We finished the project and tested.

1, The throttle can control the motor speed.
2, The MAP can be changed according to throttle change
3, All testing ports work and give out waveforms

That is a good news we almost finish this project. We put all components in and covered with clear board. Made all testing ports and some fault switch. Wiring everything and even we painted the board with silver color. I tested with PICO scope to test all waveforms including:

1, Injector and current
2, Ignition primary and current
3, TPS
4, MAP (Simulated with TPS using a programmed chip)
5, Cam Position (G1)
6, Crank Position (NE+)
7, IGT (controlled from ECU)
8, IGF (Feedback to ECU)
9, ECT (adjustable with POT)
10, IAT (hot air gun from top hole of the board)
11, Idle switch
12, Idle control (RSC & RSO)

All the waveforms have interferences (noise) which come from ignition sparks and injector BEMF.

The chip used to simulate MAP has a duty cycle output so the waveform shows different with the real MAP waveform. Therefor, we made a selector (three point switch) to provide two options. One is to select real MAP sensor. We need a vacuum pump (hand pump) to create vacuum to MAP sensor. The other option is to select this chip to foul ECU when we accelerate the throttle.

The motor is controlled manually by a motor controller. This is not acceptable for this project. We are going to make the other programmed chip to control the motor speed through throttle.

The coming days will be very very busy.....

I am resuming the project this week. I use a 900x600 whiteboard to arrange all components on it. The distributor with motor is going to sit on a 40mm timber after securing the timber on the whiteboard. The throttle body with motor controller and injector rail are also secured on timer as well. We don't use the dashboard anymore because it is too big for the completed project. We need a compact product so it is easy to carry around.

Good news is this project is working! We roughly made wiring to this project by using coolant as fuel. We used a motor controller to control the DC motor driving the distributor. All the spark plugs and injectors are working well.

After talking to Prahbat, we may make a fold board with carrying handle and roller. I need to go to some shops to see if we can buy a product which can be fitted with all the components to finish this project.

Cash, the student of this semester, will come to help us.

Cliff and me will spend our school holidays （tow weeks) to 80% finish this project.

This week we went outside to buy some parts for our project.

1, All wirings are alreday sort out and ready to connect to power to test.
2, The power and ground connectors are ready
3, The fuse and switches are ready.

Next week we are going to test the project.

We restart the project this semester. We already ready all components we need for this project including ECU, all sensors, distributor, fuel pump, dashboard, diagnostic connector, high tension leads with spark plugs, fuel rail with injectors and etc. We also ready all equipments we need to measure data including Multimeter, Pico scope, Hanatech scan tool, bench scope, signal generator. We have all electrical diagrams from Prabhat. All wirings have been sort out since last two weeks. The next job we need to do is put every thing on the board and pretest it. We are going to make the finished product if every thing is ok. Thank you Prabhat and Cliff.

I almost forgot today (it is 0.46 am now) is the due date of handing Technical project contract in. I drafted a contract:

Project Name: TOYOTA 4A-FE ENGINE ELECTRONIC COMPONENTS        DEMONSTRATION BOARD 

Project brief: 

1, Put all 4A-FE engine electronic parts on a designed demonstration board. 

2, Use a small DC motor to drive distributor rotor.

3, The speed of the DC motor is simulated to the camshaft speed which can be controlled   by a speed controller.

4, The speed controller gets input from TPS to synchronize accelerator and distributor.

5, Use spark plugs or spark plug testers to show ignition sparks.

6, Use a fuel tank with fuel pump to supply pressured fuel to rail with injectors.

7, The ECU gets all inputs like real engine and control 4 injectors to spray fuel to transparent plastic tubes which are connected back to fuel tank.

8, Make a vacuum system to simulate intake pressure. Make sure MAP sensor gives out synchronized signal to ECU.

9, ECT can be simulated by a POT or can be heated up by heat gun.

10, IAT can have the same design with ECT.

11, Knock sensor signal can be simulated by a hammer.

12, O2 sensor can be simulated by a function generator.

13, Idle control is combined with throttle body and can be tested by scope.

14, Cam and crank sensors are combined with distributor and can be tested by scope.

15, Use 12V battery to drive DC motor, fuel pump and power ECU /  injectors / ignition

16, Use a real cluster to show RPM, fuel gauge, engine temperature and engine warning light.

17, Use a key set to simulate ignition switch.

18, Diagnostic connector can be used with scan tool.

19, A designed diagnostic port with testing terminals can be easy to used with scope and function generator.

20, A professional user manual will be available.

Agreed Outcomes:

1, Safety and heavy duty design.

2, Easy to be moved around and design for education.

3, Simulate to real engine. Not only spark frequency and injection formation can be seen on board, they can be changed when accelerating, decelerating and idle. 

4, Easy to test with scope in diagnostic area. 

5, A professional user manual available. All sensors and actuators waveforms included.(Not copied waveforms)

6, Fault maker design. Can be tested with scan tool and engine light flashing codes.

 

This is the third week of this semester. We bought a board to arrange all components and got some pictures. The motor speed controller has been finished by Cliff. Need a group meeting this week to discuss further.

Group meeting with Prabhat

We had a meeting with our supervisor Prabhaat today. Went to building 100 to see an engine. Will need to come again to get some real data from a real running engine. We need to get a layout plan as soon as possible so we come back my workshop to lay out all components and took some pictures. We might need to buy a wooden board to try before we make the final product.

These are what we need to finish before next meeting with our supervisor.
1, Get the layout picture and discuss what is the best design.
2, List all components.
3, Make a wiring diagram.
4, Frame design.

Notes for today:
1, Need to get real data asap.
2, Need to make a testing area in the board including a ignition testing ports.

Today I talked to Cliff (Li Feng) and Tiitii and luckly to get these two intelligent classmates to joint this project. They are very good students who I knew them last semester. Welcome! We need to have a meeting and discuss this project soon. I talked to Prabhat and book a time on next Wed so we can have the first group meeting to see what the next step is.

I also discussed three topics with Prabhat today:

1, How to control the speed motor driving distributor?
   Need to build a speed control board to synchronize throttle POT to speed motor

2, How to create a vacuum system to make sure MAP sensor working?
   Might need set up a small vacuum system including a small pump and vacuum tank.

3, How to get the oxygen sensor working?
   Might need a device to give out signals like O2 sensor does.
   Close loop? Rich? Lean?

Will prepare something before next Wed meeting.

1, The layout design of this project.

2, Get some real data from a real engine.

Yesterday, I had a meeting with Prabhat about our Tech Project--EFI demonstration board. We need to ready all necessary parts like ECU, all sensors, injectors, distributor etc. before starting this project. Need to get quotation about all these parts  This project should be made professionally rather than a working machine.We discussed what kind of materials are good for making the board, like aluminum or high density plastic. The board should have a strong base which can put heavy battery, fuel tank etc on it.

The first time I use blog because of technical project. Will see.........