Expert training, Italian style

Frank Massey is overseas again, but while he is there, he takes a look at ways to predict common rail pressure faults

Published:  06 June, 2018

I have just returned from Modena, delivering a two-day advanced technical training seminar to 21 of Italy’s top independent technicians. I was travelling from across Italy and beyond, attending PCB Automotive’s international training programme, focusing on gasoline direct injection and common rail diesel.  

The essence of the training was the advanced application of Pico oscilloscope to diagnose and gain predictive evidence for a repair solution. The technicians were particularly interested in the techniques of high pressure pump testing pioneered by ADS several years ago.

Attending the event were diesel and gasoline specialist and Italy’s most respected Bosch trainer. No pressure then! The session began with an explanation of the importance of scope performance when gathering data at high resolution requirements. Acquisition, storage, display, test lead bandwidth and advanced triggering with math channel analysis.

As expected Bosch had a different political agender towards our pump proof testing. It was however received with enthusiasm and great interest once its accuracy and simplicity was experienced.

The session on ignition evaluation was of great interest especially when focusing on primary current ramping and slew rate. Further discussion on burn time and slope completed the morning session.

The four-course lunch was a typical treat of local Italian hospitality and cuisine. The afternoon session included the evaluation of load request with air mass and Lambda response. By comparing response and rise time evaluation it is possible to predict and confirm complex fuel delivery and combustion anomalies.

A full eight-hour day concluded with hybrid cart racing north of Bologna, followed by the inevitable pizza and Mr Moretti’s finest.

Data and interest
Day two and common rail diesel with a similar agenda,   with a strong focus on Math analysis of pressure and volume control against fuel delivery pressure. We have accumulated a vast database of rail pressure profiles, rise and decay times across all diesel manufacturers. This was of great interest to a Bosch pump and injector repair specialist. Approving nods and smiles throughout supported our confidence in this form of diagnostic analysis.

There was great interest in the examination and influence of rail pressure and air mass response time.  Converting digital air mass into a current profile enabled delegates to understand the speed and simplicity with which a technician can determine the source of an error, either hydraulic or sensor input.
The day concluded with certificates and a photo session. Teachers usually get apples from students so imagine my joy with a bottle of wine and finest olive oil.

With a 6.30am flight in the morning and 50 kilometres back to Bologna, it was a very nice gesture from Luca my host to take me for a special evening meal at a villa outside Modena.

I found it intriguing to be asked by several of the delegates, with my international training experience, where the best technicians are to be found. I responded including them with the very best, not just because of their technical fluency, but especially their mutual respect and co-operation with each other, sadly lacking with some in the UK.

Using Math
To conclude let’s look at an example of using Math to predict hydro mechanical function against rail pressure.
The system example; Bosch cp1h, volume control single point, solenoid injectors. Sample taken from stable idle, part load snap open throttle, return to idle.

Channel a blue;
Rail pressure profile idle, snap open, rtn to idle.

Channel b red;  
Volume control valve ground duty control

Channel c green;  
Volume control valve, current vis rail pressure

Channel d black;  
Air mass meter profile vis rail pressure

Math Channel purple;  
Math duty volume control

The focus of this analysis was to establish the rail pressure hydraulic response time against air mass load signal, expressing the primary control device, volume, as current and math duty conversion.

To understand the values in this test enables an unequalled understanding of the systems capability in delivering fuel vis time.
The next challenge is to sync a second 4 channel scope monitoring compression using WPS, with the 4-stroke cycle overlay, noting the secondary pressure increase when fuel is injected. Then we really are ahead of the curve.



Related Articles

  • Future-proofed: Training technicians for the long-term  

    While experience in the day-to-day activities of a workshop is vital in building a technician’s knowledge and skills, it is only one piece of the puzzle. For example, a technician who has been servicing solely petrol and diesel vehicles for the past 15 years will unlikely be able to help a customer with a hybrid or electric vehicle. What’s more, given the safety concerns involved, it would be dangerous for them to try. What about servicing the latest safety-critical systems, like ADAS? Certainly not a worthwhile risk without the appropriate knowledge or equipment.

    Systematic training in new technologies is, therefore, the best way to ensure a workshop will continue to successfully serve aftermarket customers, even in times of rapid change.

    “The Auto Education Academy portal from Euro Car Parts brings IMI-approved online and practical courses together with a database of over 500,000 resolved technical queries, with an average of 600 new repairs added daily,” observed Adam White, Workshop Solutions Director at Euro Car Parts. “It provides technicians with one of the largest technical training and knowledge resources in the independent aftermarket.”

    “Training is an integral part of ongoing success in this industry,” continued Adam. “It allows technicians to further their career and workshop owners to develop a highly-skilled team of professionals.”

    While many would agree to education’s importance in principle, it can be difficult to carry out a training plan and accept lost revenue in the short-term. Online learning can provide the flexibility to bridge that gap.

    “Repairers can login to their own skills portal to view the content of more than 75 different courses, registering and booking their place on training workshops all over the country at the click of a button,” said Adam. “They can also assess their strengths and identify weaknesses in nine key areas: Petrol engines, diesel engines, engine management and emissions, vehicle electronics, hybrid and electric cars, brakes, powertrain, tyres, steering and suspension, as well as air-conditioning.

    “Results are automatically added to an interactive skills diagram, illustrating a repairer’s current skillset and enabling them to set their own training and development targets. Where gaps exist, the learner management system intuitively recommends Auto Education courses that can help increase knowledge in those areas.”

    Invaluable
    “The platform has been designed so that anybody can complete a skills overview,” pointed out Adam. “This makes the tool invaluable to workshop managers looking to monitor staff skillsets or test potential hires. Our new learning portal represents a significant investment by Euro Car Parts in helping to nurture the knowledge and skills of technicians across the country.
    “As with any profession, it is important for technicians to continue professional development throughout their career. It is also the role of managers to identify gaps in their team and commit staff to training that will address shortcomings in the workshop’s capabilities. For more immediate solutions, the programme features a technical helpline that provides fast responses to troubleshooting, repair, diagnostics and technical information queries on any vehicle, from any manufacturer.”
    Adam concluded: “For those with an eagerness to learn and evolve, it is an exciting era for the independent aftermarket. “We consider the success of technicians and independent workshops as the foundation of our industry and believe nothing plays a greater role, or makes more of an impact, than education.”

  • Sector organisations back Top Technician and Top Garage 

  • 24 Top Technicians 

    Following completion of the initial Top Technician 2014 online test, the two dozen highest scoring entrants have been announced and will go forward to the quarter final stage of the competition. Hailing from as far apart as Orkney in Scotland and Truro in Cornwall, they will now face a stricter online test of their fault-fixing knowledge to determine which of them will be among the twelve technicians to attend the half day practical semi-finals at the Delphi training centre in Warwick on April 4. In alphabetical order, the quarter finalists are:

  • Euro Car Parts becomes Top Technician/Top Garage 2019 sponsor 

    Euro Car Parts is the latest huge name to lend its support to Top Technician and Top Garage 2019, becoming a sponsor for the two competitions.

  • LAST CHANCE TO ENTER TOP TECHNICIAN 2019  

    Techs wanting to take part in Top Technician 2019 have until 23.59 tomorrow (Friday 4 January) to take the round one quiz, or risk missing out on the competition this year.

Most read content


Search

Sign Up

For the latest news and updates from Aftermarket Magazine.


Poll

Where should the next Automechanika show be held?



Calendar

Click here to submit an event

Facebook


©DFA Media 1999-2019