Intelligent Vehicle Management Using

Microcontrollers
Satish B. Jangame
Sr. Lecturer, E&TC
K. B. P. Polytechnic
Kopargaon
Automotive Electronics Growth


Since 2000 we saw steady growth in
automotive electronic systems.

Driving this growth is consumer demand for
enhanced safety features, entertainment
systems, added convenience functions and
government norms on emissions controls.
Automotive Electronics Growth
Another factor supporting the increase of
electronic systems in the automobiles is the
networking or communication of new and
existing systems.

Microcontroller Implementation Growth in
Automobiles
ECUs of a car

The number of microcontrollers inside a car :
break control ABS ( 1 + 4)
keyless entry system(1)
active wheel drive control (4)
engine control (2)
airbag sensor(6++)
seat occupation sensors(4)
automatic gearbox(1)
electronic park brake(1)
diagnostic system(1)
driver display unit(1)
air conditioning system(1)
adaptive cruise control(1)
radio / CD-player(2)
collision warning system(2)
rain/ice/snow sensor systems (1 each)
dynamic drive control(4)
emission control system (4)
driver information system(1)
GPS navigation system(3)

MICROCONTROLLER EVOLUTION


Year MCS Product Features

1976 MCS-48 8 Bit CPU , ON-BUILT ROM 1/2/4 k
8048,49,50,21,22 64/128/256 byte RAM , Parallel IO ,
Timer / Counter

1980 MCS-51 8 Bit CPU , ON-BUILT ROM 4/8 k
8051,8052 128/256 byte RAM , Parallel IO ,
Serial IO , Timer / Counter

1983 MCS-96 16 Bit CPU , ON-BUILT ROM 8 k
8096,97 ROM LESS 232 byte RAM , Parallel IO, Serial IO
8394/95with ROM Timer / Counter, 10 Bit A/D , HSIO,
87XX with EP-ROM PWM O/P , Watchdog Timer



clock
Mem con. ROM(opt) HSIO Serial port
RAM Timer PWM ADC (opt)
16-Bit
CPU
Interupts A/D Control HIS HSO IN OUT
8096 FAMILY BLOCK DIAGRAM
clock
Memcon. ROM(opt) HSIO Serial Port
RAM Timer PWM ADC (opt)
16-Bit
CPU
Interrupts A/D
BUS
Control HSI HSO IN OUT
8096 FAMILY BLOCK DIAGRAM
HSI


The Intel 8096 device is a 16-bit microcontroller which is designed for
high speed control functions.
Component Features

232 Byte Register File

Register-to-Register Architecture
Five 8-Bit I/O Ports
20 Interrupt Sources
Pulse-Width Modulated Output
High Speed I/O Subsystem
Dedicated Baud Rate Generator
16-Bit Watchdog Timer
Four 16-Bit Software Timers
Two 16-Bit Counter/Timers
INTEL 8096
OVERVIEW
FEATURES BENEFITS

16 Bit CPU Efficient machine with higher throughput
Dyn. Reconfig. Bus Selects 8 Bit or 16 Bit bus width
8 k Bytes ROM Large space for complex programs
232 Bytes RAM Large on-board reg. File for data storage
& fast context switching
Hardware MUL/DIV Provides good math capability ( 16X16 )
( 32/16 ) in 6.25 Microsecond
6 addressing modes Greater flexibility of programing & data
manipulation
High speed I/O ( HSIO ) Can measure & generate pulses of high
resolution @ 12 Mhz, ( 2 microsec )

FEATURES BENEFITS

10 Bit ADC Reads external analog inputs
Full duplex serial port Gives asynchronous serial link to other
processors & systems
I/O ports TTL compatible I/O , System expansion
for 8/16 bit peripherals
20 INTRRUPT sources Respond to asynchronous events

PWM O/P Provides a programmable Pulse train
with variable duty cycle

Watchdog timer For graceful recovery from a S/W upset
or H/W upset
48 pin( DIP ) & 68 pin Choose better to fit in for specific appln
PLCC/PGA Versions

Engine control unit using 8097

Better Fuel economy

Reduced exhaust emission

Optimal Fuel : Air ratio

Fuel delivery by sensing Air temp. , Coolant temp. , Oil temp.

