Hello from germany

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rubmack
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Hello from germany

Post by rubmack »

Hello everybody,
I just ordered a micro rusefi and I am pretty stoked. I love the idea to have an open source engine control unit. But I dont integrate the rusefi into my private car or project. I work at a chair of combustion engines at a German university. We work with rapid control ecus, but they dont offer the flexibility, that this project do. Therefore two students do their homework (half the effort of a bachelor thesis) on this ecu. The plan is to integrate the micro rusefi into one of our engine test benches. The engine is a z10xep opel. The engine is nothing special, but the test bench is equipped with a lot of measurement equipment.

I hope we can contribute to this project. Is here someone from Germany/North Rhine Westphalia.


Best regard
rubmack
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AndreyB
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Re: Hello from germany

Post by AndreyB »

welcome! interest from academia is the best interest we can wish for!

I hope you found the wiki, there is also slack if you guys would want to chat. how to get on slack is also on the wiki
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mck1117
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Re: Hello from germany

Post by mck1117 »

Welcome! That's an awesome application!

Looked up the z10xep, it's so darn cute! It's tiny!
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kb1gtt
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Re: Hello from germany

Post by kb1gtt »

Great to hear about it. I think it would be the first 3 cyl. Looks like an interesting motor. Should make a good platform for experimentation.
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kb1gtt
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Re: Hello from germany

Post by kb1gtt »

Oh, also perhaps worth a mention. We have made many adapter PCB's which are handy for interfacing with an OEM harness. Basically get an extra ECU with a pig tail of wire from the salvage yard. Then remove the connector from the ECU. Then install that connector into a breakout board. Then wire the breakout board to the MRE, and you can now operate injectors, and similar circuits with with out having to chop up the OEM harness. This can be a handy approach. If you know details about your connector, I could help get a breakout board drafted.
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Re: Hello from germany

Post by AndreyB »

https://github.com/rusefi/rusefi/tree/master/hardware - please scroll a couple of screens and there will be a nice human-readable list
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Re: Hello from germany

Post by Simon@FutureProof »

*wave*

I work within a university/research institute and we have exactly the same issues. The modern ECUs are so complex we can spend as much time working around the ECU as performing the test program.

We have had some discussions about using rusEFI for some of the future test benches or cheaper student friendly hardware, so far nothing has moved forward but I do think there is some very interesting education applications for RE.
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rubmack
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Re: Hello from germany

Post by rubmack »

Thank you for the nice welcome.

The engine is tiny. It has nothing special or interesting on it, it is just 3-cylinder port injection and an etb. But it is the perfect starting point to get in touch with rusefi.

@kb1gtt The adapter is exactly what we want to do. With this we have the opportunity, to change ecus very fast. Because at the moment, the engine is running perfectly with the configurable oem ecu.

The plans for the two thesis (2x 180h of work) are the following:
- get the current development status and summarize the future goals and the current state (e.g. DI, knock, ...)
- get an overview over all the different rusefi hardware
- describe the workflow to compile and flash the rusefi firmware
- describe the unit test
- What is the rusefi console for
- How to set up the simulator and what is it useful for
- Add a little bit of functionality to the rusefi firmware (as an example and starting point)
- Build a breakout board for the micro rusefi
- Document all the sensors and actors on the engine
- Build the engine harness (in ecad and in real)
- Integration of the ecu into the testbench
- Test the unit at a engine simulator (just a stm32 that imitates the crank and cam signal)
- Analyze and describe the connection between TunerStudio and rusefi
- Start the engine

Maybe you have some ideas what to add or to delete. All the topics are then covered in the thesis, approximately 40 pages.

Best regards
mck1117
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Re: Hello from germany

Post by mck1117 »

rubmack wrote:
Fri Jun 05, 2020 6:29 am
- Test the unit at a engine simulator (just a stm32 that imitates the crank and cam signal)
This is an interesting one to me. We already have the capacity to generate these signals internally and inject them in to the trigger subsystem, so that the ECU "thinks" it's running an engine, when in fact no trigger signal actually exists. I think it's still a great task for someone to do, since it makes you really understand what the trigger pattern is doing, and why it's shaped like it is.

One thing that would be neat is to perform an analysis of rusEfi's accuracy with respect to fuel duration and ignition timing. I've done some testing myself (using an external signal), but it would be a great task for someone learning to analyze the jitter/accuracy/precision of the ECU's outputs. If the ignition timing is moving around a bunch, you can't necessarily make as much power, since some of your knock margin is eaten up by jitter (for example).

