ARM based EFI: - developer info!
This is the primary fuel injection system, not as fully featured as the V3 but smaller and able to communicate with the other VEMSFrontier boards
- RS485 comm to simple boards (most atmega88)
- like WBO2s
- EGTs
- EngineBoard
- CAN to big ARM based boards, like
- another armefi
- external ignition module: basically similar to armefi, with some input and output changes
- case and clamping compatible with armefi
- preferrably same LPC2292 uc
- CAN similar to armefi
- trigger inputs similar to armefi
- the DPAK clamping IGBTs (with input pads so the board can be used as dummy ignition amplifier if all else fails)
- we need a DCDC for CDI anyway.
- CAN makes timing easier: 2..5usec timesync is possible with 115200 .. 230400 baud RS485 but requires a bit averaging; with CAN it's simpler
- IonSense might be included in above
- or TractionControlArm
DROP: VemsFrontier/ArmUfo. ArmEfi will be nice and manufacturable in every aspect, we don't need a downscaled board.
- EC36 main connector 114x109mm board size
- 2 CAN busses (LPC2292)
- 1 x RS485
- 1 x RS232 (or FBUS uart)
- CRANK and CAM trigger inputs utilizing 1 LM 1815 VR interface.
- Internal MAP sensor (type ?).
- CLT; IAT and TPS sensors.
- proposed 2 (max 4) Ignition power stages for inductive ignition (with simple SMB flyback for when used for anything else than ign: unpopulated in PNP). ISL9V2040D3S (900 pieces in stock)
- 2 high current and high voltage open collector outputs. (can be used to drive ignition coils) is this just duplication of line above?
- 8 LowZ injector outputs. (Can be used for other applications too.) Controlled flyback, still nice footprint (nice routing, Jorgen!). HUF76423D3S (900 pieces in stock).
- 1 Bosch LSU Wbo2 sensor controller
- 2 L293D-like Stepper driver IC's configured as 8 push pull outputs or as 1-2 stepper drivers. Won't be used to trig external ignition modules. Unfortunately the SMD stepper driver is hard to get, so we might stick to the throughole DIP SN754410 at this point.
- 1..2*Knock sensor input. Maybe without TPIC8101
- extra pins on headers (at least on developer series)
Size does matter
- size must be slightly adjusted (92x110 mm PCB size?) according to new case design on GenBoard/VerThree/CustomCNCCase. 92mm comes from the (94mm internal width of the 100mm wide U profile ). This shorter side must have the EC36. The 110mm comes from the 111.1mm (no walls coming of there, the frontplate is added to it) minus some small clearance.
The 100mm wide U profile will probably let us use the same box for ION/CDI.
Strategy TPIC8101 or amplified acoustic signal into ARM
TPIC8101 was the perfect choice in the past. However, with the significant processing power available, I doubt it's usefulness. We can easily filter in the ARM (with slightly more lines of code than it takes to just communicate with TPIC8101), with a few percent of processing power. Note that TPIC8101 also sets gain in the digital domain, after it's internal ADC.
Power related
- the 4 IGBT-s and the 8 injdrivers should be on opposite sides of the connector - but both on bottom (we found many advantages) More on the left side, if looking from the connector.I think that we should let INJ stay where they are, only slide them closer to connector. IGN goes to the right side if looking at the connector.
- T1 PNP dissipates more heat than the INJ_1 FET in a PWM-ing application => T1 should be on bottom.
- T1 PNP: 0.5 * 1A * 1.2V = 0.6W (will it fry at 85C ? 90K/W*0.6W=54C, so junction prolly kept below 150C)
- FET dissipation: 15625 Hz * (200 + 100)ns * 1A * 14V/2 + (1A * 1A * 0.037mOhm) = 0.032W + 0.037W = 0.069W
The 200 and 100ns are estimated switchoff and switchon times for Ugs=5V (the datasheet says 240 and 120 for Ugs=4.5V).
- Note that number of switches for inj/ign (within some limits) can be decided at assembly time (minor firmware issue). I suggest that we use 10..12 switches: from which at least 2 DPAK outputs have good clearance (ign-capable), 8 have (pad for) simple SMB flyback, 6..8 has PWM capability and max 4 has controlled flyback (PNP on bottom for cooling, FET on top).
No reason for using the PowerDip version of L293D and not the SOIC L293D. In fact we need SMD.
[link to ST electronics pdf file]
On v3.2 we use the [SN754410] which has nice current range but thrughole sux (about 70 DIPs in stock, will go out with v3 easily; shouldn't be problem to get the SDS L293D in a reasonable time.). On v3 stepper is optional, so DIP was OK choice. This will be automated, so SMD is needed.
