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.