Twin and Earf - chrisada.co.uk
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1. at MMU to sustain a steady development cycle Students come and go as do undocumented designs With this document I hope to start a trend where not only the designs but the design decisions are thoroughly explained in regards to the Electrical and Electronic aspects of the 2012 car I hope that the mechanical engineers will follow suite This guide is by no means an authority on the matter in fact much of it is Don t do it like this alterations to this guide are encouraged ATRX source is available from my website http chrisada co uk 1 1 What This Document is and What it Isn t This document is not e A quick reference for the rules e The ultimate guide for everything auto electrical This document is e Designed to inspire further design e One way of doing things e A quick reference for technical information 2 Your Responsibilities As a reader of this guide you have probably been tasked with managing the Electrical and Electronic aspects of the car Typically your responsibilities will include e The Wiring Looms Power Distribution Engine Sensor Engine Control Axillary e Using ECU Software e Optional Electronics which may include Driver Interface Data Logging Wireless Telemetry Wireless Video Feed e Management of Axillary Systems Toward the competition you may find that you ll be left with odd me chanical jobs such as e Designing Small Brackets e Plumbing2. x Active three wires takes power and returns an amplified signal x Passive two wires returns a very weak signal induced by it s environment e The Cam Sensor The ECU uses this along with the crank sensor to calculate the position of the pistons such that timing of the sparks and injec tors can be controlled Like crank sensors cam sensors come in two types x Active three wires takes power and returns an amplified signal x Passive two wires returns a very weak signal induced by it s environment e The TPS Sensor The TPS sensor tells the ECU how much throttle the driver is re questing it s essentially a waterproof potentiometer that attaches to the throttle body e MAP Manifold Absolute Pressure This tells the ECU what the air pressure inside the manifold is 4 3 2 Calibration and Other Prerequisites In addition to the electrical aspects you will also need to ensure that e The fuel pressure has been calibrated this can be done once using an analogue gauge Details can be found later on e An appropriate map for the appropriate manifold is installed on the ECU e Adequate cooling if you plan on running the engine for more than a few seconds Running the Engine More Optimally While the above section will allow you to start the engine it will likely be not running at it s highest performance or highest efficiency For tuning purposes a lambda sensor should be installed in the exhaust for init
3. Twin and Erf How I Learned to Love Wiring 0 1 A Guide for EEE Students Undertaking Formula Student Chris Adams chris chrisada co uk November 6 2013 Contents 1 Introduction 1 1 What This Document is and What itIsn t 002 2 Your Responsibilities 3 2011 2012 Rules 4 Concepts Al Bhe EOU dande e Sek A eS Ae a 427 ROBNE Ne aerae 5 ee ote ee AE eee LEE aS Bode et 4 2 1 Sensors and Wiring 0 4 4 2 2 Firing Order and Other Data 4 3 Getting The Engine to Run 4 3 1 ECU Connections 0 4 3 2 Calibration and Other Prerequisites 4 4 Running the Engine More Optimally 4 5 Advanced ECU Features 2 222004 6 Car Awxiliaries sss euli e as ana gk Bl A eo 4T Loom Building a i s alete r ea dues Aad ee aa ai 4 7 1 Location of Parts oaa aaa Alea TIPS fe Wee Rak i Be ake Sok he AA 4 8 Electronics s ce ee RR we ee ee A 4 8 1 What Will the ECU Do For Me 4 8 2 Driver Interface 2 00 4 8 3 Getting Data With Minimal Sensory Input 4 8 4 Some Design Approaches 4 8 5 A Word on PCB Designs 4 97 Plum Dine 3 45 tsa ty Be ete oe Pe ae A Ao BB Ba 5 On The Day 6 Lessons from 2012 1 Introduction Whilst Formula Student nurtures students to become successful and accom plished engineers I believe that not enough design documentation occurs
4. e Sensor Name Location Properties Cam Sensor Middle of engine block be hind intake runners Active sensor blue is power black is ground and yellow is output Crank Sensor Bottom left of the engine not far from the exhaust outlet Passive sensor Helpfully light grey is ground and dark grey is Vout Water Temp In front of the runners green plug Polarity is unimportant as it is a resistive load Neutral Switch A single wire brass connector not too distant from the cam sensor Switches to ground when neu tral is active Extremely un reliable prone to bouncing sticking and non operation MAP Sensor Yamaha Bolted to the fuel rail Use of this MAP sensor is dis couraged a DTA and GM are available Polarity is sensical MAP Sensor DTA Arbitrary MAP Sensor GM Arbitrary 4 2 2 Firing Order and Other Data Fuel Pressure The fuel pressure should be set once using an analogue gauge or the digital gauge connected to the ECU This is given in the R6 service manual as approximately 3 BAR But this will be map dependant in recent years higher pressures have been used Ask a grown up Firing Order This is an all too common mistake that is made when wiring the engine It shouldn t be Firing orders What order do the cylinders go bang varies from engine to engine from left to right it may be 1 3 4 2 or 1 2 3 4 etc The ECU is d
