2000-2001 FORMULA SAE RACE CAR

CONFIDENTIAL TECHNICAL DOCUMENTS FOR ENGINE CONTROL SYSTEM DESIGN

Team 1 (Formula SAE): Robert Hotaling Jason Mangual Michael McGee Nnamdi Okam Student Advisors: Professor John Ayers, Ph.D. Professor Jim Cowart, Ph.D.

TABLE OF CONTENTS Specifications............................................................................................................................... 3 Mechanical Parameters............................................................................................................3 Electrical Parameters...............................................................................................................3 Variable Reluctance Sensor (VRS) Interface Circuit....................................................................4 Specifications........................................................................................................................... 4 Circuit Diagram......................................................................................................................... 4 Components............................................................................................................................. 4 Cylinder Compression Detector (CCD) Circuit.............................................................................6 Specifications........................................................................................................................... 6 Circuit Diagram......................................................................................................................... 6 Components............................................................................................................................. 6 Manifold Absolute Pressure (MAP) Sensor Circuit.......................................................................8 Specifications........................................................................................................................... 8 Circuit Diagram......................................................................................................................... 8 Components............................................................................................................................. 8 Rich/Lean (R/L) Circuit.................................................................................................................9 Specifications........................................................................................................................... 9 Circuit Diagram......................................................................................................................... 9 Components............................................................................................................................. 9 Ambient Air Sensor (AAS) Sensor Circuit..................................................................................11 Specifications......................................................................................................................... 11 Circuit Diagram....................................................................................................................... 11 Components........................................................................................................................... 11 Throttle Position Sensor (TPS) Circuit.......................................................................................12 Specifications......................................................................................................................... 12 Circuit Diagram....................................................................................................................... 12 Components........................................................................................................................... 12 Microcontroller........................................................................................................................... 13 Specifications......................................................................................................................... 13 Pin Diagram........................................................................................................................... 13 Port Schema.......................................................................................................................... 14 Electronic Fuel Injection (EFI)....................................................................................................15 Introduction............................................................................................................................ 15 Circuit Diagram....................................................................................................................... 15 PCB Diagram......................................................................................................................... 16

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Specifications Mechanical Parameters Control Box Size Weight Durability Vibration Electrical Parameters Power Supply Frequency of Injection Pulse Bank Firing Sequential Firing Frequency of Spark Trigger Inputs Ambient air temperature Engine speed Engine position Engine load 12V battery supply 14000-per/minute maximum 28000-per/minute maximum 14000 per/minute maximum 3" x 12" x 8" 10lbs max Operate in hard turning and acceleration Operate under vehicle vibration conditions

Outputs Spark trigger frequency Injection pulse width and frequency

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Variable Reluctance Sensor (VRS) Interface Circuit Specifications Input 0.6V to 30V Sinusoidal Crank Sensor Signal fmin = 6.7Hz (400 RPM) at cranking fmax = 166.7Hz (10000 RPM) at wide-open throttle 0-5V Square Wave DC Signal (TTL)

Output Crankshaft Position Sensor (CPS)

The Variable Reluctance sensor (VRS) reacts to variations in flux density created by a rotating (7-1 tooth) wheel attached to the crankshaft. The sensor contains a coil of wire, a magnet, and a pole piece. The changing flux field induces an A/C voltage in the CPS sensor. One A/C cycle is generated for each tooth on the wheel. Normally, the A/C signal is converted into a digital pulse. The CPS sensor output voltage is 600 mV peakto-peak at a minimum engine speed of 400 RPM, and 30 V peak-to-peak at a maximum engine speed of 10000 RPM. Circuit Diagram

Components Resistors (1) 1k (3) 10k (1) 20k Capacitors none

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Diodes (2) 10V 2W Zener Diodes (1) 1.1A 40V Schottky Diode Design Considerations:

