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Design and ECU project

Guys,
I just got involved in a project to create an open source, open design ECU and I’m trying to see how many more people I can suck in to try and get the project to critical mass…. so I left the safety of the Ferrari forum where I normaly live and came over to the lion’s den

We are working on 2 ECUs

FreeEMS - it is a fully user programmable 6 cylinder (and then some) ecu. It will have sequential 6 fuel output, 6 additional staged sequential fuel outputs and 12 ignition outputs…..and can be built for under $200 in parts you can get anywhere. This ECU will be about ideal for more 4 and 6 cylinder applications and is probably 3-6 months way form working.

This project needs (desperately needs) anyone who can write code to help get it done.

Here is where everything stands http://freeems.sourceforge.net/

FreeEMS+ - this is the be all, end all, make a motec look second rate, God’s gift to the performance car world that I am taking the lead on and just getting it done. It will have 24 (maybe 36) fuel outputs, 12 ignition outputs and do stuff like traction control, individual cylinder tuning maps, and anything else you heart could ever desire. I’m working out the basic design specs now but trust me, if you want it the hardware will be able to do it. It will cost under $1000 (probably well under) to build.

http://www.diyefi.org/forum/viewtopic.php?f=41&t=734

I’ve got a hardware engineer but he could probably use help
I’ve got a software guy signed up to convert and upgrade the FreeEMS interface software to this ECU
I need more code guys.

If you can right code, this is your change to help SAVE THE WORLD for poor performing or over priced ECUs. If you can write code we need your help. If you know someone who can writ code, send them over. These are fantastic projects that will help anyone who has or wants to have fuel injection and doesn’t have a billion $ to spend.
Old 08-20-2009, 01:37 PM
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You guys are letting me down....3 ferrari guys have already stepped up to the plate.

We now have
A program manager (me)
A hardware designer
A user interface guy
3 programmers

We are very near critical mass but a couple more programers would be a big help....even if you will need to help to get rolling you can still help.

Here's the first cut at the design specs.

General requirements:
1) Easy setup. This should be a 1 board solution if possible, with commercially produced boards available and no extra anything required but DIY board construction should be possible.
2) Finished product appearance when installed.
3) The smallest foot print possible…should compare to commercial option (I’ll get a number for this)
4) And Oooooh it needs to be fast with way more input/ouput capability than anyone will ever actually find a need for (what should this spec actually say???....something we can put a number to)
5) Water tight case
6) Surface mount components preferred
7) CPC or connector(s)
Software requirements:
8) Compatible with FreeEMS tuner
9) Traction and launch control possible
10) 32x32 tuning maps, with user defined points
11) At least 8x8 trim maps on each fuel/ignition output…16x16 would be better
Output requirements
12) 24 fuel High impedance injector driver
13) 12 low high impedance injector drivers and
14) 12 ignition outputs capable of driving coils directly (this may want a separate board, but must be in the main case.
15) IAC Stepper motor output
16) At least 8 digital outputs
17) At least 8 PWM out puts
Input requirements
18) Standard inputs for TSP, MAP, coolant temp air temp
19) 2 Hall and 2 reluctor triggers
20) At least 4 O2 sensor inputs
21) 12 inputs for ETG would be nice
22) 4 Hall inputs for wheel speed
23) At least 8 digital inputs
24) At least 8 analog inputs

what else?
Old 08-21-2009, 03:16 PM
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Here's what I think is the final spec list. It's going to be a heck of an ECU. I'll start moving docs like this to a wiki page very soon.

This is the WHAT it will do, now it;s time for the HOW we will do it.

If you have ever been involved in a software project and have any thoughts on what works and what doesn't work, I could use your input either on this thread or here:

