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Automotive Automotive Control SolutionsControl Solutions
The AF OptimizerThe AF Optimizer
- An ENSC440 project -- An ENSC440 project -
Automotive Control Solutions
Russell Potter – CTO, President
Alex Gutica - CFO
Brian Nelson - CTO
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ContentsContents
1.1. The ACS TeamThe ACS Team
2.2. The AF OptimizerThe AF Optimizer The 440 projectThe 440 project In-car DemoIn-car Demo NowNow The futureThe future
3.3. ConclusionConclusion
4.4. Questions?Questions?
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Automotive Control Automotive Control SolutionsSolutions
A cutting-edge development teamA cutting-edge development team specialize in control of automotive specialize in control of automotive
performance through electronic air/fuel performance through electronic air/fuel optimizationoptimization
Appeal to owners of any car, Appeal to owners of any car, particularly older vehicles with particularly older vehicles with simple electronic controlsimple electronic control
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Who Are We?Who Are We?
User Interface Firmware LeadUser Interface Firmware Lead Russell PotterRussell Potter
DSP Firmware LeadDSP Firmware Lead Alex GuticaAlex Gutica
Hardware LeadHardware Lead Brian NelsonBrian Nelson
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Internal Combustion Internal Combustion EngineEngine
Requires a correct Requires a correct mixture of fuel and mixture of fuel and air in order to air in order to functionfunction
Fuel is mixed with Fuel is mixed with the air, compressed, the air, compressed, and ignited. and ignited.
When ignited, the When ignited, the air/fuel mixture air/fuel mixture drives pistons down, drives pistons down, which turns a which turns a crankshaft.crankshaft.
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Fuel DeliveryFuel Delivery
The most efficient burn mixture has an The most efficient burn mixture has an 14.7:1 air-fuel ratio.14.7:1 air-fuel ratio.
The lean conditionThe lean condition The air-fuel ratio is too highThe air-fuel ratio is too high Results in detonation, power loss, increased Results in detonation, power loss, increased
emissionsemissions The rich conditionThe rich condition
The air-fuel ratio is too lowThe air-fuel ratio is too low Results in reduced economy, increased Results in reduced economy, increased
emissions, power lossemissions, power loss
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Fuel Injection SystemFuel Injection System Proper fuel delivery is electronically controlled through a fuel Proper fuel delivery is electronically controlled through a fuel
injection and ignition timing systeminjection and ignition timing system
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Fuel DeliveryFuel Delivery
Based on a 2-Based on a 2-variable variable present map present map in the ECUin the ECU Load/Airflow Load/Airflow
metermeter RPM RPM
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The ProblemThe Problem
Fuel maps and fuel delivery are Fuel maps and fuel delivery are designed for compromisedesigned for compromise
By modifying fuel delivery and By modifying fuel delivery and consequently air-fuel ratios, consequently air-fuel ratios, improvements can be madeimprovements can be made PerformancePerformance EconomyEconomy Improved EmissionsImproved Emissions
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Why Modify an Already Why Modify an Already “Tuned” System?“Tuned” System?