Other Components LM324 Op-Amp

The variable reluctance interface (VRS) interface circuit is designed to convert the analog sinusoidal signal from the engines crankshaft sensor to a square wave that can be recognized by the microcontroller. The circuit must take a sinusoidal signal that varies from about 0.6V @ 6.7 Hz at cranking speed to above 30V at higher speeds into a square wave that is 0V or 5V. ****The circuit was originally designed for a voltage range of 150mV to 500V based on information from Ford crankshaft sensor data extrapolated out for the higher engine speed of the Honda. ****We have not yet tested the crankshaft signal at higher speeds without having the sensor connected to the Hondas spark microcontroller since we are currently using the Hondas ignition to run the engine. This means that we do not know if the crankshaft signal would greatly increase for higher engine speeds, as originally expected. Even if this is the case we have designed our interface circuit for a signal that goes as high as 500V for short accelerations. We chose to use an LM324 op amp that operates with a single power supply for our circuits since the microcontroller requires only positive voltages. The VRS interface uses a non-inverting op amp circuit to condition the crankshaft signal. The two 10V zener diodes (D1 and D2) are configured as a zener limiter to isolate the op amp from the higher voltage signal as engine speed increases. The Schottky diode (D3) prevents the input of the op amp from going more than 0.3V negative. The op amp has a +6V supply so it will output +5V at saturation (due to a 1V internal drop in the op amp). The op amp has a gain of (R3+R4)/R3 which is 21. This amplifies a small signal of 0.6V to 12.6V, since the op amp saturates at 5V its output is 5V. The resulting wave is a close approximation to a square wave at low engine speeds, and a very close approximation to a square wave at higher engine speeds. This results in a TTL signal that is a series of 7 pulses corresponding to the teeth of the VRS followed by a gap that corresponds to the missing tooth region of the VRS. The signal allows the microcontroller to recognize both engine speed and position.

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Cylinder Compression Detector (CCD) Circuit Specifications Input Output Logic Circuit Diagram 150/1??V Transient Pulse Signal from Ignition coils 1 and 4 0/5V Pulsed DC Signal (TTL) If Vcoil4 > Vcoil1, then output is positive If Vcoil4 < Vcoil1, then output is zero

Components Resistors **(5) 1k Diodes None Capacitors (2) 1nF Miscellaneous LM324 Op-Amp

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Design Considerations: The Cylinder Compression Detector (CCD) is essentially a comparator circuit. It is designed to convert the transient pulses found at the primary ignition coils during spark plug firing into a TTL signal that will correspond to the compression stoke of number four and number one cylinders. This signal will allow the microcontroller the necessary information to supply fuel sequentially without the use of a camshaft sensor. The input from the ignition coil primaries of number one and four cylinders is connected to two voltage dividers to reduce the voltage to acceptable levels for the op amp. The capacitors in series parallel with the input resistors act as low-pass filters (LPF) to spread the short ignition pulse out in time **so the op amp can react in the short amount of time.** This results in a TTL signal corresponding to the compression cycles of number one and four cylinders. According to the logic of the op-amp comparator, if Vcoil4 > Vcoil1, then the output is positive 5V, and if Vcoil4 < Vcoil1, then output is zero. Therefore, if the output is positive, coil four has fired. If the output is zero, coil one has fired. This signal is to be sampled at the same time as the firing of ignition coils one and four in order to determine where we are in the engines compression cycle.

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Manifold Absolute Pressure (MAP) Sensor Circuit Specifications Input Output Circuit Diagram 8V DC (from 8V regulator circuit) Manifold Pressure 0-5V Variable DC

Components Resistors (2) 10k Diodes None Note: The MAP sensor returns a voltage between 0V and 6.2V DC depending on manifold pressure. Therefore, a voltage divider is needed to provide the microcontroller with a voltage less than or equal to 5V DC. Capacitors none Other MAP sensor

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Rich/Lean (R/L) Circuit Specifications Input Output Circuit Diagram 6V DC (from 6V regulator circuit) Switch Position (Driver Selected) 0-5V Variable DC in 1V steps

Components Resistors (6) 1.8k Diodes None Note: Capacitors none Other 12 Position Rotary Switch

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The rotary switch allows the user to select a desired voltage at the microcontrollers reference pin in 1V steps. Using a 6V supply and six resistors of 1.8k in series creates a voltage divider circuit in -1V/step increments to ground with a current of 6V/(6 x 1.8 k) = 0.55mA. As the contact within the switch alternates between each step, the output voltage can be used to determine whether the user wants rich fuel supply for racing or lean fuel supply for all other parts of the competition by the microcontroller. It is understood from the circuit diagram that between R1/2 is 5V, R2/3 is 4V, R3/4 is 3V, R4/5 is 2V, and R5/6 is 1V. These five steps will be mapped to very rich, rich, stoichyometric, lean, and very lean, respectively. It should be noted mechanically that turning the switch clockwise is for more rich and counterclockwise for more lean.

