1987 Volvo 780

[zed65]

Hi, my name is Alex and this is my project car.

780.jpg (2.36 MiB) Viewed 28085 times

The engine is swapped from the V6 to a 3litre inline 6 from a Volvo 960.
At the moment it runs on a custom board with discoveryF407 firmware.
The ECU reads all the "usual" stuff (clt, iat, map) and Fuelpressure , Oilpressure, VSS, EMAP, EGT, flexfuel and 2 knock sensors.
It runs full sequential with coil on plug and 6 875cc injectors.
The engine is force feed with a K29 turbo and a 60mm Chinese wastegate.
Behind the engine is a BMW Getrag GS6-45DZ gearbox and stock axel with a Torsen LSD.

780engine.jpg (2.86 MiB) Viewed 28085 times

[AndreyB]

It's gorgeous! There is also some green on the left?

[zed65]

Thank you, yeah that's my sons Volvo 242 1975 with a 16v Turbo engine.

Here is the box and pcb, it has some bodges and the MAX31855 is flapping in the wind
Maybe one day I'll 3d print some caps to cover the gaps in the enclosure.

780box.jpg (2.34 MiB) Viewed 27988 times

780pcb.jpg (3.99 MiB) Viewed 27988 times

[AndreyB]

Superseal and pretty hand-solderable? Thats a nice combo!

[zed65]

I took the Volvo for a short test run today.
Here is a cold-start-log from 15C to 40C (I haven't barely touched the tune).

cold2.zip

(2.52 MiB) Downloaded 36 times

Here are a log when driving, really need to give her some more fuel

testdrive2.zip

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Now to the features/problems I have discovered.
1. Flexfuel still don't work as intended. I've added a pull-up resistor but it's still swinging from 0 to actual value.
I need to investigate with oscilloscope to see what happens at the input.

flexfuel.png (184.23 KiB) Viewed 27205 times

2. Fueltemp via the flexfuel sensor would be nice to have implemented.
3. MEMS/Accelerometer, as of now I've connected a ADXL-335 to rawAnalogInput1 but it would be nice to have a more dedicated thing.
4. Non CAN Traction-control using AuxSpeed1 and AuxSpeed2 and cutting the ignition AND using a ETB.
5. Exhaust-MAP to measure back-pressure in turbo system. as of now I-ve connected a MAP-sensor to AuxLinear1.

Don't get me wrong, this is just features that would be nice to have.
The engine runs so smooth, can't say exactly what it is but it's a huge difference from my previous ECU (MS-2).
I think one huge improvement is the control loop of EGO that make it so nice.

CurrentTune.zip

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/Alex

[AndreyB]

"Fuel Temperature" is supposed to be there?

ithardwheneverythingispiledtogetherbutstructuremakesiteasierpleasecreateseparateticketsunlesyou see existing tickets?

[AndreyB]

Please understand and accept my question: why do you refuse https://rusefi.com/online/ but insist on manual file management for tune and logs?

[zed65]

I'll give https://rusefi.com/online/ a try.

[AndreyB]

3. MEMS/Accelerometer, as of now I've connected a ADXL-335 to rawAnalogInput1 but it would be nice to have a more dedicated thing.

I do not get it. What's the idea? Feed three analog signals from external MEMS? Let's please not do that. Let's either use a board with a supported SPI MEMS or let's use an external CAN-based MEMS?

[AndreyB]

4. Non CAN Traction-control using AuxSpeed1 and AuxSpeed2 and cutting the ignition AND using a ETB.

that sounds doable https://github.com/rusefi/rusefi/issues/5897 https://github.com/rusefi/rusefi/issues/5898

[zed65]

3. MEMS/Accelerometer, as of now I've connected a ADXL-335 to rawAnalogInput1 but it would be nice to have a more dedicated thing.

I do not get it. What's the idea? Feed three analog signals from external MEMS? Let's please not do that. Let's either use a board with a supported SPI MEMS or let's use an external CAN-based MEMS?

