TECHNOLOGY MODULES

for high-performance gas engine control systems

 

The control of modern gas and dual-fuel engines requires precise and dependable combustion data for each individual cylinder, in order run the engine at high efficiency close to its load limit while at the same time protecting it from overload. This is where AVAT combustion control devices come into the picture. They compute combustion parameters out of the complex sensor signals and transmit them to the engine controller via a CAN-Bus interface.

Actuator control

E²CORE

E²CORE: multivariable control
for speed, power, lambda, ...

The unique strength of the E²CORE modules lies in the multi-variable control of the engine, taking into account all available manipulated variables. The result is a highly dynamic response to deviations and better efficiency while complying with emission limits.

The modules of the E²CORE series are universal, highly dynamic and compact multi-variable controllers for speed, power and mixture control in gas engines. Well-proven actuators are pre-stored as profiles and can thus be used immediately to power throttle valves, exhaust gas waste gates, turbocharger bypass valves, variable gas mixers or gas metering devices. Via the CAN interface, the modules of the E²CORE series can be easily integrated into various existing engine control systems. Typical inputs for common sensors are available. With our E²SERVICE, a powerful service tool is available for their integration, commissioning and service.

Advantages AVAT E²CORE

  • Fast and stable regulation of speed, power, mixture and boost pressure without overshoot
  • Direct regulation and cloud monitoring for compliance with the NOx emission limits according to 44. BImSchV
  • Direct connection of actuators and sensors
  • All functions are integrated in an engine controller and comprehensively configurable
  • Higher engine efficiency due to wastegate control
  • Mixture control of lambda-1 or lean burn engines
  • Lower emissions
  • Input for two lambda probes (E²CORE-control+)
  • Fast and stable compensation of temperature and gas quality variations
  • Engine speed measurement with overspeed monitoring
  • Most compact assembly on the market
  • Library for Bachmann PLC included (others on request)

E²CORE series at a glance

E²CORE-driver covers the fast and accurate position-control of two DC servomotors and a step motor. Well-proven actuators are pre-stored as profiles and can thus be used immediately to power throttle valves, exhaust gas waste gates, turbocharger bypass valves, variable gas mixers or gas metering devices.

E²CORE-control also independently regulates rpm, power, charging pressure and air/gas mixing on gas engines. In addition, E²CORE-control records the engine speed and power, boost pressure and sensors for mixture control. The real strength of the E²CORE modules lies in the multivariable control of the engine using all available actuating variables.

E²CORE-control+ additionally includes a direct connection to a broadband lambda sensor. The lambda signal can be acquired via CAN bus, analog input or via the direct connection on the module. The result is the fastest possible reaction times to deviations and optimized efficiency while complying with NOx emissions limits according 44. BImSchV.

Structure Borne Noise

E²KNOCKCON

Reliable control knocking
and misfiring onshore and offshore

The E²KNOCKCON series offers reliable knock and misfire detection with high sensitivity in a compact size. Up to 20 sensors for structure-borne sound are mounted in appropriate places on the engine and connected directly to the E²KNOCKCON. Our modules for anti-knock control and misfire detection are proven on more than 7,000 engines.

Using sophisticated digital signal processing algorithms the knock information is reliably filtered from the customary engine noises even under challenging acoustic conditions. E²KNOCKCON computes knock levels and ignition timings for each engine working cycle and transfers them to the engine control system or to the ignition system directly.

But there is far more useful data in structure-borne sound than that. E²KNOCKCON reliably detects misfiring and irregular combustion timings with no extra sensors and considerably faster than other methods.

Advantages AVAT E²KNOCKCON

  • Suitable for any engine with the modules for 4, 12 or 20 cylinders
  • Cylinder-individual knock control
  • Reliable misfire detection
  • High sensitivity and selectivity
  • Easy to integrate via CAN bus to engine control systems or PLCs
  • Direct communication to ignition system (option)
  • Library for Bachmann PLC included (others on reques)

E²KNOCKCON series at a glance

With the E²KNOCKCON-c control components, the most compact modules for controlling up to 20 cylinders, with a multitude of additional functions, are available for use in stationary gas engines.

The marine version E²KNOCKCON-M, was specially developed by us for on engine operation. Likewise the use in harsh environments is certainly possible. The M-Series is already prepared for the marine certifications according to ABS, BV, DNV GL and LR.

