[JapanTurbo]

ich habs mal zitiert ;-)

Just to keep you all updated on progress, I have created this topic to let you know what's going on with the 'E-Manage' replication inside the GTti ECU.

This unit will sit inside the existing GTti controller, and be visible only by a USB lead coming out of the case (for tuning). It is a small daughter board based on a Silabs C8051F340 micro (for cost), which will allow similar feature to the E-Manage, but without changing the original driver hardware, potentially making it more robust.

The embedded part of the software for the unit is close to finished now. This gives:

Injection:
Scalable 'old vs new' injector size to allow the user to change injectors on the car, but maintaining same injection quantity
16x16 override map allowing a percentage offset to the base fuel from the original controller (break points can be altered Jim!)
Injection pulse size can be decreased and increased (was originally increase only, but I have had to allow for larger injectors, so it is both now)
Spark:
16x16 override map allowing ignition advance/retard from original values (again, break points can be scaled)
MAP:
Original map sensor can be changed on original harness for, as an example, a 3 Bar sensor, and the Xenomorph unit will generate a 'fake' map signal to go back to the original controller, making it think that the sensor is unchanged. Obviously, this includes a limit for preventing fuel cut.

Turbo:
Original wastegate control valve controlled by unit, and can be re-mapped to allow boost increase by software, not bleed valve. Work in progress on this one.

Data/Calibration:
Board is reading engine temp, inlet temp, MAP, O2Sensor input (in case someone wants to see a wideband on the same screen as controller data), engine speed, throttle position, battery voltage, sensor supply voltage and vehicle speed, and is passing the data over USB (not a serial port emulation) to a quite basic PC application (nothing fancy at all, just functional - still working on this s/w - PC is struggling with data throughput of the board)

On board logging:
The board will have a connector for a microSD card to allow it to log to a FAT16 file while you are not connected.

Board layout:
The software is being tested using an evaluation board at the moment. The board layout for the real unit won't start until August in all likelihood. The board size should be less than 100mm x 50mm.

Problems (this is a request for help!):
The following are not currently calibrated (remember, I do not have a GTti, just a controller on a bench!!)

Coolant temp sensor Temperature to voltage
Air temp sensor Temperature to Voltage
MAP sensor pressure to voltage for both original, and 3Bar replacement sensor
Pulses per revolution of speedometer read head, and therefore frequency to speed conversion

Target unit hardware cost is £75 pounds now(including board/tooling) - the project is not for profit, it is for learning only.