LPC2294 (144pin, 4 CAN) or LPC2129 (64pin, 2 CAN)
Quick info:
http://www.semiconductors.philips.com/acrobat/literature/9397/75013968.pdf
User manual May 3rd 2004:
http://www.semiconductors.philips.com/acrobat/usermanuals/UM_LPC21XX_LPC22XX_2.pdf
Errata:
April 1st 2005:
http://www.semiconductors.philips.com/acrobat/erratasheets/2292_2.pdf
http://www.semiconductors.philips.com/acrobat/erratasheets/2294_2.pdf
The 2294 is more expensive, but you can only buy 1 hamburger for the difference. Footprint is also a few mm bigger. But:
- more AD
- more CAN - we won't take advantage now. Is the LPC2292 otherwise fully pin compatible with LPC2294 ?
- more IO
- easier mapping,
Mapping isn't much easier, it has the same collisions as the 64 pin chip, all the extras is only generic IO. But generic IO also helps, so featured IO need not be sacrificed.
2 CAN or more
I have a feeling that we will like 4 CANs in the future. With the new modular approach, it's good to have a board that is extendable to be the central brain. This suggests LPC2294 later, even though no need to stuff all 4 CAN transceivers onboard if it's hard.
I'm not sure there's a compelling reason for needing more lines. The only need for addition channels is to support different speed networks (eg 10Kbsp, 20Kbps, and 1Mbps), or maybe for an extreme level of redundancy (2x 1Mbps). If the cost diffrence (part + routing) is low then there's no obvious downside, but the benefits aren't that great either.
2292 and 2294 will be identical in our application, it seems like the two addtional CAN busses collides with more useful special functions.
when to use MCP3208 channel and when to use internal AD
Even though MCP3208 is relatively cheap, we like the internal ADC more: because reading data from MCP3208 still requires 3 (!!!) interrupts for a sample since the SPI ain't have a queue.
So MCP3208 is ideal for temperature and alike, while knock should go into CPU (after AMPlified). This also suggests LPC2294 that has more nice ADC channels.
Reading through LPC user manual again, I was horrified to find that there is an interrupt for each internal ADC sample (or every received SPI byte). Still better than 3 interrupts for an MCP3208 sample, but sucks a bit.
- the CAN, UART (16 byte FIFO) and timers are properly designed in the LPC..
- the SPI and especially the internal ADC lack a few bytes buffer to be even more useful
- I have checked the documentation and the ADC lack a FIFO
- looks like the ADC can accumulate up to 256 readings which is useful for lowpass filtering, but not for knock
- The SPI has the absolute minimum 1 byte receive buffer (same as the AVR) so it does not immediately overwrite previous byte with new value (and no write buffer)''
TODO: check the time of a minimalistic interrupt handler, that just passes up received data to userspace'''. I'm sure it is below 2 usec (maybe 1), we'll need it to sample 30ksps of sound (and the max interrupt processing should be lower than 33 usec, including a dispatcher action and an event insert).
Trigger
Software configurable VR/HALL (to let the end-user choose between VR and HALL without changing anything on the board).
VR CRANK go through the main connector too, it share pin with the HALL CRANK sensor but they use different internal signal conditioning and is connected to different CAP pins on the MCU to allow the choice to be made in software.
It's a waste of pins to have separate VR and HALL-level inputs. (although it is possible to use HALL-input as a general digital input pin).
- 1 VR + 5 HALL level captured inputs possible? Do we have enough CAP channels available on processor? (this would allow a simple board with 4 LM1815 chips to shape VR inputs to HALL for traction control). No need for too much protection on the inputs.
For example CAP 0.0 is available on several pins! We can probably find a CAP channel where we can connect HALL and VR CRANK to different pins but same channel.
About trigger pullup options:
- direct pull-control from 0/5V remove the transistors and control the pull (up/down) resistor from a 0/5V output pin (there are free pins because of HALL shaping NANDso) We apply a BAV99 to protect the 5V logic output in a special way: anode to GND, cathode to pullup resistor, midpoint to NAND output. This protects the NAND output and also eliminates the pullup resistor completely when NAND output is 0V. This looks like the best solution we can find
Amplifiers
- we'll use quad OPA-s with low temperature-offset dependence.See VemsFrontier/OpaSelection
- measure board temperature
- have 1 highZ instrumentational amplifiers (3 OPA each ouch)
- have 2..3 simple differential amplifiers (1 OPA, input is lowZ, but perfect for EGT, knock or even MPX700A)
- measuring GND current would be interesting. total-sum, or several individual channels. Only if space is left...
- 1 external GNDx referenced PWM output (just 1 OPA) would be desirable, I think (driving gauge, or Autronic wbo2 input).
