Automotive Control Solutions The AF Optimizer - An ENSC440 project - Automotive Control Solutions Russell Potter – CTO, President Alex Gutica - CFO Brian Nelson - CTO

2 Contents 1. The ACS Team 2. The AF Optimizer  The 440 project  In-car Demo  Now  The future 3. Conclusion 4. Questions?

3 Automotive Control Solutions A cutting-edge development team A cutting-edge development team specialize in control of automotive performance through electronic air/fuel optimization specialize in control of automotive performance through electronic air/fuel optimization Appeal to owners of any car, particularly older vehicles with simple electronic control Appeal to owners of any car, particularly older vehicles with simple electronic control

4 Who Are We? User Interface Firmware Lead User Interface Firmware Lead Russell Potter Russell Potter DSP Firmware Lead DSP Firmware Lead Alex Gutica Alex Gutica Hardware Lead Hardware Lead Brian Nelson Brian Nelson

5 Internal Combustion Engine Requires a correct mixture of fuel and air in order to function Requires a correct mixture of fuel and air in order to function Fuel is mixed with the air, compressed, and ignited. Fuel is mixed with the air, compressed, and ignited. When ignited, the air/fuel mixture drives pistons down, which turns a crankshaft. When ignited, the air/fuel mixture drives pistons down, which turns a crankshaft.

6 Fuel Delivery The most efficient burn mixture has an 14.7:1 air-fuel ratio. The most efficient burn mixture has an 14.7:1 air-fuel ratio. The lean condition The lean condition The air-fuel ratio is too high The air-fuel ratio is too high Results in detonation, power loss, increased emissions Results in detonation, power loss, increased emissions The rich condition The rich condition The air-fuel ratio is too low The air-fuel ratio is too low Results in reduced economy, increased emissions, power loss Results in reduced economy, increased emissions, power loss

7 Fuel Injection System Proper fuel delivery is electronically controlled through a fuel injection and ignition timing system Proper fuel delivery is electronically controlled through a fuel injection and ignition timing system

8 Fuel Delivery Based on a 2- variable present map in the ECU Based on a 2- variable present map in the ECU Load/Airflow meter Load/Airflow meter RPM RPM

9 The Problem Fuel maps and fuel delivery are designed for compromise Fuel maps and fuel delivery are designed for compromise By modifying fuel delivery and consequently air- fuel ratios, improvements can be made By modifying fuel delivery and consequently air- fuel ratios, improvements can be made Performance Performance Economy Economy Improved Emissions Improved Emissions

10 Why Modify an Already “Tuned” System? Are the original engineers incompetent? Are the original engineers incompetent? No but, the original characteristics of the motor can be changed No but, the original characteristics of the motor can be changed Performance enhancements Performance enhancements Changing the amount of air\fuel flowing into the motor Changing the amount of air\fuel flowing into the motor General engine wear General engine wear Perhaps a different “compromise” is desired Perhaps a different “compromise” is desired

11 Current Solutions for Modifying Air- Fuel Ratios Modifying the computer: new fuel maps Modifying the computer: new fuel maps Model-specific Model-specific Costly Costly Lack of user-specific ability to tune Lack of user-specific ability to tune Standalone systems Standalone systems Complete computer replacement is very intrusive Complete computer replacement is very intrusive Requires extensive, expensive tuning Requires extensive, expensive tuning Mechanical solutions Mechanical solutions Rudimentary Rudimentary APEXi SAFC APEXi SAFC Our direct competition Our direct competition

12 The AF Optimizer Its functionality and potential market Its functionality and potential market Its competitive edge Its competitive edge Features Features System Design and Implementation System Design and Implementation Hardware and firmware Hardware and firmware

13 The AF Optimizer What does it do? What does it do? Recalibrates air flow sensor data, while monitoring car Recalibrates air flow sensor data, while monitoring car Allows for flexible tuning of air fuel ratios Allows for flexible tuning of air fuel ratios Moves to different location on original fuel map Moves to different location on original fuel map Monitors automobile sensors with real-time visual display to users Monitors automobile sensors with real-time visual display to users Why would one buy it? To inexpensively and safely optimize delivery of fuel to their engine

14 Target Market Customer needs to tune their fuel system Customer needs to tune their fuel system Desires better performance Desires better performance Wants a simple, noninvasive install Wants a simple, noninvasive install 29 Billion Dollar aftermarket part industry 29 Billion Dollar aftermarket part industry Our target demographic is young people Our target demographic is young people With older cars With older cars Who demand an inexpensive, feature packed fuel control system Who demand an inexpensive, feature packed fuel control system