http://www.diyefi.org/forum/viewtopic.php?f=10&t=736


General requirements:
1) Easy setup. This should be a 1 board solution if possible, with commercially produced boards available and no extra anything required but DIY board construction should be possible.
2) Finished product appearance when installed.
3) The smallest foot print possible…should compare to commercial option , under 160mm x 120mmx60mm preferred
4) Automotive grade components
5) Water tight case
6) Surface mount components preferred
7) CPC or connector(s)
8) On board memory for logging….say enough for 1 minute.
Software requirements:
9) Compatible with FreeEMS tuner
10) Traction and launch control
11) 32x32 tuning maps, user defined points prefered
12) 8x8 trim maps on each fuel/ignition output
13) 4D Fuel and ignition tables (RPM, TPS, MAP)
14) Closed loop O2 or Lambda control
15) Idle speed control
16) Boost control
17) Nitrous Control
18) Data Logging
19) Sensor diagnostic limits
20) Hi/Low and staged injection
Output requirements
21) 12 fuel High impedance injector drivers, may also be used as auxiliary outputs
22) 12 low impedance injector drivers (should also drive high impedance injectors)
23) 12 ignition outputs capable of driving coils directly (this may want a separate board, but must be in the main case.
24) At least 8 digital outputs
25) At least 8 PWM/variable voltage out puts (tach, IAC, ect)
26) 5V (sensors)
27) 8V (sensors)
28) 12V
Input requirements
29) 2 reluctor (triggers)
30) 8 digital inputs, 0/1v (hall trigger, wheel speed, ect)
31) At least 4 O2 sensor inputs, should accept narrow or wide band
32) 12 Thermocouple inputs (EGT temp, ect)
33) 8 digital inputs 0/12V (gear selection, nitrous switch, ect)
34) 8 analog inputs (TPS, MAP, ect)
35) 4 Temp inputs (air temp, coolant temp, ect)
36) 12V DC (approx 8V-16V)
37) 2 knock detectors
Communication Requirements
38) CAN
39) RS232
Old 08-22-2009, 05:56 AM
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We are eyeing up this chip


This chip would give us a motec killer when finished. The real problem is that it's 416 pins....not a DIY thing. The board, at least the chip part would have to be made commercailly and we'd be pushing right up against the $1000 price target most likely and I has hoping to come out more in the $600 range on the board.


Does anybody here know anything about getting boards made (or have the equipment to do it by any chance ) and can comment of cost or have any suggestions for holding cost down?

It looks like it's going to be 2 boards not 1. The processor and inputs will be on 1 and the outputs and power supply will be on the second. This will help keep the foot print down, give better isolation to the sensative stuff and make heat management easier.

Also it doesn't look like the boards will be DIY. We'll get the boards made and have all the surface mount stuff done commercailly and the DIY part will be any through mount components, wires, put it in the case. The processor has 416 pins...I don't think you could DIY this even if you wanted to.
Old 08-23-2009, 11:42 AM
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I think the basic hardware design is set

Freescale MPC5554 procressor and we will ues premade the phytec development board

A low power I/O card will be made to go in the case with the processor

A high power I/O board will be made to go in a second case, this will be the ingector drivers and ignition modules mainly

I'm going to try and work a discount deal with phytec on the processor boards, list is $499. Is anyone out there lurking and thinking they might want to jump in and build one of these so we can order together and try to get everything cheaper?

I have to say, not a lot of feedback here....is anyone reading this so I should keep it updated of just end it with a link to the ferrari site? I figured someone over here would think inexpensive and high perfomance ECUs were a good idea, no?
Old 08-25-2009, 02:41 PM
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81 views so far. This isn't the most active section of this BBS... I also think that the audience you're aiming this project at is pretty small, but that's just a guess.

--DD
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Old 08-25-2009, 08:05 PM
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Originally Posted by Dave at Pelican Parts View Post
81 views so far. This isn't the most active section of this BBS... I also think that the audience you're aiming this project at is pretty small, but that's just a guess.

--DD
you're probably right on the audience.

Computers scare me to death, but to make hp you need one and still have the car run good you need one.

In my case the motec guys tell me I need a to buy $12,000-$15000 worth of computers to run the engine I'm building (an 800 hp 9500rpm V12 with 24 staged and sequential injector and 12 coil)....and I don't have $12000 much less $15000.

Now that I'm digging it a bit this is shaping up to actually be more like $700 worth of hardware that needs to be purchase. $700, a passion for car stuff, and some time I have.

The stuff to run a 4 or 6 cyl is more like $200 not the $1500-$5000 you would spend on commercial stuff. I guess I just figured there were more Porsche guys that want to add hp and are cheap. This topic has almost 4000 views and a 1/2 doz volunteers at one level or another over on the ferrari site, guess now we know were the cheap b*stards live


Today's update I got the inputs/outputs sorted out I think. Now I'm working on the user inputs....it turns out there are a lot. Once this is done a flow chart has to be made that shows what is supposed to do when it's all done. Very boring stuff. We've also started working out ther I/O board.
Old 08-26-2009, 04:49 PM
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Well, since most Porsches have four or six cylinders, the $200 setup is about 90% as effective (maybe more??) as what you're talking about doing. And the $200 one has already been done. (And us 914 people are notoriously cheap, so the $200 solution would be much more typical for us! )

24 injectors and 12 coils; yeah... That takes a lot of computer "horsepower" to run, I bet. You could get partway there with batch-fire (and use the cheaper stuff), but if you really want to get the most out of it. I can see that there is a need.