5. e Making References to Twin and Erf See Steve Moyle 3 2011 2012 Rules WARNING THIS MAY NOT BE UP TO DATE CONSIDER THIS FALSE INFORMATION YOU HAVE BEEN WARNED Reference this section with caution rules for FS often change for up to date rules check the FSAE website Everything that goes on the car must comply with strict rules which generally involves the following 1 Master Switches a Three switches should be installed b Actuating either disables power to all circuits in the car including alternator c Primary Master i Must be of rotary type ii Actuating anti clockwise disables the power ili May not act through a relay iv Must be mounted to the right hand side of the chassis in line with the driver s head d Driver Kill Switch i May act through a relay ii Must be of push type iii Pushing on the switch disables power iv Must be in easy reach of the driver e Brake Over travel Switch i Positioned mechanically such that A A loss in brake pressure allows actuation of the switch disconnecting power to all circuits B It s almost impossible for the driver to re enable it ii May act through a relay e In reality you ll find it very difficult to not use a relay 2 Wiring a Any wiring passing through the firewall should be grommeted b The live wire of the battery should be clearly marked along its full extent with yellow tape 3 Battery a It should be fixed securely to t
6. esigned for 4 cylinder engines but will support any firing order It is not possible or required to change the firing order on the ECU The ECU will fire in ascending order regardless of any settings or any wiring 1 2 3 4 It is your responsibility to connect the wiring in such a way that the required firing order is achieved On the Yamaha R6 the firing order is 1 2 4 3 Left to right with the starter motor on the right hand side Connections should be made in the following way ECU Engine Coil 1 Coil 1 Coil 2 Coil 2 Coil 3 Coil 4 Coil 4 Coil 3 4 3 Getting The Engine to Run This section details the absolute bare minimum you ll need to get a running car It will be far from optimal and may not suffice for the competition 4 3 1 ECU Connections Below are the absolute minimum connections for the ECU to get the car running e All four coils The coils can be thought of as one side of a transformer they are highly inductive They control the power to the spark plugs Peak current can be in excess of 5A each average current is rel atively low e All four injectors These are essentially solenoids that control the flow of fuel into the cylinder Current draw is minimal e The Crank Sensor The ECU uses this along with the cam sensor to calculate the po sition of the pistons such that timing of the sparks and injectors can be controlled Crank sensors come in two types
7. he frame b The live terminal should be thoroughly insulated from the rest of the car 4 Brakelight e Not explicitly given in rules as an electrical requirement e Appropriate brightness for distant visibility e Correct height Providing you don t break these rules and the car goes brum you re sorted 4 Concepts 4 1 The ECU In fuel injected cars the control of the coils fuel injectors and management of sensors is performed by the ECU it is an essential component for the car to run As of November 6 2013 MMU has two ECUs both made by DTA the S60 and S80 The S80 is more feature full and is the preferred choice The S60 may be used for experimentation and development purposes however as their protocols and software are identical 4 2 R6 Engine 4 2 1 Sensors and Wiring The original coil and injector looms from the R6 should be preserved where possible Individual connectors are both expensive and difficult to source As depicted in the ECU wiring diagrams the common live wires for the injectors and coils are wired in parallel post fuse whilst individual coils injectors are switched to ground For the most part wire colouring is intuitive darker colours are usually ground whilst green and red are preserved for Vry Where wire colours are not obvious I have explicitly mentioned them Below is a table of where sensors can be found when the engine is facing forward with the starter motor on the right hand sid
8. ial testing while the engine is on the dyno rig a wide band should be used This can be later replaced with the narrow band sensor Installation of the lambda sensor allows the engine to be run in a closed loop configuration so it can calculate the Perrin ratio The lambda sensor requires a 12V heater input this is controlled by the ECU and as such does not need to be fused Additionally the water temperature sensor should be connected so the ECU can make temperature based adjustments such as cold starting 4 4 Advanced ECU Features The S80 also offers many other features which may be of interest e Gear Estimation Via potentiometer on a sequential gearbox Gearbox output speed comparison e Traction Launch Control 4 5 Car Auxiliaries 4 6 Loom Building 4 6 1 4 6 2 Location of Parts Tips 4 7 Electronics 4 7 1 4 7 2 4 7 3 4 7 4 4 7 5 What Will the ECU Do For Me Driver Interface Getting Data With Minimal Sensory Input Some Design Approaches A Word on PCB Designs 4 8 Plumbing 5 On The Day 6 Lessons from 2012 7 Lessons from 2013 10
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