Powerful logic chips driving the gates see VemsFrontier/ArmEfi/FetDrive
Locking:
Locked: armefi_r039_kh.zip
some clean up
TODO:
- Fit MAX232
- Make board wider to make room for connectors and fitting on front panel.
- Consider header for 'advanced communications board' CAN would move here and stuff like bluetooth, USB and Ethernet could also be implemented on this board in the future.
- Add NPN output for fuel pump relay
- Add NPN output for activating relay with the board in powersave mode. (to bring it to full power mode)
- Split powersupplies to support several weeks in powersave mode. I have local sketches for this that I haven't had the time to transfer to sch -Jörgen
- Fit a heartbeat LED.
- Wire up the stepper drivers.
- Make powersupplies. Using MC33269DT-5.0 for 5 and 6v(diode) and MC33269DT (MC33269DT or MC33269DT-adj)adjustable regulator for 1.8 and 3.3v (even if we plan to use the fixed versions.)
- U14 supply from GND referenced 5V (either separate 78L05 or shared). The GND5 referenced 5..6V supply will fry it. -As planned. !!!!!!!
- R64 boardtemp NTC available in 0603 ? -Yes, Elfa has them stocked.
- CH7 (MAT) to ARM or mcp3208
- Assign subcircuits to powersupplies based on sensitivity and power demand.
- Set ground strategy. It seems that FETs, IGBTs and stepper drivers are on GND5 while everything else on GND. anything special ? Yes, we share one GND wire between sensors, logic, trigger and so on. That force us to set tighter routing rules for GND. But I'm on top of it, noone else seem interested in good GND.
- MAP the MAT0.* pins to the ignition IGBT's and the MAT1.* pins to one of the stepper drivers. It can be the other way around too, let routing decide.
- Map drivers and sensors to connector.
- add headers for unused pins
- Add 1 external GND referenced PWM out (high frequency).
- Have at least 1 (2 if possible) diff-input channel. Low-impedance is OK (=>no need for the 3 OPA instrumentational circuit, just the 1 OPA circuit as on v3.x (small footprint). This is very important for injector-diagnostics and we cannot implement auto-dwell without it. Unfortunately packing on EC36 is impossible, so this will be available on the "diag connector" - only on extra version (higher priced) units.
Done:
- Add scope input
- Fix that LM1815 clamps the hall to 3v (move LM1815 feed to before the first protection resistor and make the LM1815 protection resistor larger).
- Check SMD stepper driver for problems and if it passes make footprint and replace powerdip version. - Done, SMD version will be very nice.
- Fit gate resistors to IGBT's.
- Design safety feature that shuts off all outputs if PowerGND is more then 0.7 volt higher then GND. Done, I only have to move from paper to sch. -Jörgen Are you planning on some peak-rectifier ? I hope this is not an OPA circuit, but a simple DR or just a 2-resistor voltage divider towards 5V should be perfect (best on an interrupt-capable input). I can't come up with a good way to do it without an OPA, with hysterisis and treshold resistors we are at 4 resistors and one OPA. We don't need anything special, the noninverting output stage will automagically switch off the FET (without oscillation!) when PGND rises. -wrong, it may turn on again when the PGND get closer to GND as current decrease.
- Add 603 or 805 NTC as board temp sensor.
- Improve Hall input by using 74HCT132 chip in series. Let VR and Hall share input pin but use different signal conditioning and CAP pins. (Software configurabel VR to HALL at almost no cost.) 90%
- Fit gate resistors to FET's.
- Add 74HCT132 driver chip for the IGBT's.
- Add voltage sense.
- Add LM1815 VR interface: The v3 design is perfect.
- Fit new surface mount crystals for knock and MCU (available in latest revision of jurg.lbr).
- Try to route and map the injector and flyback wires. They can swap places. mapped, routed, but needs cleaning
- Really consider removing the IGBT's and building an external IGN module instead, this will let us use a MUCH smaller connector. Most people already have coil drivers or smart coils. -Done, we keep the ignition drivers.
- Change 74HCT08 AND chips on ijectors to 74HCT132 Schmitt NAND chips.
- dip switches (various HW configurations, for example Hall pullups) dropped, they would ruin our robust design.
- Decide what do remove from connector, we need 39 pins and only have 36. See below. -Done
Layout Notes
- Set Grid to 5 MIL
- MIN: 10mil width, 12 drill via with 24mil diameter
- Middle 4 pins on the DIP packages are for heat sink, strong ground plane
- pin 3,6,11,14 of the DIP's go to the connector.
- the logic-stepper connections. 1A, 2A,3A, 4A, 1-2EN and 3-4EN on both stepper chips can be connected to any of the remaining outputs of IC3 and IC4. Pin mapped to optimize routing.
- Stepper Driver connector wires ~ 24mil
ECIII 36 pin mapping:\nÿ1ÿ