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Old 08-26-2009, 09:06 PM
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Originally Posted by Dave at Pelican Parts View Post
Well, since most Porsches have four or six cylinders, the $200 setup is about 90% as effective (maybe more??) as what you're talking about doing. And the $200 one has already been done. (And us 914 people are notoriously cheap, so the $200 solution would be much more typical for us! )

24 injectors and 12 coils; yeah... That takes a lot of computer "horsepower" to run, I bet. You could get partway there with batch-fire (and use the cheaper stuff), but if you really want to get the most out of it. I can see that there is a need.

--DD
The base version would be ideal for most posche set-ups. It will do sequential fuel and direct fire ignition and run the engine as well as anything you could buy. It's only if you want stuff like traction control that you would need to think about the + version.

The $200ish (+/- depending on what you do and what you just buy) is well along but still needs help. If somebody want to jump in and help with that they need people who can help with the firmware. The core "engine" part of the firmware is working (I think) and they are now working on stuff like the crank pick versons and such. Plenty to do.
Old 08-27-2009, 05:33 AM
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Why not just tweak Megasquirt. Seems to do most of what you want in V3.
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Old 11-10-2009, 12:13 PM
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Why not just tweak Megasquirt. Seems to do most of what you want in V3.
sorry I missed this post.

The MS has come a long way with the MS3....but it's still a very primitive processor and the core code is pretty sketchy as a result. MS3 has stretched that poor processor to its very limit I think.

My project, now called O5e is also about to test run an engine with a 5634 based ecu. It uses a $99 5634 demo board, a $90 MS3xpander board and a $5 USU to TTL cable




MS is getting ready to release a new ecu based on the mpc5634 processor and that will be a big step forward for them. The board is 5634 demo ECU made/owned by FreeScale and will be available directly from them for about $500. It has 4 spark and 8 fuel channels but I think that could be made 6/6. i don't kow what MS is planning to charge, but the free O5e code will run on it and I'll have a protoytpe in my hands late next week so I'll know for sure what can be done with it then. It's a nice ecu hardware option for a 4 of 6 cylinder car.


We are also very close to being able to reflash a Chrysler ecu with the O5e operating code. You can get these for about $100 and once the new code is in it becomes a 8 spark/8 fuel fully programmable, completely generic ecu. this uses a 5554 processor which is about double the power of a 5634 so it very capable once you strip all the epa/dot regulated for production crap out of it......and it's $100. That is pretty much an unbeatable price I'd think

Then the big daddy is the gen1 board we designed (the design is a free download)

40 high power drivers with up to 12 spark and 24 fuel channels allowed. It accepts a 5554 processor module for phytec. Mine cost me about $500 to build I think.





we've come a long way since I started this thread, but help is always welcome and we need testers at this point

you can sign up here:
http://forum.open5xxxecu.org/index.php

Last edited by mk e; 05-24-2012 at 05:37 AM..
Old 05-24-2012, 05:24 AM
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For got the with case pic



This case is used for the O5e gen 1 with a 112 pin connector shown or the FreeScale demo ECU board with a 60 pin connector and i assume MS will use this case as well with there new product based on the FreeScale board.
Old 05-24-2012, 05:35 AM
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MS is getting ready to release a new ecu based on the mpc5634 processor and that will be a big step forward for them. The board is 5634 demo ECU made/owned by FreeScale and will be available directly from them for about $500.
This bit was a lie....sorry. I saw the new MS unit prototype last week and it is a MS design with 8 fuel, 8spark. Basically its and MS3 but with the 5634 processor and an automotive grade connector in a nice single board design. A big step forward for them I think. I was told it will be Priced in the $400 - $500 range but I' was unclear if that included the connector. I'm supposed to have a prototype in a month or 2 do do some testing on. MS is obviously releasing software with the unit but my O5e SW will also run on the hardware and will support different options and different tuning methods than the MS SW which some people might prefer.


I have the FreeScale demo ECU in my hands and it's pretty nice too. It's set to retail at $500 I was told and is 8 fuel/4 spark with a good amount of optional I/O stuff and is overall a bit fancier HW than the MS option but is also in a bigger case. I'm working on setting the code up for it now and hope to have it running an engine this month. I think they said this hardware will be available for sale about October. I uses the same cinch case in the O5e gen1 HW pics but with a 60 pin connector instead if the 112 pin we use.

The O5e SW is now running on a Chrysler ECU and making spark......we're getting there. These are under $100 on ebay
Old 06-08-2012, 11:31 AM
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Old 06-08-2012, 11:31 AM
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