[info] Frankenso - ECU shield compatible with OEM case / official

[kb1gtt]

Various tests were preformed on Frankenso's R0.3 power supply, including load dumping. The 5V is very solid, while there is some ripple from the 12V. Yellow trace below is 12V ripple, and blue is 5V signal. The normal load is .120 amps, which is what's seen in the middle section of the below. While the 5V load dump was a resistor that passed an additional 1.25A. I had the blue scope probe connected to the load resistor. Ripple at the normal .120 amps load is about 75mVp-p and ripple at 1.25A load is 225mVp-p. The 5V ripple is below what I can measure with the DSO Quad, which means the ripple is below 5mV on the 5V signal.



The LM2596 datasheet suggest C1001 to be 680uF, we were able to fit 470uF. I changed this up to 980uF and saw minimal differences in the ripple. So the 470uF is fine. To remove this ripple from the 12V I'll likely add a choke. See below spectrum analyzer picture, it shows the switcher frequency of 150kHz and it's harmonics are playing a huge role in the ripple.

[kb1gtt]

Added to known issues list
68) Look into LCD dimming R99, perhaps replace with a POT. Perhaps connect to a GPIO

[AndreyB]

) place USB connectors closer to board edge or notch the board

There is an opinion that we have placed these USB connectors too far from the edge of the board and this actually causes poor mechanical connection, @ had to grind his cable a bit to work around this. I guess notching the PCB would be another option to resolve this?

[kb1gtt]

I'll have to look at this. I seem to recall the issue is caused by the vertical mount connector that's also there. I seem to recall it take up the space at the edge.

[AndreyB]

That's version 0.3 on the picture, MAX9926 chip input



I wonder if W1002 silkscreen is actually not where it should be?

Also I think we should eliminate these jumpers altogether, maybe leave a through-hole for a test point pin, but not a jumper? Since we have pads for a pull-down and a pull-up, that should be enough.

[AndreyB]

) W1002 - silksceen on the wrong place? remove these jumpers anyway?
) 1K and 0R on the MAX9926 input: need to put a comment on the schematics page explaining that none or just one of them should be installed depending on the use-case

[kb1gtt]

Do we need more / clearer explanation, or was the below perhaps not enough?

Capture.PNG

[AndreyB]

https://sourceforge.net/p/rusefi/tickets/184/

dev console/microUSB connection dies

on a real engine dev console sometimes disconnects and can not connect back - looks like an issue more with the port then with the console. this does not happen on a bench

[AndreyB]

https://sourceforge.net/p/rusefi/tickets/184/

dev console/microUSB connection dies

on a real engine dev console sometimes disconnects and can not connect back - looks like an issue more with the port then with the console. this does not happen on a bench

There are reports that multiple rpm hard limit events kill even the USB/TTL port with some certainty

[kb1gtt]

Is there a way to can get these reports from the horses mouth? I've only heard of the issue as relayed through russian. There are many engine layout items that might be effecting it as well as my guesses below. It might be as simple as a poor wiring connection, or an incorrectly selected AWG wire. Are we talking a setup with 1 injector, or 8 injectors? I have almost no data to work from, which makes it hard to help offer a solution. However below are my best guesses with a blind fold on.

I suspect part of the issue is partly affected by the laptop's floating ground. The discovery has via's, stubs and no GND plane which are know for increasing the Bit Error Rate (BER) as those are known for decreasing the eye diagram. These discovery board layout doesn't help the issue, but there also isn't much we can do about it. What we have some control over is your referenced USB GND voltage. If that is wandering around, the combination of all of these weaknesses could apparently be putting your USB in unhappy land. I believe the bench test is successful, either because the GND is more solid in that setup, or perhaps it has less current running through the GND wire which keeps the GND voltage at a lower level.

A suggestion for the short term would be to make sure you have a fat / over sized GND to the Frankenso board, this will help prevent generating a voltage on the GND wire as you run injector currents through the GND wire. As well adding a separate GND strap to the latop. This will help keep the laptop GND reference at the reference voltage as the Frankenso board.

Does the reporter have a scope? DMM? Other test equipment? I can think of several tests that would let you check the GND voltages.

Probably the best short term solution, is to avoid using the Discovery USB when you know you have a problem. It's not likely you really need to do both TS and dev console at the same time. If you can put the dev console on the FT232 chip and only run one connection at a time, you will likely find the problem doesn't exist on the Frankenso USB. You will likely get better performance out of the FT232 chip, as it does not have via's, stubs, and uses a GND plane. The eye diagram should be much better on the FT232 USB, and should have a much lower BER.

[AndreyB]

Starting to place an order for frankenso_rev00.40 ETA mid-June.

[AndreyB]

Starting to place an order for frankenso_rev00.40 ETA mid-June.

Order placed! Looks like there would be a ~$40 bump in the price. Time to test http://rusefi.com/forum/viewtopic.php?f=4&t=577 this would shave about $20 off the price.

[puff]

costly assembly service?

[AndreyB]

Starting with 0.4, a fire extinguisher is required.

[puff]

looks a bit frightening

[AndreyB]

Fully assembled boards are back in stock @ https://www.tindie.com/stores/russian/

[AndreyB]

Battery holder is too tall to fit under the cover on the back of the board, I suggest we move it to the front and place it on top of the 'discovery' region. This cheaper through-hole holder has 20mm (0.7874 inches) between terminals, I guess we can use both SMD and through-hole options if we want to.

Code: Select all

95)                  cheaper battery holder - through-hole (20mm between terminals)

[puff]

we've got a battery there? what is it used for? system clock?

[AndreyB]

we've got a battery there? what is it used for? system clock?

yes, we have battery - just to have correct dates on the log files to be able to figure out which log is what.

[AndreyB]

Ohm by the way Bluetooth works. You need to solder HC-06 module @ 6 pads and it just works right away @ 9600. No configuration, no setup needed on the Bluetooth side - you just need to set rusEfi binary protocol speed to 9600.

See also http://rusefi.com/wiki/index.php?title=Manual:HC-06

[puff]

not much use without the gauge values, right?
in this regard torque seems to be much more promising (connected to elm327 via bluetooth - pretty much the same way).

[AndreyB]

not much use without the gauge values, right?

TS works perfectly, so does rusEfi console. The other application has it's own thread

[AndreyB]

Undisclosed location.

[AndreyB]

101) connector middle mounting holes - need a 5.5mm diameter area for screw head on the back

[kb1gtt]

100) RESOLVED IN R0.5 update TPIC chip for 39k's, 3.3nF, and DNP 1M.
Also
102) RESOLVED IN R0.5 TPIC/HIP knock SPI was not working properly, R170 changed to 5k and R172 to R174 removed to correct the SPI bus.

I changed the 100k's to 39k's as they better match the components noted here http://www.ti.com/lit/df/tidr519/tidr519.pdf

Thanks spilly for the help with getting that resolved.

[edit]fixed typo[/edit]

[AndreyB]

vs

typo in the .txt?

[kb1gtt]

fixed typo.

[AndreyB]

103) button silkscreen notch is barely visible

[AndreyB]

@ has Frankenso 0.1 and he uses it on his supercharged Passat. He reports some noise on the radio, the noise frequency follows RPMs:

[video][/video]

[kb1gtt]

Very nice. Are we sure it's the radio? After all super chargers tend to have a similar noise

I would think that could be a GND, so I would make sure there is a good GND, as well I would try to mount it away from the radio physically if possible. Part of it could be alternator wine.