Behind the scenes- The development of performance improvements
The basis for the development of a new engine management system and / or performance enhancing components are the test results of a vehicles stock configuration. By using the dynamometer, HP / kW values and Nm values are recorded. These values are basically only the documentation of the power delivery and the maximum ratings. The dynamometer captures the engines power by measureing the force applied to its rolls by the wheels of the vehicle. A dynamometer is thus merely an instrument which serves the documentation of the performance. In developing, this simulates driving on a road. If the development is carried out correctly, all measurable data such as Lambda values, intake temperatures, boost pressures, etc. are recorded. In figures: over one hundred readings are taken every 10-ms and recorded. To provide clean measurement results, it is necessary to simulate the driving operation as close to reality as possible. This requires i.a. a very good engine cooling, otherwise the values will get distorted and are thus unusable for development. All of the resulting measurements represent the starting point for the tuning and provide an overview of the engines potential. It is then decided, whether changes to the hardware are required, e.g. engine components, elements of the cooling system or exhaust components, as well as whether the factory-installed hardware can still fulfill its designated tasks. At the same time, the engineers check which loads the mechanical components have to bear, e.g. the torque at the transmission and drive train, always considering the limits set by the manufacturer of these parts. The purpose of the development is to not only get an increase in power, but also to develop a stable and durable tuning. It is a compromise between performance and durability that characterizes a good tuning. After the first data has been collected and analyzed, the so-called engine-management-system is read and saved, this code basically represents the control of the engine in form of software. This is a sequence of binary / hexadecimal digits (binary = 10101000101010 and hexadecimal = 0-9 A-F). Decrypted, this data provides a three-dimensional chart. Now, all the requirements for the electronic performance enhancement are available.
Exhaust-Tuning!
Furthermore, there are projects in cooperation with the manufacturer Supersprint, to develop and tune exhaust systems for new vehicles, such as the Mercedes V8 bi-turbo engine (500 and 63 AMG). First the original exhaust system is evaluated to explore the possibilities of optimizations. Helpful with this is the experienced development manager of the company Supersprint, Davide Branchini. Again, advanced measuring techniques monitor all the values of a vehicle on a dynamometer. For example, with the exhaust-pressure measurement the resistance is determined, which the exhaust gases have to overcome. This resistance has significant impact on the performance characteristics and the characteristics of the engine. Contrary to most opinions about the issue, it is not the goal to minimize the pressure to the lowest level, but to find the optimum pressure for the engine. In addition to recording the pressure, the values of the exhaust flow angle and the heat of the exhausted gas are tested end recorded too. They are also significant for the power deployment of an engine. After the analysis of the collected data, the exhaust prototypes are built and calibrated. They will be tuned and improved until they reach the intended goal and create the optimal conditions for the engine to deploy its power.
Of course, the development of the exhaust sound also plays a big role. After all, the car is supposed to sound good too. The muffler and the resonator are the primary components for regulating the sound. They usually have no major impact on power development. The components, which influence the characteristics and performance of an engine, are the ones installed from the exhaust manifold up to the muffler.
Also a part of the exhaust developement is the optical design of the visible parts like the exhaust tailpipes which should integrate harmoniously into the overall concept of the vehicle.
After completion of the development work, all the hardware changes are implemented in the engine control module (chip). That means: ignition, boost pressure and air/fuel ratio have to be adjusted to match the new components in order to create the optimal performance and durability. Now, the created potential can finally be used. A development like this usually takes several weeks to complete and requieres a lot of pioneering work. However, it is also often stolen in minutes and badly copied. We therefore advise you, when it comes to performance enhancement, make sure to work with a reliable partner who has the necessary equipment, experience and knowledge.
The basis for the development of a new engine management system and / or performance enhancing components are the test results of a vehicles stock configuration. By using the dynamometer, HP / kW values and Nm values are recorded. These values are basically only the documentation of the power delivery and the maximum ratings. The dynamometer captures the engines power by measureing the force applied to its rolls by the wheels of the vehicle. A dynamometer is thus merely an instrument which serves the documentation of the performance. In developing, this simulates driving on a road. If the development is carried out correctly, all measurable data such as Lambda values, intake temperatures, boost pressures, etc. are recorded. In figures: over one hundred readings are taken every 10-ms and recorded. To provide clean measurement results, it is necessary to simulate the driving operation as close to reality as possible. This requires i.a. a very good engine cooling, otherwise the values will get distorted and are thus unusable for development. All of the resulting measurements represent the starting point for the tuning and provide an overview of the engines potential. It is then decided, whether changes to the hardware are required, e.g. engine components, elements of the cooling system or exhaust components, as well as whether the factory-installed hardware can still fulfill its designated tasks. At the same time, the engineers check which loads the mechanical components have to bear, e.g. the torque at the transmission and drive train, always considering the limits set by the manufacturer of these parts. The purpose of the development is to not only get an increase in power, but also to develop a stable and durable tuning. It is a compromise between performance and durability that characterizes a good tuning. After the first data has been collected and analyzed, the so-called engine-management-system is read and saved, this code basically represents the control of the engine in form of software. This is a sequence of binary / hexadecimal digits (binary = 10101000101010 and hexadecimal = 0-9 A-F). Decrypted, this data provides a three-dimensional chart. Now, all the requirements for the electronic performance enhancement are available.
Exhaust-Tuning!
Furthermore, there are projects in cooperation with the manufacturer Supersprint, to develop and tune exhaust systems for new vehicles, such as the Mercedes V8 bi-turbo engine (500 and 63 AMG). First the original exhaust system is evaluated to explore the possibilities of optimizations. Helpful with this is the experienced development manager of the company Supersprint, Davide Branchini. Again, advanced measuring techniques monitor all the values of a vehicle on a dynamometer. For example, with the exhaust-pressure measurement the resistance is determined, which the exhaust gases have to overcome. This resistance has significant impact on the performance characteristics and the characteristics of the engine. Contrary to most opinions about the issue, it is not the goal to minimize the pressure to the lowest level, but to find the optimum pressure for the engine. In addition to recording the pressure, the values of the exhaust flow angle and the heat of the exhausted gas are tested end recorded too. They are also significant for the power deployment of an engine. After the analysis of the collected data, the exhaust prototypes are built and calibrated. They will be tuned and improved until they reach the intended goal and create the optimal conditions for the engine to deploy its power.
Of course, the development of the exhaust sound also plays a big role. After all, the car is supposed to sound good too. The muffler and the resonator are the primary components for regulating the sound. They usually have no major impact on power development. The components, which influence the characteristics and performance of an engine, are the ones installed from the exhaust manifold up to the muffler.
Also a part of the exhaust developement is the optical design of the visible parts like the exhaust tailpipes which should integrate harmoniously into the overall concept of the vehicle.
After completion of the development work, all the hardware changes are implemented in the engine control module (chip). That means: ignition, boost pressure and air/fuel ratio have to be adjusted to match the new components in order to create the optimal performance and durability. Now, the created potential can finally be used. A development like this usually takes several weeks to complete and requieres a lot of pioneering work. However, it is also often stolen in minutes and badly copied. We therefore advise you, when it comes to performance enhancement, make sure to work with a reliable partner who has the necessary equipment, experience and knowledge.