Our accuracy is pretty decent already, but you could absolutely play the game of "intentional worsening" for the sake of analyzing its effects.
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kb1gtt
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Re: Hello from germany

Post by kb1gtt »

The wiki page is currently migrating, there may be an updated version of the below link. I know this link so it is what I'll provide. It details how to create the self generated cam and crank signals to the cam and crank decoder pins.
https://rusefi.com/wiki/index.php?title=Manual:Software:User/en#rusEfi_Console
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rubluk
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Re: Hello from germany

Post by rubluk »

Also hello to everybody,
My name is Lukas and i am one of the guys occupied with the above mentioned Tasks. My Background is the one of a mechanic, so i will be more in charge of the Tasks involving the handy work. rubwen, the other guy, is more experienced in programming. I have a full blown car lift in my backyard and a Rototest hub dyno, so if anybody in the vicinity wants to check his rusefi performance is gladly invited. I am looking forward to contribute my share to this great Project
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kb1gtt
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Re: Hello from germany

Post by kb1gtt »

Pleasure to hear from you. Those are some nice tools. If you get me dimensions for your connector, I can help make a breakout board. Do you have an electrical person who is looking to do PCB stuff? If not I can do the breakout board. However if you have an electrical who is looking to learn PCB design stuff, a breakout board is a great way to learn.

Do you have specific start and stop times? When do you plan to have it running on MRE?
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rubmack
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Re: Hello from germany

Post by rubmack »

@kb1gtt I took a foto of the original ecu. It is attached. I havent measured anything yet, but maybe you know the connector already. I am doing the pcb stuff.
We are starting right now. So we are at the beginning. The Rusefi will arrive approximately at july 7th. We try to sort the pcb and harness stuff out, until then. The end time and the first start with the Rusefi, is not terminated yet.

@mck1117 The accuracy analysis sounds really interesting. I put it on the list of tasks. I thought about doing it with the pressure indicating system of the engine testbench. We can measure the in cylinder pressure on a crank angle basis. We can also add two current clamps. With one clamp we can measure the current to the injector and with the other, we can measure the current to the ignition coil. With this setup and a constant ignition angle and injection time and angle, we can evaluate, how accurate the Rusefi is doing its job. Did I understand it correct? What did you mean with intentional worsening?

Did someone already build an universal breakout board? I want to have something, to put between the original harness and the Micro Rusefi. Then there should be bridges that can be opened, to separate electrical paths. And there should be pins, to measure, while the Ecu and the Engine are connected properly. This is just for the purpose of troubleshooting.

Best regards
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Foto original Ecu
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kb1gtt
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Re: Hello from germany

Post by kb1gtt »

I do not recognize the connector. Should I recognize it?

Perhaps you mean this break out board.
https://rusefi.com/forum/viewtopic.php?f=4&t=454
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AndreyB
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Re: Hello from germany

Post by AndreyB »

I do not recognize this 64 pin connector. http://te.com/ has amazing chat support and they did not recognize it either.
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mck1117
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Re: Hello from germany

Post by mck1117 »

Any identifying marks on the connectors? Most have a part number or at least manufacturer logo hidden on them somewhere.
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Re: Hello from germany

Post by AndreyB »

Mating harness connector 1-284272-5

284331-1 64+64 header restricted
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rubmack
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Re: Hello from germany

Post by rubmack »

Wow this is amazing. Thank you very much. There is a datasheet online, that can help building the adapter.

@kb1gtt This is not exactly what I meant. Attached you will find a breakout adapter, we built for an ECU we use regularly. When we are solving problems, we can put this between the engine and the ecu. Every Pin is available for measuring (green) and we can separate every electrical connection (orange). It is super handy and saves a lot of time while seeking for errors.
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Simon@FutureProof
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Re: Hello from germany

Post by Simon@FutureProof »

One thing you may be able to do is get a donor ECU and remove the plugs.

A 1l vauxhall ECU is worth nothing in the UK, you can pick them up for £20 on ebay.


Forget using an ECU as a donor, this is a ME7.x based ECU so it's a funny non-standard internal setup without a PCB. I believe one of our members has searched extensively for the connector as it is the same units used on the Alfa romeo V6, he has not been able to find one but I believe there was a Marellii made ECU version that did use a PCB.

https://cartechnology.co.uk/showthread.php?tid=20082

Your only easy option may be to cut the existing look and put a set of standard wire to wire connectors in that allow you to change between the OEM plug and the rusEFI plugs.
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kb1gtt
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Re: Hello from germany

Post by kb1gtt »

rubmack wrote:
Tue Jun 16, 2020 6:20 am
@kb1gtt This is not exactly what I meant. Attached you will find a breakout adapter,
For us we generally only hook up to an ECU to migrate it. The board we have uses pigtails to connect to the ECU and fuses as your switches. Our board is much lower cost and no were near as fancy and doesn't use those nice phoenix connectors. That box is fancy and nice. Also this migration board we have is very rarely used. I'm not quite sure why. I think it's because every setup has a different setup. combined with a bunch of test points on our PCB, makes it less important to sniff the harness signals.
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rubluk
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Re: Hello from germany

Post by rubluk »

I pried open the donor ECU and flooded it with silicone remover to get rid of the goo. The gold pins on the connectors are taking solder. Will be kind of fiddly to get the Pigtail soldered to the pins, but we will try
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AndreyB
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Re: Hello from germany

Post by AndreyB »

Wow that looks unusual to me!
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