[Mk2] [Turbo] !!! REV2 Turbo Mappable ECU !!!

[TUBBY-DEUCE]

excellent work, i really cant wait for this, has there been any thoughts on what the cost is going to be for one of these little beauties

[spowy]

Just caught up on all the news,Jesus Jeremy you haven't half been busy looks like all your hard work has payed off

Can't wait to the final production run now

Chris

[JasonB]

Great to see advances being made on this.

When i put my name down originally I was still rebuilding my engine after a turbo failure. If getting miles on this to prove and test it is now a must then I have no problem in offering my car as a test mule.

The car is used daily (45 mile round trip) on a variety of roads and has put about 4K KM on the new engne. I seem to remember you were in Gloucester (sp?) area so not that far from cardiff area.

Not trying to be cheeky or jump the line or anything just happy to help a project such as this along.

PM me if required.

JB

[Gersen]

The first 'production' hardware (ie the actual version of the final hardware) is currently on soak test in the car. Fitted on January 12th.

The plan is to put a couple of thousand miles of real world motoring on it using a standard map in the totally customisable area to make sure everything is tickety boo - make sense?

It's getting hot, cold, snow, rain, full throttle spanks, motorway runs, trundles to work and sitting in traffic and it's being totally 110% sweet as a nut. I'm doing rather alot of miles per week so this shouldn't take too long.

So the car is running totally off Jeremy's ECU but with standard settings for ignition, fueling, fuel cut, speed limiter, TVSV, TVIS etc.

This means all of Jeremy's hardware is getting a solid work out and.....

...it's being data logged

(PS Nothing has made me sadder than seeing in real time what MPG I'm REALLY doing)

We are currently at 300 miles since fitting.

Jeremy is currently finishing off the software side of things (making it rather more monkey (user) proof )

When the road testing is done it will be off to Ryan @ TwoBar for a mapping session.

Data logs, dyno numbers and traces and other results will be posted as they become available.

HTH

[raptor95GTS]

excellent news. Keep us up to date

[mrfil13]

yeah and hurry up getting those few thousand miles on it

What real world MPG are you getting then?

[Gersen]

I only have anecdotal evidence as of yet but the logs and traces will be coming soon!

These are of course the totally standard mpg from the ECU but you just have instant access to them and see them in real time.

The 70 and 80 cruises meant that the system was in closed loop and the ECU was in auto trim mode.

70 mph cruise 36 mpg
80 mph cruise 25 mpg (on a private road of course)
Lead foot mode 3 mpg

440cc injectors can throw a fair amoung of fuel about!

The speed was logged by the ECU and agreed to within 0.5mph with the GPS.

I'll be doing some testing on what I can get it up to at 56 mph in a cruise which should give me a figure close to the best possible mpg.

The last two tanks of fuel I did (this is pre ECU) were :-

43.5l for 210 miles = 21.95 mpg
38.6l for 190 miles = 22.38 mpg

I have to do quite alot of stop/start driving atm.

HTH

[ci_newman]

Looking good Just get this sorted for a rev1 engine and I'll be chuffed

[mrfil13]

Cheers gersen just shows how much of a difference an extra 10mph can do. When i first got my turbo my first trip up the M1 got me 37mpg and that was at 65/70mph,my gauge reads 5mph over what im doing, wasnt until i switched on my gps to see how far up the m1 i had left and i found i was in fact doing 65mpg instead of 70mph.

Would be good to see thr 56mph cruise, i got 45mpg out of my Gen6 celica because i had the space saver on

[ast]

Monitoring my wideband lambda I see that cruising at 70 mph is approximately maximun speed the car can do 14.7:1 AFR in fifth gear. When you go any faster the AFR rapidly drops to 12-13:1 level even in steady speed cruising. Combined with increased airflow to motor this equals to big change in fuel consumption. I think that the stock ECU is trying to lower AFR too soon and maps could be tweaked here to get more fuel efficiency in highway cruising.

[turbosupra]

Does anyone have jmr's contact info?

[darryl_p]

i'm logging my stock ST185ECU

and closed loop only happens while the TVIS valve is closed, and very low throttle openings. ie max of 15~20%

boost or over 4200 rpm on my ECU its off closed loop and into the map's not good for economy

[JMR_AW11]

I only have anecdotal evidence as of yet but the logs and traces will be coming soon!

These are of course the totally standard mpg from the ECU but you just have instant access to them and see them in real time.

The 70 and 80 cruises meant that the system was in closed loop and the ECU was in auto trim mode.

70 mph cruise 36 mpg
80 mph cruise 25 mpg (on a private road of course)
Lead foot mode 3 mpg

440cc injectors can throw a fair amoung of fuel about!