I thought the LIS2D was broken or is there a alternative SPI chip?. I'm mostly interested in one axis anyway so on analog input isn't that much.

[zed65]

"Fuel Temperature" is supposed to be there?

ithardwheneverythingispiledtogetherbutstructuremakesiteasierpleasecreateseparateticketsunlesyou see existing tickets?

My bad, the temp is working.

[AndreyB]

I thought the LIS2D was broken or is there a alternative SPI chip?. I'm mostly interested in one axis anyway so on analog input isn't that much.

I see https://github.com/rusefi/rusefi/issues/4870#issuecomment-1859043810

I am definitely not adding MEMS analog input into the official firmware. You might be able to use Lua to convert aux analog into mems.

[zed65]

You don't need to add analog MEMS into firmware.
But as SPI-MEMS is broken I've temporary done this hack

[AndreyB]

But as SPI-MEMS is broken I've temporary done this hack

I am still confused. LIS2DW12TR on-board Accelerometer support #4870 seems to state that SPI-MEMS is now available for the chip used by Hellen boards? Which matches what Proteus uses?

[AndreyB]

that sounds doable https://github.com/rusefi/rusefi/issues/5897 https://github.com/rusefi/rusefi/issues/5898

just pushed pretty untested wheel speed input https://github.com/rusefi/rusefi/commit/21e698f951a24af694a5bf7dab081e41768599a2

there is a good change that some hardware frequency divider would be needed on those inputs to get frequency well under 10KHz?

[zed65]

Nice!, I'll do some testing.
One problem might be that I don't think my car have the same number of pulses front/rear but I'll have to check.

[zed65]

Bench test seems to work https://rusefi.com/online/view.php?log=1338

[AndreyB]

Bench test seems to work

Appreciate testing! Happy to add a constant multiplier if your real vehicle would require it.

[zed65]

Can we/you make a change to the firmware to allow for use of the already existing VSS sensor?
That way we save a VR-input and less wires to be added in the car.

[AndreyB]

Can we/you make a change to the firmware to allow for use of the already existing VSS sensor?

https://github.com/rusefi/rusefi/commit/c250d321dc313c067961bc0a239c4e39ee26b40f

[zed65]

Can we use the "raw" VSS pulses to calculate with?
Now when VSS is 72km/h the auxSpeed neds to be at 72Hz to get slipratio 1
Or even better (but more work) to have a proper dialog for auxSpeed's with pulses per km and so on.

[zed65]

One other thing, can you revert back the changes made to the LUA problem https://github.com/rusefi/rusefi/issues/5889
The EGT worked for me before that but not now.

[AndreyB]

One other thing, can you revert back the changes made to the LUA problem https://github.com/rusefi/rusefi/issues/5889
The EGT worked for me before that but not now.

Not excited about reverting because the change was overall in the right direction. Just needs a developer to look into this once again and improve the change to make it right Which is not me at this point.

[zed65]

I understand, no problem.
One small problem I discovered is that every time I hit "Burn" the auxSpeed goes to zero and stays there.
After a reboot it's back again.

[AndreyB]

One small problem I discovered is that every time I hit "Burn" the auxSpeed goes to zero and stays there.
After a reboot it's back again.

please create a github ticket, sounds like a firmware defect

[AndreyB]

https://rusefi.com/online/view.php?log=1336 is the first known to me log of real engine rusEFI SPI EGT

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[zed65]

I've investigated some more in my flexfuel-sensor problem, can't find any.
Thing is that when the engine stalls (0 rpm) I get a nice clean signal but not when the engine runs.
https://rusefi.com/online/view.php?log=1343

I don't want to bring my oscilloscope to the car but I guess I don't have any choice

[AndreyB]

Thing is that when the engine stalls (0 rpm) I get a nice clean signal but not when the engine runs.

You know that you would have to bring a fancy tool and poke into wires

[zed65]

Yea, I know I know