Automotive spark plugs are essential ignition circuit components being of importance for combustion engine reliability and performance. The majority of spark plugs have ribbed ceramic insulator to ensure high resistance along the surface from the terminal to the metal shell to minimize leakage current and to provide flashover protection. The leakage current intensity depends on electric field distribution, physical insulator properties and such factors as humidity, insulator contamination or defects in insulation material. Furthermore, leakage current not infrequently interferes with discharge process causing misfire effect being harmful to exhaust manifold components, mainly to catalytic converters. This paper presents simulation results of electric field distribution in ceramic insulator, in silicone rubber boot and in space surrounding a spark plug. Assuming that a spark plug can be considered as an object having cylindrical symmetry the electric field distribution was calculated for a two-dimensional case in accordance with Laplace’s and Poisson’s equations. In this paper, the finite difference method (FDM) for the solution of the Laplace’s equation was applied. The FDM algorithm based on the Liebmann’s method was developed in the MATLAB environment. Presented simulation results can be helpful to automotive spark plugs and high-tension cables manufacturers interested in improvement of insulating properties.

http://www.diagnostyka.net.pl/pdf-69065-17759?filename=Electric field.pdf

Electric field distribution in spark plugs insulators – modeling and computer simulation

Spark Ignition Circuit Energy Characterization based on a Simplified Model and Measurement Analysis

In this study, since it can be analyzed in term of practically and easily in application, a 15 kV ignition coil was designed, and analyzed in electromagnetic way. In order to benefit from this design in automotive industry, it has been determined an ignition coil construction here. Magneto static designing of the ignition coil have been done as 3 dimensional analytical way with help of finite elements methods (Ansoft Maxwell V12 program). By this way, electrical and magnetic parameters and quantities have been calculated; the static magnetic data obtained have been commented. In this design, the effects of using different electromagnetic materials such as nanocrystalline, amorphous and enni55 as core of the ignition coil have been explored. By using Ansoft-Simplorer program, different types of ignition coil cores could have been obtained. It has been inferred that more accurate dynamic analyzing conclusions for the ignition coil would result in the calculation. Streszczenie. W artykule zaprezentowano projekt 15 KV cewki zaplonowej z przeznaczeniem do silnikow benzynowych. Projekt wykorzystuje obliczenia magnetostatyczne wykonane z pomocą metody elementow skonczonych. Uwzgledniono zastosowanie roznych materialow jak materialow nanokrystalicznych czy amorficznych. Przedstawiono rozne koncepcje projektu cewki. (Komputerowe projektowanie cewki zaplonowej do silnikow benzynowych)

Computer aided design of an electromagnetic ignition coil for high speed benzine engines

This paper discusses the research and analysis of the dynamics of high-voltage generating systems. The test subject is an ignition system modelled by a set of two induction coils with an open ferromagnetic core that constitutes an ignition coil. The essence of the tests involved the application of magnetic coupling of the fractional order that enabled taking into account the non-idealities of the coils and the connector that implements the ignition point. The paper contains the results of a theoretical analysis, supported by digital simulations. The conducted experiments confirm the purposefulness of the conducted analyses and the possibility of modeling real objects based on circuits with fractional-order elements. 

/pdf/modeling-of-internal-combustion-engine-ignition-systems-with-3fx559w4.pdf

Modeling of Internal Combustion Engine Ignition Systems with a Circuit Containing Fractional-Order Elements

This paper envisages studying the features of a conventional inductive ignition system along with its MOSFET and IGBT-based transistorized modifications. The influence of mechanical contact breaker dynamics and ignition coil characteristics on the current and voltage waveforms of the primary and secondary circuits of these studied ignition systems are mathematically and experimentally exposed. The investigation is considered necessary prior to attempting subsequent modeling and diagnostics procedures on the current-voltage performance characteristics of conventional and transistorized ignition systems. The work has demanded the development of an experimental setup based on a basic modifiable ignition system mockup and an instrumentation system to measure and analyze the voltage-current parameters of inductive ignition systems. The paper describes the design details of such instrumentation system, presents mechanical and electrical models for contact breaker and ignition circuits, then simulated to obtain base free-run response waveforms and electrical continuity behavior of the contact. A test of frequency response of the ignition coil provided additional input to the model. An experimental test of continuity of the contact, in agreement with its model, shed light on the actual excitation of the primary coil. The work comments on a sample of the registered current and voltage waveforms in primary and secondary coil windings of the ignition system at atmospheric conditions. Comparisons of waveforms and energy for mechanical contact, MOSFET and IGBT switches are made to establish them as a reference for future tests.