The speed was logged by the ECU and agreed to within 0.5mph with the GPS.

I'll be doing some testing on what I can get it up to at 56 mph in a cruise which should give me a figure close to the best possible mpg.

The last two tanks of fuel I did (this is pre ECU) were :-

43.5l for 210 miles = 21.95 mpg
38.6l for 190 miles = 22.38 mpg

I have to do quite alot of stop/start driving atm.

HTH

Hi Tom

Glad the ECU is performing well
The fuel economy display is calculated with a few simple sums from raw data from the ECU.

The calculation totally relies on the accuracy of the fuel delivery from the fuel injectors.

i.e. I assume 440cc/min flow rate for the rev2 turbo.

Because the ECU always knows the injector duration (in microseconds) and it knows the engine speed in rpm (both 16 bit) the laptop can gather this info over the datalogging and can calculate

how much fuel is going into the engine per hour. i.e. gallons per hour delivery rate.

it's then just a simple sum with vehicle speed in mph for economy in mpg(the ECU actually measures speed in kph).

It looks like the displayed figures are pretty reasonable. I've not had to add any fiddle factors so the data you see is based on the raw ECU data. I've added 16x smoothing to the laptop display so the displayed reading is the average of the last 16 calculations. This is easier on the eye as without the averaging/smoothing the figure can really leap about.

I've got a similar economy readout on my mk1 MR2 and it's amazing how much the economy tanks down even on a slight incline or if you are heavy on the throttle.

It's easy to see 75mpg+ on a slight downhill stretch on a mk1 MR2.

It's also very difficult to find a flat stretch of road to get a long steady reading. Probably best to average the data over a few miles.

I use a handheld PDA in my mk1 MR2 to talk to the ECU and I also wrote a PDA GUI for the rev2 turbo that shows a scaled down version of what is on the laptop.

it looks a bit crude but displays stuff like mpg, speed, rpm, EFI, ignition timing etc. Also TVIS and TVSV status and knock corrections. (for the 3SGTE)

This was for a H2210 PDA as these PDAs have a proper serial port (loads of these old PDAs available s/h on ebay for about £50)

[mrfil13]

What OS do those PDA's use, i guess you are using the serial rs232 connection to the pda. Ive seen some serial to usb converters but i have a feeling that they require drivers which will be a problem on a PDA.

[JMR_AW11]

What OS do those PDA's use, i guess you are using the serial rs232 connection to the pda. Ive seen some serial to usb converters but i have a feeling that they require drivers which will be a problem on a PDA.

Windows CE.

I programmed the GUI in EVB for it.

It has a proper RS-232 port so no need for converters etc. However you do need to buy a cable to plug into it. The cable has a regular 9 way D type at the free end = COM1.

I've got a couple of them and they are really useful because of the COM port. They will be dirt cheap on ebay this time next year IMO.

[ast]

Does the backup switch require shutting down the engine? Or is there any other way to change to safe maps with external signal on the fly?

This would be useful with water injection as some kits have monitoring that alerts if you run out of water, the injector is blocked or if water hose is disconnected. As you can run more timing / boost with water it would be useful if ECU automatically switches to safe maps if there's a problem. This would be even more useful with methanol injection as methanol is fuel and AFR gets leaner if the injection fails for some reason.

[mrfil13]

I was interested in the pda side as i have a pocket pc thats running windows mobile but only has usb connectivity.

[JMR_AW11]

Does the backup switch require shutting down the engine? Or is there any other way to change to safe maps with external signal on the fly?

This would be useful with water injection as some kits have monitoring that alerts if you run out of water, the injector is blocked or if water hose is disconnected. As you can run more timing / boost with water it would be useful if ECU automatically switches to safe maps if there's a problem. This would be even more useful with methanol injection as methanol is fuel and AFR gets leaner if the injection fails for some reason.

That's a good question...


If you look at the image below, one of the 'internal' white connectors can be configured as addressable (logic level) input or output ports.

So with a mod to the ROM code I could get the ECU to monitor the status of one of them on every lap of the program code and force the ECU to its safe maps for fuel and ignition as applicable. This would only need a few lines of code to do.

The stock ROM code already has these maps and it also forces the TVIS into one state and also limits the boost via the TVSV.

The only problem is that this connector is inside the ECU!

[darryl_p]

any news from over the weekend ?????

[Gersen]

Not a great deal to report right now.

Got another 300 miles on her this week and still running perfectly.

I have time this weekend to get data logging done for Jeremy - he has written a new version of the code and GUI for the logging/display interface that I haven't tested yet.

I know that isn't much new info but things are progressing very nicely