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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Baseline RunBaseline Run

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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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Rich RunRich Run

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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

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Questions?Questions?