Modern engine control unit

Accurate ADC

Precise time of ignition

Exact control of start & duration of fuel injection

Complete management like MPFI, Ignition control, Idle speed
control, EGR, Diagnostic checks

ACH 0
ACH 1
ACH 2
ACH 3
ACH 4
ACH 5
ACH 6
ACH 7

Ext int

HSI.0
HSI.1
HSO.0
HSO.1
HSO.2
HSO.3
HSO.4
HSO.5

P1.0
P2.6
P2.7

PWM
TXD
RXD
Throttle Position
Coolant temp.
Air temp
Mass air
Manifold Air
Spare1

Spare 2
Battery Volt
Crank ident.
Engine RPM
Crank Position
Fuel Inject 1
and 2
Fuel pump
Idle Motor 1 & 2
Spark plug

LCD Data and
control





EGR
Serial link
( Diagnostic )
+5 V
8097 Engine Control unit
ENGINE CONTROL UNIT
Throttle Position Sensor
(TPS)
Throttle body
Components of throttle body
Throttle Position Sensor (TPS)
A throttle position sensor (TPS) is a sensor
used to monitor the position of the throttle in an
internal combustion engine. The sensor is usually
located on the butterfly spindle so that it can
directly monitor the position of the throttle valve
butterfly.

The sensor is usually a potentiometer, and
therefore provides a variable resistance
dependent upon the position of the valve (and
hence throttle position).
TPS
The sensor signal is used by the engine control unit
(ECU) as an input to its control system.

The ignition timing and fuel injection timing (and
potentially other parameters) are altered depending
upon the position of the throttle, and also depending
on the rate of change of that position.

19
Air Flow Sensors
MAF Sensor

Mass air flow sensor is used to find out the
mass flow rate of air entering a fuel-injected
internal combustion engine.

The air mass information is necessary for the
engine control unit (ECU) to balance and deliver
the correct fuel mass to the engine.


MAF Sensors
There are different types of Mass Air Flow Sensors. The
Vane air flow meter and Karmen Vortex are two older
styles of air flow sensors.

The newer and more common is the Hot Wire MAF
sensor.

The primary components of the MAF sensor are a
thermistor , a platinum hot wire, and an electronic
control circuit .
Hot Wire MAF Sensor

The thermistor measures the temp. of incoming air. The
hot wire is maintained at a constant temp. in relation to
the thermistor by electronic control circuit.

An increase in air flow will cause the hot wire to loose
heat faster and the electronic control circuitry will
compensate by sending more current through the wire .

The electronic control circuit simultaneously measures
the current and outputs voltage signal in proportion to
current flow.
MAF Sensor


Engine Coolant Temperature
(ECT) Sensor


The engine coolant temperature sensor changes
resistance in response to the temperature of the
engine coolant.

Resistance decreases as the surrounding
temperature increases ( NTC ), providing a signal to
the power-train control module (PCM) that indicates
the temperature of the engine coolant.
ECT Sensor
This data from the sensor is then used to adjust
the fuel injection and ignition timing.

On some vehicle the sensor may be used to
switch on the electronic cooling fan.

The data may also be used to provide readings
for a coolant temperature gauge on the dash.

Hall Effect Sensor

A Hall effect sensor is a transducer that varies its
output voltage in response to a magnetic field.

Hall effect sensors are used for proximity switching,
positioning, speed detection, and current sensing
applications.
Hall Effect Sensor
Using groups of sensors, the
relative position of the magnet
can be deduced.


The magnetic piston (1) in this
pneumatic cylinder will cause the
Hall effect sensors (2 and 3)
mounted on its outer wall to
activate when it is fully retracted
or extended.

Hall Effect Sensor
Hall sensors are commonly used to time the speed of
wheels and shafts, such as for internal combustion engine
ignition timing, tachometers and anti-lock braking systems.

They are used in brushless DC electric motors to detect
the position of the permanent magnet.

Hall Sensor
In the pictured wheel with two equally spaced magnets,
the voltage from the sensor will peak twice for each
revolution.

MAP sensor

The manifold absolute pressure sensor provides
instantaneous manifold pressure information to the
engine's electronic control unit (ECU).