Are the original engineers incompetent?Are the original engineers incompetent? No but, the original characteristics of No but, the original characteristics of
the motor can be changedthe motor can be changed Performance enhancementsPerformance enhancements
Changing the amount of air\fuel flowing into the Changing the amount of air\fuel flowing into the motormotor
General engine wearGeneral engine wear Perhaps a different “compromise” is Perhaps a different “compromise” is
desireddesired
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Current Solutions for Current Solutions for Modifying Air-Fuel RatiosModifying Air-Fuel Ratios
Modifying the computer: new fuel mapsModifying the computer: new fuel maps Model-specificModel-specific CostlyCostly Lack of user-specific ability to tuneLack of user-specific ability to tune
Standalone systemsStandalone systems Complete computer replacement is very Complete computer replacement is very
intrusiveintrusive Requires extensive, expensive tuningRequires extensive, expensive tuning
Mechanical solutionsMechanical solutions RudimentaryRudimentary
APEXi SAFCAPEXi SAFC Our direct competitionOur direct competition
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The AF OptimizerThe AF Optimizer
Its functionality and potential Its functionality and potential marketmarket
Its competitive edgeIts competitive edge FeaturesFeatures System Design and ImplementationSystem Design and Implementation
Hardware and firmwareHardware and firmware
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The AF OptimizerThe AF Optimizer
What does it do?What does it do? Recalibrates air flow sensor data, while monitoring Recalibrates air flow sensor data, while monitoring
carcar Allows for flexible tuning of air fuel ratiosAllows for flexible tuning of air fuel ratios
Moves to different location on original fuel mapMoves to different location on original fuel map Monitors automobile sensors with real-time visual Monitors automobile sensors with real-time visual
display to usersdisplay to users
Why would one buy it?Why would one buy it? To inexpensively and To inexpensively and
safely optimize delivery safely optimize delivery of fuel to their engineof fuel to their engine
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Target MarketTarget Market
Customer needs to tune their fuel Customer needs to tune their fuel systemsystem Desires better performanceDesires better performance Wants a simple, noninvasive installWants a simple, noninvasive install
29 Billion Dollar aftermarket part 29 Billion Dollar aftermarket part industryindustry Our target demographic is young people Our target demographic is young people With older carsWith older cars Who demand an inexpensive, feature packed Who demand an inexpensive, feature packed
fuel control systemfuel control system
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CompatibilityCompatibility
Compatible with wide range of Compatible with wide range of manufacturersmanufacturers
Required:Required: Fuel injectionFuel injection MAP or VAF sensorMAP or VAF sensor 0-5V Scale0-5V Scale
Reality: Older, simple computer is Reality: Older, simple computer is betterbetter
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AF Optimizer AdvantagesAF Optimizer Advantages
First and foremost, priceFirst and foremost, price Versatile for use on many different Versatile for use on many different
vehiclesvehicles Easy to install and removeEasy to install and remove Un-intrusive to the vehicleUn-intrusive to the vehicle Real-time monitoringReal-time monitoring Works on older carsWorks on older cars
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Feature OverviewFeature Overview
Airflow tuning featuresAirflow tuning features Shift Light FeaturesShift Light Features Monitoring FeaturesMonitoring Features
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Tuning FeaturesTuning Features
Many Tuning points provides more Many Tuning points provides more tunabilitytunability based on RPM and Throttle %based on RPM and Throttle %
RPM TuningRPM Tuning 2000-8750 RPM - 250 RPM increments2000-8750 RPM - 250 RPM increments 75% to 125% - 1% increments75% to 125% - 1% increments
Linearly Interpolates between tuning pointsLinearly Interpolates between tuning points
3000 3250 3500 3750 >102% 110% 109% 107% 98% 100% 97% 98%
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Tuning FeaturesTuning Features
Throttle Percentage TuningThrottle Percentage Tuning 2 Calibration Curves: High / Low Throttle2 Calibration Curves: High / Low Throttle User defined - based on throttle % thresholdsUser defined - based on throttle % thresholds
Throttle ThresholdsThrottle Thresholds Low: e.g. <30% throttleLow: e.g. <30% throttle High: e.g. >90% throttleHigh: e.g. >90% throttle
Linearly interpolates between the Linearly interpolates between the thresholdsthresholds
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Tuning FeaturesTuning Features
Overall: 2-Dimensional interpolationOverall: 2-Dimensional interpolation RPM and Throttle % are variablesRPM and Throttle % are variables