Experimental and numerical approach to assess the dynamic performance of an inductive ignition system

This paper presents a comprehensive approach to improve the analysis and design process of automotive ignition coils. The delivered voltage and energy of the coil to the spark plug load are the two essential requirements placed on a coil design. The prediction of these two quantities, derived from the simulated transient secondary current and voltage, is fundamental to the design process and allows early assessment of design robustness. With only the data required for electromagnetic finite element analysis (FEA), including material loss data, the magnetic and electrostatic interactions among the coil laminations and windings can be modeled. These field computations are converted to equivalent circuit elements employed in a systems model. The systems model allows the calculation of requisite transient signals. This approach is highly flexible and gives fast simulations. Good agreement was obtained between the test data and the simulation results in both the time-domain and the frequency-domain. INTRODUCTION The objective of this work is to provide tools and methods to improve the design process, and ultimately to improve the design and performance of automotive ignition coil systems. These modeling efforts allow the early assessment of design robustness and improve the reliability of the automotive ignition coil system. The analysis of the ignition coil system discussed here includes a driver, a coil, and a load. Ignition coils deliver the high voltage (several tens of kV) necessary to initiate the breakdown of the sparkplug gap, and then sufficient energy (several tens of mJ) to sustain the combustion, and overcome plug losses. The delivered kV and energy are the two essential requirements imposed on the ignition coil design. These two quantities, as well as other parameters, are derived from simulated transient signals of the coil, i.e., the primary and secondary currents and voltages. The accurate prediction of the time variation of these quantities is fundamental to the design process. The proposed approach is from first principles to the extent possible. The number of experimentally determined factors from actual coil prototypes was minimized in predicting the coil behavior. A coil design process was developed that begins with only dimensions, material properties, and topology. Then the non-linear magnetic and linear electrostatic interactions among the windings and laminations of the coil were modeled using electromagnetic finite element analysis (FEA). A simple model was developed to account for the winding resistance. The proposed approach is to convert field computations into equivalent circuit elements to be employed in a systems modeling program. The equivalent circuit approach allows a high degree of flexibility, and relatively fast time-transient simulations. The physical modeling is with static magnetic and electric fields, but the system simulator properly accounts for dynamic effects through an interpolation process. In addition to the coil model, the equivalent circuit models for the electronic driver and sparkplug load must be included. However, the parameters and physics of these two subsystems are less well known, or harder to obtain, than for the coil itself. The rest of the paper is arranged as follows: First, the motivation, objectives, and the approach of the proposed work are discussed. Next, the basic coil behavior is demonstrated in terms of a Fundamental Coil Model. Then more complex behavior is introduced in terms of Simple Coil Model. Simulations are given for the Simple Coil Model that illustrates the effects on signals from non-linear components. Following this Simple Coil Model, the detailed modeling of the individual components of the Comprehensive Systems Model is presented. Finally, the simulated results are compared with measured data, on a particular developmental coil, in the time domain and frequency domain. IGNITION COIL MODELING MOTIVATION, OBJECTIVES AND APPROACH Motivation: The motivation to pursue a comprehensive modeling effort for ignition coils is several-fold, and common to 2007-01-1589 Comprehensive Modeling of Automotive Ignition Systems Visteon/ACH-LLC, CAE University of Michigan, Dearborn C. S. Yang, S. K. Park and C. Mi R. C. Stevenson and R. Palma Licensed to University of Michigan Licensed from the SAE Digital Library Copyright 2009 SAE International E-mailing, copying and internet posting are prohibited Downloaded Thursday, January 15, 2009 8:22:26 PM Author:Gilligan-SID:1178-GUID:15736962-141.215.16.4 2 most engineering modeling efforts. A good model promotes basic physical understanding of the surprisingly complex operation of ignition coils. It allows the design engineer to pose “what if” questions, which can generally be answered relatively quickly. Most importantly, it reduces cost in terms of the number of prototypes, the testing, and the time dedicated to building physical prototypes. There is scant to non-existent literature on the modeling of automotive ignition coils [1]. There appears to be little