Cylinder pressure analysis

E²PRECON

E²PRECON: The key to cylinder pressure
based combustion control of large engines

Using well-proven digital signal processing algorithms E²PRECON computes combustion characteristics for each cylinder and every combustion cycle. These are the key parameters engine builders need to implement advanced combustion control, monitoring and diagnosis.

With the E²PRECON series we have been pioneering in the area of ​​cylinder-pressure-controlled engine control since 2006. E²PRECON offers comprehensive real-time cylinder pressure analysis in a compact size and supports a wide range of cylinder pressure sensors from various manufacturers.

Incorporating thermodynamic models, E²PRECON modules calculates net heat release and pattern of heat release rate (HRR). From this, the important combustion parameters Start (SoC), Duration (DoC) and Center of Combustion (CoC) are computed. Indicated mean effective pressures (IMEP), peak pressures and knock levels are provided as well.

Advantages AVAT E²PRECON

  • Suitable for any engine with the modules for 4, 12 or 20 cylinders
  • Cylinder pressure based combustion control
  • Cylinder-individual combustion characteristics
  • Enables balancing, misfireand knock detection
  • Interface to condition monitoring systems
  • One service tool assists in engine diagnostics and optimization
  • Library for Bachmann PLC included (others on request)

E²PRECON series at a glance

With the E²PRECON-c control components, the most compact modules for a cylinder-pressure-based combustion control of up to 20 cylinders, with a multitude of additional functions, are available for use in stationary gas engines.

The marine version E²PRECON-M, was specially developed by us for on engine operation. Likewise the use in harsh environments is certainly possible. The M-Series is already prepared for the marine certifications according to ABS, BV, DNV GL and LR.

NOx emissions

AVAT NOx-REGULATION

NOx-control: Real-time regulated
engine operation according to BImSchV

Designed for this very purpose, the AVAT NOx-control is a comprehensive solution that uses the NOx probe connection in the E²CORE-control+ multivariable controller to efficiently regulate the interaction of the engine and the SCR catalytic converter in real time.

Operators of power generation plants with CHP gas engines must now provide sufficient evidence that the legally prescribed limits are being observed. Technically this is usually met though the use of small NOx boxes that continuously measure and record the amount of nitrogen oxide in the exhaust gas.

However, this method alone only solves half the challenge for many plant operators. Simple monitoring does not change the NOx values of the engine. To benefit generators, suppliers, communities and the environment, technical NOx solutions must actively regulate the combustion process to ensure that fewer nitrogen oxides are actually emitted and the prescribed limits are consistently met.

Advantages of the AVAT NOx control

  • Direct control, including cloud monitoring
  • Lower risk of exceeding NOx limits, which forces operators to intervene or report to authorities
  • Reliable engine operation without safety margin from NOx limits for continued high efficiency
  • Hybrid control for lean-burn engines with lambda control of NOx values inside the engine and subsequent admixture of AdBlue

Our E²CON-CHP gas engine and CHP control system features the E²CORE-control+ multivariable controller, which is designed to regulate probe operation, process measurement data (30-minute & daily averages) and provide continuous monitoring. Based on operating data from the gas engine and the NOx measurement prior to the SCR catalytic converter, the E²CON-CHP engine control system determines the necessary amount of AdBlue and immediately transfers that amount to the SCR system. This allows the engine to maintain optimal operation in accordance with the preset NOx values. The measurement values of the NOx probe are continuously checked for plausibility. If an engine knock or misfire occurs, the E²CORE-control+ will automatically switch to safe mode without NOx measurement to prevent engine damage.

Control NOx values from anywhere

All NOx and SCR measurements are recorded in the engine operating history, appear in the snapshots from the E²SERVICE software and are available for high-resolution diagnostics from anywhere in the world. To enable this, our E²CON-CHP engine control system transfers the encrypted measurement values to the AVAT CLOUD at regular intervals. If the internet connection fails, unsent data will be transmitted once the connection is restored. If a notifiable event occurs, an e-mail will be automatically sent to the saved address for notification.

In the AVAT CLOUD, data from all the connected systems are archived for a minimum of 6 years and can be exported for further processing. The amount of data archived is significantly more than those supplied by many of the NOx boxes currently available on the market. The data are encrypted and password-protected and can be accessed from any computer with an internet connection.

Our cloud dashboard includes

  • Plant status in terms of emission compliance
  • Complete presentation of all emission-relevant events
  • History of logged measurement values by day, week, month and year