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Shift Light FeaturesShift Light Features 2000-10000 RPM in 100 RPM increments2000-10000 RPM in 100 RPM increments
5 Sequentially lit LEDs5 Sequentially lit LEDs LEDs light up every 100 RPM as you LEDs light up every 100 RPM as you
approach your desired shift pointapproach your desired shift point Increasing brightnessIncreasing brightness
Example where shift light set to 5000 Example where shift light set to 5000 RPMRPM
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Monitoring FeaturesMonitoring Features
Real-time monitoring of engine’s Real-time monitoring of engine’s sensorssensors RPMRPM Throttle %Throttle % Battery VoltageBattery Voltage OO2 2 Sensor VoltageSensor Voltage
Airflow and calibration monitoringAirflow and calibration monitoring Calibration %Calibration % Pre and Post Airflow VoltagesPre and Post Airflow Voltages
RPM: 3250rpmThrottle: 80% Battery: 14V O2 Sensor: 220mV
Airflow: 106% Pre: 2050mV Post: 2184mV
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System OverviewSystem Overview
AF Optimizer
RPM Sensor
Throttle Sensor
Airflow Sensor
ECU
Component and System Layout
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AF Optimizer: Hardware AF Optimizer: Hardware
Part SourcingPart Sourcing PIC 16F MicrocontrollerPIC 16F Microcontroller Maxim 10-bit DACMaxim 10-bit DAC Noritake 4-line x 20 character VFD Noritake 4-line x 20 character VFD 5Volt Regulator5Volt Regulator Input CircuitryInput Circuitry
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Hardware ChallengesHardware Challenges
PIC MicrocontrollerPIC Microcontroller Need to service the display, inputs and DAC Need to service the display, inputs and DAC
fastfast Fast speed for calculationsFast speed for calculations
DAC AccuracyDAC Accuracy Power ManagementPower Management I/O conditioningI/O conditioning
Noisy car signals, voltage scalingNoisy car signals, voltage scaling Creating a stable, fast analog output with Creating a stable, fast analog output with
DACDAC
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AF Optimizer: FirmwareAF Optimizer: Firmware Performed two functionsPerformed two functions
Sample inputs, calculate, Sample inputs, calculate, outputoutput
Handle interaction with Handle interaction with useruser
ButtonsButtons DisplayDisplay
Written in CWritten in C High level functionalityHigh level functionality Easy writing, debuggingEasy writing, debugging Memory & Processor UsageMemory & Processor Usage
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Firmware ChallengesFirmware Challenges
Debugging and SimulationDebugging and Simulation Simulator has limited Simulator has limited
functionalityfunctionality PIC was new to usPIC was new to us
TimingTiming We had strict timing demandsWe had strict timing demands Needed all three hardware Needed all three hardware
timerstimers Required very careful time Required very careful time
managementmanagement
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Final Product Final Product Performance 1Performance 1
Successful Successful integration into the integration into the vehicle was vehicle was dependent upon dependent upon system response system response speedspeed
Response to a 16Hz Response to a 16Hz sine as airflow input sine as airflow input (unrealistic, but (unrealistic, but illustrates system illustrates system performance)performance)
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Final Product Final Product Performance 2Performance 2
A more realistic A more realistic response to a response to a square wavesquare wave
1.5 ms system 1.5 ms system delaydelay
Small capacitor Small capacitor used to eliminate used to eliminate discontinuitiesdiscontinuities
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Integration ChallengesIntegration Challenges
Very smooth integrating into the carVery smooth integrating into the car Research of sensor signalsResearch of sensor signals In-car signal testing with oscilloscopeIn-car signal testing with oscilloscope Great lab setup for proper simulationGreat lab setup for proper simulation
Start up and Connection issuesStart up and Connection issues Starter draws current and dropped the battery Starter draws current and dropped the battery
voltagevoltage FIX: Cap and diodeFIX: Cap and diode
Bad connections with breadboard and car wiringBad connections with breadboard and car wiring FIX: Soldered car wiring harness & PCBFIX: Soldered car wiring harness & PCB
Car has a bad OCar has a bad O22 Sensor Sensor
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Demo TimeDemo Time
Things to demonstrate:Things to demonstrate: MonitoringMonitoring How to setup throttle valuesHow to setup throttle values Shift lightShift light How to set airflow calibrationsHow to set airflow calibrations Car running and drivingCar running and driving
Out to B-LOT everyoneOut to B-LOT everyone
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Dyno ResultsDyno Results