The data is used to calculate air density and determine
the engine's air mass flow rate, which in turn
determines the required fuel metering for optimum
combustion.

A fuel-injected engine may alternately use a MAF
(mass air flow) sensor to detect the intake airflow. A
typical configuration employs one or the other, but
seldom both.
Crank Position Sensor
A crank position sensor is an electronic device used in
an internal combustion engine to monitor the position or
rotational speed of the crankshaft.

This information is used by engine management systems
to control ignition system timing and other engine
parameters.

Before electronic crank sensors were available, the
distributor would have to be manually adjusted to a
timing mark on the engine.

Commonly a hall effect sensor is used, which is placed
adjacent to a spinning steel disk.
Oxygen sensor ( lambda sensor )
An oxygen sensor or lambda sensor measures the
proportion of oxygen (O2) in the gas or liquid being analyzed.

It determines in real time whether the air fuel ratio of a IC
engine is rich or lean.

Located in the exhaust stream & do not directly measure the air
or the fuel entering the engine. Information from oxygen sensor
is coupled with information from other sources to indirectly
determine the air-to-fuel ratio.

Closed-loop feedback-control system varies the fuel injector
output according to real-time oxygen sensor data rather than
operating with a predetermined (open-loop) fuel map.
Oxygen sensor
The sensor does not actually measure oxygen concentration,
but rather the difference between the amount of oxygen in the
exhaust gas and the amount of oxygen in air.

Rich mixture causes an oxygen demand. This demand causes
a voltage to build up, due to transportation of oxygen ions
through the sensor layer. Lean mixture causes low voltage,
since there is an oxygen excess.

By measuring the proportion of oxygen in the exhaust gas, and
by knowing the volume and temperature of the air entering the
cylinders amongst other things, an ECU can use look-up tables
to determine the amount of fuel required to burn at the ratio
(14.7 : 1 - air : fuel by mass) to ensure complete combustion.
Oxygen sensor

The sensor element is a ceramic cylinder plated inside and out
with porous platinum electrodes. The whole assembly is
protected by a metal gauze.

It operates by measuring the difference in oxygen between the
exhaust gas and the external air, and generates a voltage or
changes its resistance depending on this difference.

The sensors only work effectively when heated to
approximately 316 C (600 F), so most newer lambda probes
have heating elements encased in the ceramic that bring the
ceramic tip up to temperature quickly.

Oxygen sensor
The zirconium dioxide, or zirconia, is used to form a solid-state
electrochemical fuel cell called the Nernst cell. Its two electrodes provide
an output voltage corresponding to the quantity of oxygen in the exhaust
relative to that in the atmosphere.

An output voltage of 0.2 V DC represents a "lean mixture" of fuel and
oxygen, where the amount of oxygen entering the cylinder is sufficient to
fully oxidize the carbon monoxide (CO) produced in burning the air and
fuel into carbon dioxide (CO2).

An output voltage of 0.8 V DC represents a "rich mixture", one which is
high in unburned fuel and low in remaining oxygen.

The ideal set-point is approximately 0.45 V DC. This is where the
quantities of air and fuel are at the optimum ratio such that the exhaust
output contains minimal carbon monoxide.
Oxygen sensor
Oxygen sensor

Idle Air Control Valve ( IAC )
An idle air control actuator or idle air control valve
is a device commonly used in fuel-injected vehicles to control
the engine's idling RPM.

The IAC actuator is basically an electrically controlled solenoid
valve, which gets its input from the vehicle's ECU. The valve is
fitted such that it bypasses the actual throttle valve.

Thus, the ECU can control the amount of air that bypasses the
throttle when the throttle is fully closed, thereby controlling the
engine's idle RPM.
Knock Sensor
The knock sensor detects engine knock and sends a
voltage signal to ECU. The ECU uses knock signal to
control timing.

Engine knock occurs within a specific frequency range.
The knock sensor is tuned to detect that frequency.

Inside the knock sensor is piezoelectric element.
Piezoelectric elements generate a voltage when pressure
or vibration is applied to them.

The piezoelectric element in the knock sensor is tuned to
engine knock frequency.
THANK you !
Contact :
Satish B. Jangame
MOB: 9921962009
satishjangame@yahoo.co.in