15 Compatibility Compatible with wide range of manufacturers Compatible with wide range of manufacturers Required: Required: Fuel injection Fuel injection MAP or VAF sensor MAP or VAF sensor 0-5V Scale 0-5V Scale Reality: Older, simple computer is better Reality: Older, simple computer is better

16 AF Optimizer Advantages First and foremost, price First and foremost, price Versatile for use on many different vehicles Versatile for use on many different vehicles Easy to install and remove Easy to install and remove Un-intrusive to the vehicle Un-intrusive to the vehicle Real-time monitoring Real-time monitoring Works on older cars Works on older cars

17 Feature Overview Airflow tuning features Airflow tuning features Shift Light Features Shift Light Features Monitoring Features Monitoring Features

18 Tuning Features Many Tuning points provides more tunability Many Tuning points provides more tunability based on RPM and Throttle % based on RPM and Throttle % RPM Tuning RPM Tuning RPM RPM increments RPM RPM increments 75% to 125% - 1% increments 75% to 125% - 1% increments Linearly Interpolates between tuning points Linearly Interpolates between tuning points >102% 110% 109% 107% 98% 100% 97% 98%

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20 Tuning Features Throttle Percentage Tuning Throttle Percentage Tuning 2 Calibration Curves: High / Low Throttle 2 Calibration Curves: High / Low Throttle User defined - based on throttle % thresholds User defined - based on throttle % thresholds Throttle Thresholds Throttle Thresholds Low: e.g. <30% throttle Low: e.g. <30% throttle High: e.g. >90% throttle High: e.g. >90% throttle Linearly interpolates between the thresholds Linearly interpolates between the thresholds

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22 Tuning Features Overall: 2-Dimensional interpolation Overall: 2-Dimensional interpolation RPM and Throttle % are variables RPM and Throttle % are variables

23 Shift Light Features RPM in 100 RPM increments RPM in 100 RPM increments 5 Sequentially lit LEDs 5 Sequentially lit LEDs LEDs light up every 100 RPM as you approach your desired shift point LEDs light up every 100 RPM as you approach your desired shift point Increasing brightness Increasing brightness Example where shift light set to 5000 RPM Example where shift light set to 5000 RPM

24 Monitoring Features Real-time monitoring of engine’s sensors Real-time monitoring of engine’s sensors RPM RPM Throttle % Throttle % Battery Voltage Battery Voltage O 2 Sensor Voltage O 2 Sensor Voltage Airflow and calibration monitoring Airflow and calibration monitoring Calibration % Calibration % Pre and Post Airflow Voltages Pre and Post Airflow Voltages RPM: 3250rpm Throttle: 80% Battery: 14V O2 Sensor: 220mV Airflow: 106% Pre: 2050mV Post: 2184mV

25 System Overview AF Optimizer RPM Sensor Throttle Sensor Airflow Sensor ECU Component and System Layout

26 AF Optimizer: Hardware Part Sourcing Part Sourcing PIC 16F Microcontroller PIC 16F Microcontroller Maxim 10-bit DAC Maxim 10-bit DAC Noritake 4-line x 20 character VFD Noritake 4-line x 20 character VFD 5Volt Regulator 5Volt Regulator Input Circuitry Input Circuitry

27 Hardware Challenges PIC Microcontroller PIC Microcontroller Need to service the display, inputs and DAC fast Need to service the display, inputs and DAC fast Fast speed for calculations Fast speed for calculations DAC Accuracy DAC Accuracy Power Management Power Management I/O conditioning I/O conditioning Noisy car signals, voltage scaling Noisy car signals, voltage scaling Creating a stable, fast analog output with DAC Creating a stable, fast analog output with DAC

28 AF Optimizer: Firmware Performed two functions Performed two functions Sample inputs, calculate, output Sample inputs, calculate, output Handle interaction with user Handle interaction with user Buttons Buttons Display Display Written in C Written in C High level functionality High level functionality Easy writing, debugging Easy writing, debugging Memory & Processor Usage Memory & Processor Usage

29 Firmware Challenges Debugging and Simulation Debugging and Simulation Simulator has limited functionality Simulator has limited functionality PIC was new to us PIC was new to us Timing Timing We had strict timing demands We had strict timing demands Needed all three hardware timers Needed all three hardware timers Required very careful time management Required very careful time management

30 Final Product Performance 1 Successful integration into the vehicle was dependent upon system response speed Successful integration into the vehicle was dependent upon system response speed Response to a 16Hz sine as airflow input (unrealistic, but illustrates system performance) Response to a 16Hz sine as airflow input (unrealistic, but illustrates system performance)

