuresnot a better
at inhibition
different to inhibit
strategy
working mega knock.
which
conditions, can
so take
that
different
paper measures
presents at
a better different
inhibition working conditions,
strategy which can so that
take


different
it can measures
protect the at different
engine better. working conditions, so that
Fig. it can
different protect
measures the engine
at differentbetter. working conditions, so that
Fig. 1.1. Different
Different combustion
combustion situations
situations of of cylinder
cylinder  it can protect the engine better.
Fig. 1. Different combustion situations of cylinder  it can protect the engine better.
When 1. the mega 2.
2. MEGA
MEGA KNOCK KNOCK DETECTION DETECTION METHOD
Fig.
When the mega knock
Different combustion
knock occurs,
occurs, the
the instantaneous
situations of cylinderpressure
instantaneous pressure METHOD
When
in the the mega
cylinder knock
will occurs,
increase the
by instantaneous
several times, pressure
and the 2. MEGA KNOCK DETECTION METHOD
in
When the cylinder will increase by several times, and the 2. MEGA KNOCK DETECTION METHOD
in the the
consequent
consequent
mega
cylinder
large
large
knock
will
impact
impact
occurs,
increase
force
force
the several
by
will
will
instantaneous
damage
damage times,
the
the
pressure
andplug,
spark
spark the For
plug, For the
the 44 cylinder
cylinder GDI
GDI engine,
engine, every
every cylinder
cylinder is
is ignited
ignited
in
the the
consequent cylinder
intake largeand
valve will
impact increase
the force
exhaust by valve.
will several
damage times,
These andplug,
the destruction
spark the For only the
once 4 cylinder
at each GDI engine,
cycle, so one every
knock cylinder
sensor is ignited
can detect
the intake
consequent valve
large and
impactthe exhaust
force willvalve.
damage Thesethe destruction
spark plug, only
For once
the 4 at each
cylinder cycle,
GDI so one
engine, knock
every sensor
cylinder can
is detect
ignited
the
will intake
cause valve
the and the
engine exhaust
scrap, what’svalve.more,These a destruction
mega knock only
the once at each
vibration of the cycle,
4 so one The
cylinders. knock sensor canbetween
relationship detect
will
the cause
intake the
valve engine
and the scrap, what’s
exhaust valve.more,These a mega knock
destruction the
only vibration
once of
at signal
each the 4 cylinders.
cycle, so one The
knock relationship
sensor between
canbetween
detect
will cause
happened
happened the engine
continuously
continuously scrap,
in a what’s
short
in a short time
timemore,can a mega
bring
can abring theknock
seri-
seri- knock
theknock the
knock vibration
sensor
sensor signal of the 4
and
andcylinders.
the every
the every The relationship
engine
engine cylinder can
can be
cylinderbetween be
will cause the engine scrap, what’s more, mega the seri- knock the vibration of the 4 cylinders. The relationship
happened
ously
ously damage
damage continuously
to
to the in a short
the cylinder.
cylinder. So
So a atime
mega
mega canknock
bringdetection
knock detection known sensor
known according
according signal to and
to the the
the every
timing
timing engineThe
system.
system. cylinder
The can be
principle
principle of
of
ously damage to the cylinder. So a mega knock detection known according to the timing system. The principle be
happened continuously in a short time can bring the seri- knock sensor signal and the every engine cylinder can of
ously damage to the cylinder. So a mega knock detection known according
2405-8963 © 2018, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. to the timing system. The principle of
Copyright © 2018 IFAC 588
Copyright
Peer review© under
2018 IFAC 588 Control.
responsibility of International Federation of Automatic
Copyright © 2018 IFAC
10.1016/j.ifacol.2018.10.121 588
Copyright © 2018 IFAC 588
IFAC E-CoSM 2018
550
Changchun, China, September 20-22, 2018 Xin Zhou et al. / IFAC PapersOnLine 51-31 (2018) 549–552
mega knock detection proposed in this paper is shown in
Fig. 2.
Fig. 2. Mega knock detection schematic diagram
AD converter: the sampled frequency of AD should be 2
times larger than the characteristic frequency of knock
signal, and the higher the frequency, the more accurate
the signal is.
Measuring window: mega knock only occurs before ignition
time, therefore, it is just needed to measure a part of
crankshaft angle which is before the ignition. The mea-
suring window is shown in Fig. 3. To calculate the signal
only in the window can improve the validity of the signal.
0HDVXULQJ
:LQGRZ
Fig. 3. Measuring window schematic diagram
Bandpass filter: bandpass filter is needed in order to
reduce the interference of vibration noise, and the center
frequency of the bandpass filter is gotten based on Fourier
transform of mega knock signal, the filter transfer function
is shown in equation (1).
∑
M by the other value β at the same time. When no mega
br z −r
r=0
H(Z) =
∑
N
1+ ak z −k
k=1
Here N is the order of the filter, and the filter parameter-
s ak and br determine the format of filter. In this paper,
Butterworth filter is used to reduce the vibration noise,
and ak and br can be calculated by Matlab function (2).
[N, Wn ] = buttord(Wp , Ws , Rp , As )
[b, a] = butter(N, Wn )
Wp is the passband cut-off frequency, Ws is the stopband
cut-off frequency, Rp is the maximum attenuation of pass-
band, and As is the maximum attenuation of stopband.
The mega knock’s frequency of the 4GA12TD engine is
between 6KHz and 30KHz through the Fourier transfor-
m, so Wp is selected as 6, Ws is selected as 30, both Rp
and As are selected as 5.
Integrator: the mega knock will cause a great shock, so
the strength of the sensor signal Ey can be obtained by
accumulating the absolute value of the signal, as shown in
equation (3).
n
∑
Ey = |Xi | (3)
i=1
Threshold: the mega knock can cause a large pressure
oscillation, and the strength of mega knock is much larger
than that of ordinary signal, so the threshold doesn’t
need to be adjusted according to the working condition,
and only one threshold needs to be calibrated. During
the calibration, firstly, mega knock should be created by
means of advancing the ignition time at some different
working conditions, and then the integral value of mega
knock should be recorded, finally, the minimum integral
value is regarded as the threshold. If Ey is higher than
the threshold, it means mega knock has happened, some
measures should be taken to protect the engine.
3. MEGA KNOCK INHIBITION STRATEGY
Because of the randomness and complexity of mega knock,
taking any measure wouldn’t ensure mega knock not occur
in the next cycle, but reduce the possibility. So the purpose
of this paper is to reduce the possibility of consecutive
mega knocks, and the engine is protected at same time.
Each cylinder of the engine has the possibility of mega
knock occurrence, and the mega knock frequency of each
cylinder is different. so the mega knock inhibition system
should have the ability to record the frequency of the mega
knock occurrence of each cylinder, to take more flexible
measures for each cylinder.
In order to reflect the mega knock frequency of each
cylinder, a short term counter is designed for each cylinder,
and a long term counter is designed to reflect all the
cylinders’s mega knock frequency. When a mega knock
is detected in a certain cylinder, the corresponding short
term counter’s value should be accumulated by a constant
value α , and the long term counter’s value is accumulated
knock is detected in the next cycle, the value of long term
counter and the value of short term counter should be
(1)
reduced by 1 at different speeds. The action of the counters
are shown in Fig. 4.