Very Impressive Results!!Very Impressive Results!! Running too rich loses power.Running too rich loses power. Running too lean loses power…Running too lean loses power… We are able to change the air fuel We are able to change the air fuel
ratiosratios Here are the resultsHere are the results
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Rich RunRich Run
Tried 120% but threw Check Engine Tried 120% but threw Check Engine LightLight
Tuned to 110% from 2000-6700 RPM Tuned to 110% from 2000-6700 RPM (redline)(redline)
Results:Results:
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Lean RunLean Run
Running too lean lost power in low Running too lean lost power in low RPMsRPMs
Original ECU runs too rich at high Original ECU runs too rich at high RPMsRPMs Use AF Optimizer to lean high RPMsUse AF Optimizer to lean high RPMs
Results:Results:
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Engineering Engineering ConsiderationsConsiderations
Positive system feedback due to vehicle Positive system feedback due to vehicle velocityvelocity Does not affect airflow into engineDoes not affect airflow into engine Dynamometer is appropriate for vehicle tuningDynamometer is appropriate for vehicle tuning
System memory considerations (derivatives)System memory considerations (derivatives) Precautions were taken to prevent derivative Precautions were taken to prevent derivative
reversalreversal Airflow signal adjustability range limited to 75% - Airflow signal adjustability range limited to 75% -
125%125% High and low throttle curves at least 20% of entire High and low throttle curves at least 20% of entire
throttle range apartthrottle range apart Testing indicates airflow signal changes much faster Testing indicates airflow signal changes much faster
than throttlethan throttle
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BudgetBudget
Proposed Budget:Proposed Budget: $665$665 Actual Spending:Actual Spending: $200$200 Difference:Difference: $-465$-465
SummarySummary
We We UNDERSPENT! UNDERSPENT! Due to building only 1 prototype, cheap dyno Due to building only 1 prototype, cheap dyno
timetime
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AF Optimizer: ScheduleAF Optimizer: Schedule
Firmware:
Hardware:
System Integration:
Final Testing:
Predicted Completion
Dates
February 27
March 6
March 13
March 24
Actual Completion
Dates
March 15
March 6
March 17
April 4
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AF Optimizer: NowAF Optimizer: Now
Have a fully functional prototype!Have a fully functional prototype! We’ve priced many parts in quantitiesWe’ve priced many parts in quantities
The display dominatesThe display dominates Accounts for as much cost as all others Accounts for as much cost as all others
combinedcombined Produced prototype PCB and casingProduced prototype PCB and casing Plans underway for production modelPlans underway for production model Designed to use 1 PIC for costDesigned to use 1 PIC for cost
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AF Optimizer: The FutureAF Optimizer: The Future
Small distribution at firstSmall distribution at first Use online car clubs for marketingUse online car clubs for marketing Will hopefully get feedbackWill hopefully get feedback
If all goes well, incorporate!If all goes well, incorporate! Outsource manufacture to overseasOutsource manufacture to overseas Build relationships with distributorsBuild relationships with distributors Maybe make a few $$Maybe make a few $$
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Future Design Future Design ConsiderationsConsiderations
Split it up into modulesSplit it up into modules Display and buttonsDisplay and buttons Main PC Board and wiring to car’s Main PC Board and wiring to car’s
wiringwiring Shift light (remotely mounted)Shift light (remotely mounted)
Optimize PCB designsOptimize PCB designs
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ACS Team SummaryACS Team Summary
This was a great learning experienceThis was a great learning experience ConclusionsConclusions AcknowledgementsAcknowledgements
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Lessons LearnedLessons Learned
Time and hard work invested early Time and hard work invested early pays offpays off
Research allows for easier problem Research allows for easier problem solvingsolving
Documentation is important for Documentation is important for complicated projectscomplicated projects
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ConclusionsConclusions
We chose a great projectWe chose a great project Because we love carsBecause we love cars It was complex, but workableIt was complex, but workable
We honed our skills learned in 4 We honed our skills learned in 4 yearsyears
This product can make moneyThis product can make money
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AcknowledgementsAcknowledgements
Scott, Lucky, FredScott, Lucky, Fred Dave Atchison, for experience with Dave Atchison, for experience with
PIC and Dyno timePIC and Dyno time ESSEF fundingESSEF funding