31 Final Product Performance 2 A more realistic response to a square wave A more realistic response to a square wave 1.5 ms system delay 1.5 ms system delay Small capacitor used to eliminate discontinuities Small capacitor used to eliminate discontinuities

32 Integration Challenges Very smooth integrating into the car Very smooth integrating into the car Research of sensor signals Research of sensor signals In-car signal testing with oscilloscope In-car signal testing with oscilloscope Great lab setup for proper simulation Great lab setup for proper simulation Start up and Connection issues Start up and Connection issues Starter draws current and dropped the battery voltage Starter draws current and dropped the battery voltage FIX: Cap and diode FIX: Cap and diode Bad connections with breadboard and car wiring Bad connections with breadboard and car wiring FIX: Soldered car wiring harness & PCB FIX: Soldered car wiring harness & PCB Car has a bad O 2 Sensor Car has a bad O 2 Sensor

33 Demo Time Things to demonstrate: Things to demonstrate: Monitoring Monitoring How to setup throttle values How to setup throttle values Shift light Shift light How to set airflow calibrations How to set airflow calibrations Car running and driving Car running and driving Out to B-LOT everyone Out to B-LOT everyone

34 Dyno 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 ratios We are able to change the air fuel ratios Here are the results Here are the results

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36 Baseline Run

37 Rich Run Tried 120% but threw Check Engine Light Tried 120% but threw Check Engine Light Tuned to 110% from RPM (redline) Tuned to 110% from RPM (redline) Results: Results:

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39 Rich Run

40 Lean Run Running too lean lost power in low RPMs Running too lean lost power in low RPMs Original ECU runs too rich at high RPMs Original ECU runs too rich at high RPMs Use AF Optimizer to lean high RPMs Use AF Optimizer to lean high RPMs Results: Results:

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43 Engineering Considerations Positive system feedback due to vehicle velocity Positive system feedback due to vehicle velocity Does not affect airflow into engine Does not affect airflow into engine Dynamometer is appropriate for vehicle tuning Dynamometer is appropriate for vehicle tuning System memory considerations (derivatives) System memory considerations (derivatives) Precautions were taken to prevent derivative reversal Precautions were taken to prevent derivative reversal Airflow signal adjustability range limited to 75% - 125% Airflow signal adjustability range limited to 75% - 125% High and low throttle curves at least 20% of entire throttle range apart High and low throttle curves at least 20% of entire throttle range apart Testing indicates airflow signal changes much faster than throttle Testing indicates airflow signal changes much faster than throttle

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45 Budget Proposed Budget:$665 Proposed Budget:$665 Actual Spending:$200 Actual Spending:$200 Difference:$-465 Difference:$-465 Summary Summary We UNDERSPENT! Due to building only 1 prototype, cheap dyno time

46 AF 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

47 AF Optimizer: Now Have a fully functional prototype! Have a fully functional prototype! We’ve priced many parts in quantities We’ve priced many parts in quantities The display dominates The display dominates Accounts for as much cost as all others combined Accounts for as much cost as all others combined Produced prototype PCB and casing Produced prototype PCB and casing Plans underway for production model Plans underway for production model Designed to use 1 PIC for cost Designed to use 1 PIC for cost

48 AF Optimizer: The Future Small distribution at first Small distribution at first Use online car clubs for marketing Use online car clubs for marketing Will hopefully get feedback Will hopefully get feedback If all goes well, incorporate! If all goes well, incorporate! Outsource manufacture to overseas Outsource manufacture to overseas Build relationships with distributors Build relationships with distributors Maybe make a few $$ Maybe make a few $$

49 Future Design Considerations Split it up into modules Split it up into modules Display and buttons Display and buttons Main PC Board and wiring to car’s wiring Main PC Board and wiring to car’s wiring Shift light (remotely mounted) Shift light (remotely mounted) Optimize PCB designs Optimize PCB designs

50 ACS Team Summary This was a great learning experience This was a great learning experience Conclusions Conclusions Acknowledgements Acknowledgements

51 Lessons Learned Time and hard work invested early pays off Time and hard work invested early pays off Research allows for easier problem solving Research allows for easier problem solving Documentation is important for complicated projects Documentation is important for complicated projects

52 Conclusions We chose a great project We chose a great project Because we love cars Because we love cars It was complex, but workable It was complex, but workable We honed our skills learned in 4 years We honed our skills learned in 4 years This product can make money This product can make money

53 Acknowledgements Scott, Lucky, Fred Scott, Lucky, Fred Dave Atchison, for experience with PIC and Dyno time Dave Atchison, for experience with PIC and Dyno time ESSEF funding ESSEF funding

54 Questions?