(2) 



Fig. 4. The action of the counters
The mega knock inhibition strategy is shown in Fig. 5,
according to the occurrence frequency of mega knock, four
different measures will be taken: when mega knock occurs
in one cylinder, fuel enrichment will be trigged for a pre-
defined number of cycles, generally 30 cycles; if the value of
one short term counter exceeds the threshold, and other
cylinder is already to be cut off at the moment, boost
589
IFAC E-CoSM 2018

Changchun, China, September 20-22, 2018 Xin Zhou et al. / IFAC PapersOnLine 51-31 (2018) 549–552 551

control will be closed, otherwise the cylinder will be cut is shown in Fig. 8, the system is able to detect every
off; if the value of long term counter exceeds the threshold, cylinder’s mega knock occurrence accurately through the
the maximum engine load will be limited to about 75% , comparison of the two figures.
and the maximum load will be recovered with a certain
step after the value of long term is equal to 0.


 

   


 
 

 
 
Ͳ

 

     Ͳ 

 
 
 Ͳ
Ͳ
  

 

 

   


  
         
 

   
    
 Fig. 7. the enable operation steps
                  

  

  
 

 
   
 


 Ͳ

 
  
 Ͳ





          
Fig. 5. Mega knock inhibition strategy schematic diagram 



4. EXPERIMENT VERIFICATION 




As mega knock is destructive to the engine, and the 
conditions for producing mega knock are difficult to reach, 
the detection method is verified on the HIL of 4GA12TD 

engine. The real mega knock signal can be simulated 

by enabling the HIL voltage oscillation function. The 

          
difference between the simulated normal combustion’s 

voltage and the mega knock’s voltage of HIL are shown
in Fig. 6. Fig. 8. the results of the detection system
 The probability of mega knock occurrence can not be
       



 quantifiable, so it is difficult to verify the effectiveness
  of the inhibition strategy by experiments. However, the
 adiabatic isentropic compression formula which is shown

 in equation (4) is possible to judge whether the measures
 are effective.


 ( )k
 T1 V2
 = (4)
 T2 V1

 Here, V1 is the volume of gas before compression, V2 is

 the volume of gas after compression, T1 is the temperature
          of gas before compression.


The measurement of fuel enrichment can decrease the adia-
Fig. 6. The voltage value of HIL knock sensor batic coefficient k , and the temperature of the compressed
gas T2 can be reduced, so the temperature of hot spot is
The voltage oscillation function of each cylinder is enabled hard to satisfy the natural temperature of the mixture gas.
randomly, and the operation step is shown in Fig. 7. The thus fuel enrichment can inhibit the production of mega
identified result of the detection system in this paper knock. The method of reducing the maximum engine load

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and closing boost control function both can reduce the

mixture gas mass of the cylinder, so that the temperature
of the cylinder can be decreased. The measurement of fuel
cut-off can protect engine from destroy in abnormal condi-
tion. In summary, this consecutive mega knock occurrence
inhibit strategy is reasonable.

5. CONCLUSION

A mega knock detection method and a inhibition strategy

for GDI turbocharged engine are proposed in this paper.
However, for different engine, the related parameters,
such as the integral threshold , is very different. So the
parameters for different engines should be re-calibrated.

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