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Ambient Air Sensor (AAS) Sensor Circuit Specifications Input Output Circuit Diagram 5V DC (from 5V regulator circuit) 0-5V Variable DC

Components Resistors (1) 1k Diodes None Note: The potentiometers resistance will change with temperature. This will in turn change the voltage at the microcontrollers reference pin. Capacitors none Other Potentiometer

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Throttle Position Sensor (TPS) Circuit Specifications Input Output Circuit Diagram 5V DC (from 5V regulator circuit) 0-5V Variable DC

Components Resistors (1) 1k Diodes None Note: The potentiometers resistance will change with throttle position. This will in turn change the voltage at the microcontrollers reference pin. Capacitors none Other Potentiometer

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Microcontroller Specifications PIC16F877: 28/40-Pin 8-Bit CMOS FLASH Microcontroller with 10-Bit A/D Converter Program Memory: 14336(Bytes), 8192x14 (Words)
Data RAM 368 Speed MHz 20 I/O Ports 33 ADC 10-Bits 8 Serial I/O USART/ MSSP PWM 2 Brown Out Yes Comparators Timers 3+WDT ICSP Yes

The PIC16F877 is a high-performance FLASH microcontroller that provides engineers with the highest design flexibility possible. In addition to 8192x14 words of FLASH program memory, 256 data memory bytes, and 368 bytes of user RAM, PIC16F877 also features an integrated 8-channel 10-bit Analog-to-Digital converter. Peripherals include two 8-bit timers, one 16-bit timer, a Watchdog timer, Brown-Out-Reset (BOR), In-CircuitSerial Programming, RS-485 type UART for multi-drop data acquisition applications, and I2C or SPI communications capability for peripheral expansion. Precision timing interfaces are accommodated through two CCP modules and two PWM modules. The PIC16F877 also supports low voltage self-programming, allowing the user to program the device in-circuit at the users operating voltage. The in-circuit debugging feature allows the designer to emulate the PIC16F877 device without an in-circuit emulator (the MCU itself is the emulator). PIC16F877 applications range from body controllers, programmable machine controls, network maintenance, feature phones and field-upgradable pointing devices. PIC16F877 has 33 I/O pins and is available in the following package options: 40 PDIP(P), 44 PLCC(L), 44 PQFP(PQ), and 44 TQFP(PT). Pin Diagram

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Port Schema Port MCLR/VPP/THV VDD VDD VSS VSS OSC1/CLKIN OSC2/CLKOUT RA0/AN0 RC0/T1OSO/T1CKI RC2/CCP1 RE0/RD/AN5 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+ RD0/PSP0 RD5/PSP5 RD6/PSP6 RD7/PSP7 RD1/PSP1 RD2/PSP2 RD3/PSP3 RD4/PSP4 I/O I I I I I I I I I I I I I I O O O O O O O O Name 5V Regulator Circuit 5V Regulator Circuit 5V Regulator Circuit GND GND Resonator (RES) Circuit Resonator (RES) Circuit Manifold Air Pressure (MAP) Circuit Variable Reluctance Sensor (VRS) Circuit Variable Reluctance Sensor (VRS) Circuit Cylinder Compression Detector (CCD) Circuit Rich/Lean Sensor (R/LS) Circuit Ambient Air Sensor (AAS) Circuit Throttle Position Sensor (TPS) Circuit Fuel Injector Driver (FID) Circuit 1 Fuel Injector Driver (FID) Circuit 2 Fuel Injector Driver (FID) Circuit 3 Fuel Injector Driver (FID) Circuit 4 Ignition Driver (IGD) Circuit 1 Ignition Driver (IGD) Circuit 2 Ignition Driver (IGD) Circuit 3 Ignition Driver (IGD) Circuit 4 Pin 1 11 32 12 31 13 14 2 15 17 8 3 4 5 19 28 29 30 20 21 22 27

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Electronic Fuel Injection (EFI) Introduction Combining the VRS, CCD, MAP, R/L, AAS, and TPS sub-systems with a microcontroller into one complete system results in Electronic Fuel Injection (EFI). Essentially, EFI is a microcontroller that runs subroutines using data from five inputs to control fuel width delivered to injector solenoids at a finite voltage and on-time. The coding needed to control fuel width delivered involves A/D on the five inputs unless those inputs are already at TTL levels of 0-5V DC, checking ambient temperture of the engine at crank to determine if the engine is hot ( or cold,

At cranking, the microcontroller uses the capture & compare method to determine where the missing tooth region (MTR) is on the crank shaft wheel. MTR is at top dead center which is the compression cycle of the pistons. After that, it counts from them on to keep track of the MTR. on the The crank signal is checked Ambient temperture Ambient temperature checked only at cranking to determine if the engine is hot or cold. If cold, add more fuel. If hot, add less fuel. It is used as a correctional adjustment, nothing more. Checking ambient temperature is also an inaccurate reading because of the instrumentation used.

Circuit Diagram

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Figure X: PIC16F877 I/O Circuit Diagram (Pspice)

PCB Diagram

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Figure X: PIC16F877 Printed Circuit Board Diagram (PCBoards)

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