or no literature on electromagnetic FEA modeling of ignition coils. Design methods for coils seem to be closely held secrets in the industry, and most design work appears to be done from historical precedence. Design modifications in the past have been guided by basic transformer theory, without resorting to detailed modeling. The construction of coil prototypes, typically with several design iterations, is an expensive and a time consuming process. It involves the specification and fabrication of annealed laminations, the design and fabrication of bobbins and packaging, the winding of the primary and secondary coils, the potting the coils, and the testing the coils. This type of prototyping can have cycle times of several months. By comparison, modeling can produce comparable answers with in a week or less. Objectives Given these prototyping costs, both temporal and financial, the objectives of this modeling work become apparent: reduce cost by minimizing the need to build prototypes. To this end, the electromagnetic engineer should create a modeling process whose short-term objective provides accurate guidance for the design engineer during initial screening of design variations. As a derivative of this goal, the prototypes that are built with the modeling guidance should be close to the design objectives. These goals require that the modeling effort should be based on “first principles” to the extent possible. It is to predict accurate transient behavior, not to fit the model to data gathered after prototypes are built, that the modeling effort is directed. However, because of the magnetic, electrical, and geometrical complexity of the coils, modeling approximations are inherent. Thus, some adjustment of systems and models to test data may be necessary. The longer-term objective is to advance from an analysis of design to a synthesis of design. That is, given a set of specifications, produce an optimized design that accounts for constraints on performance, material costs, package space, etc. This type of design work requires having an analysis procedure coupled to the ability to iterate, sample, or search many designs subject to the constraints. There is likely no unique solution. This longer-term objective will be accomplished in future work. Approach With regard to the modeling approaches, there are at least three potentially viable schemes. The first scheme, and the most physically accurate, would be to solve the complete set of Maxwell equations, beyond the lowfrequency approximation which is generally used for electric machine modeling. In this complete formulation, Ampere’s Law ( t H D J ) includes the displacement current density, t D , while in the lowfrequency case, the displacement current density is ignored. For this scheme, the full coupling of the electric and magnetic fields is obtained, i.e., the magnetic inductive and capacitive effects are automatically accounted. For the current state of the art in electromagnetic solvers, the direct solution of the complete set of Maxwell equations, with strong material nonlinearity, is not practical. A second approach is to solve a transient FEA model of the magnetics, including external circuitry for the driver, the load, and capacitive effects. This approach is feasible but cumbersome, since a transient magnetic FEA problem would need to be solved for changes in any minor model parameter. A third approach, detailed in this paper, is a more flexible method. In this third approach, the model includes an equivalent circuit of the driver, the load, and the coil. The lumped circuit elements for inductive, capacitive, and resistive effects are obtained from FEA. The inductive elements account for non-linear material properties. The flexibility of this approach comes with studies requiring changes to circuit elements, other than those derived from FEA. These changes can be accommodated quickly and easily. Simulations can be run in a matter of a few minutes. IGNITION COIL OPERATION OVERVIEW Automotive ignition system requirements and operation with regard to engine and spark plug performance is discussed in [2]. For the modeling effort described in this section, the focus is more narrowly on describing how the coil works. The ignition coil system consists of a coil, which acts as a transient voltage transformer; a driver, which “charges” the primary winding; and a load (a spark plug) to which the coil delivers a high voltage pulse. The coil system block diagram is shown Fig. 1. The basic job of an ignition coil system is to convert a low-voltage DC source into a very high voltage and very fast transient at the spark plug gap. Driver The driver part of the system consists of a voltage source (the automotive battery, nominally 14.4 V) and a controlled switch. The switching device is commonly an IGBT [3]. However, this simple switch will not suffice, because the large voltage that develops in the Licen

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Comprehensive Modeling of Automotive Ignition Systems

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Comprehensive Modeling of Automotive Ignition Systems