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Enhanced Diesel Engine Control

Periodic Reporting for period 2 - EDEC (Enhanced Diesel Engine Control)

Reporting period: 2018-03-01 to 2019-12-31

What is the problem/issue being addressed?
Existing old ECU for 4-cylinder diesel engines is overall outdated - as for el. components, solution of inner communication, SW and HW and finally also because of missing optional ECU functions which become during the time more less standard.
Also 6- cylinder diesel engine is now coming as new product of Safran AE and old ECU is not suitable with this product so become necessary to develop new generation of ECU.
Together with propeller supplier we analyse possibility to optimize fuel burn by low speed mode and actual conclusion is to not recommend this solution for this case - the reason are vibration coming from propeller. The low level of propeller rotation is causes extreme vibration and this is just emergency solution for saving the life and airplane but side effect is rapid decrease of propeller lifetime. That's why we decide to not apply this solution as economic fly mode.

Why is it important for society?
Common international development makes connection not only on business basis but also cultural and social basis.
Especially young experts from university could work and apply his knowledge on projects with real commercial potential and this will help to connect academic community closer to the common industrial production.
From point of view ECU there will be progress on level of safety/reliability, reduction of noise and operating costs.
Modular design enable flexible solution for wide range of users.

Overall objectives:
- created robust System requirements based on new customer strategy = to have new generation of electronic ECU easy exchangeable with existing one and also compatible with new coming 6-cylinder diesel engine.
- prepared detailed safety and reliability analysis reflecting new requirements
- designed system with respect to control and optimize engine operation in all modes
- new ECU will be also more universal and compatible with all 3 basic types of electric motors (DC, BLDC, Stepper motors)

Activities carried within EDEC project contributed to all main objectives. Fundamental grounds was provided for development of modern Electronic Control Unit for light weight and efficient jet-fuel reciprocating engine used in general aviation.
All the EDEC design aims provided in the DoA were into the detail communicated with Topic Leader (Safran AE), priority tasks were identified and exchange of necessary knowledge was performed.

Actually - 4 years after Call for Proposal of project EDEC - one significant business prediction was changed.
The mail target of the project EDEC was to develop modern ECU (actual model of ECU is more than 20 years old concept) for 4-cylinder and in the same time for coming new 6-cylinder diesel engine from Safran AE – ECU usable for both applications.
Based on actual information from customer - Safran AE - the project of new 6-cylinder engine was suspended (with no specific potential re-launch date). This mean that prototype of new ECU EDEC is over sized and over developed for existing 4-cylinder diesel engine because demands for 6- cylinder includes extra components and SW functions and it influence consequently size, weight and number of cables. This is a bit disadvantage from point of view optimization of effort and expenses for ECU but anyway it’s not blocking from point of usability of new ECU.
The real demand for existing type of 4-cylinder diesel engine is now saturated by existing (old - already produced by Safran) ECU units so there are no actual commercial requests for new ECU.
The main points of 2 (final) reporting period of EDEC project were to:
- Production of 2pcs ECU prototypes
- Production of tester and integration of SW model of motor (HIL)
- Perform selected Preliminary DO-160 tests
- Perform Functional and system testing on bench (HIL)
- Analysis of certification requirements
- Definition of certification basis for the ECU
- Perform Functional Hazard Assessment (FHA)
- Perform Detailed safety and reliability assessment
• Developed and implemented the plan for disseminating results of the project
• Publishing the key results in a peer-reviewed leading scientific journals

There is list of deliveries prepared during 2 (final) period:
Delivery nu: Title: Work Package:
D3.1 ECU Prototypes WP3
D3.2 Preliminary DO-160G test results WP3
D3.3 Functional and system test report WP3
D4.3 Safety and reliability assessment of system architecture WP4
D5.1 Updated Dissemination Plan WP5
D5.3 Updated Exploitation Plan WP5
D5.4 Publication in a Peer-reviewed Journal WP5
As result of phase Preliminary HW Design we analyze in detail whole measuring chain - from sensors, through all electronic components on PCBs till final action output (fuel rack).
This analysis (Calculation of measurement precision of analogue variables) show us several weak points of actual (old) system and give us opportunity to make reasonable improvements with new design.
Finally we agreed with our customer (Topic Leader) on version of new product, which will represent not only update of existing control unit (for 4-cylinder diesel engines) but give us chance to cover (HW level) also new generation of 6-cylinder diesel engine (which is actually under development phase).
The ECU will respect technological progress respecting existing level of electrical components, data communication and associated material.