Almost ready to test MAF conversion...[PICS too]

Author Topic: Almost ready to test MAF conversion...[PICS too]  (Read 17839 times)

bmwman91

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Almost ready to test MAF conversion...[PICS too]
« on: March 20, 2006, 11:51:48 AM »
I recently finished my final sensor calibration tests.  All I have to do now is load the conversion program onto my controller and finish wiring the electronics (the digital stuff).  I really really hope to be testing by the end of the week.  Not just for me, but my grade in Senior Project and graduation depend on it as well!




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Febi Guibo

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« Reply #1 on: March 20, 2006, 01:10:56 PM »
well, it will make a hell of a CPU cooler in any event...

looks great man... congrats!!
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bmwman91

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« Reply #2 on: March 20, 2006, 01:37:27 PM »
Lol.  There's an idea...I can use it to clock the air inflow rate into my computer...

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asubimmer

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« Reply #3 on: March 20, 2006, 01:56:09 PM »
lookin good william, can't wait to see it on the car
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2002maniac

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« Reply #4 on: March 21, 2006, 01:09:22 PM »
Cool!  Keep us updated!

romkasponka

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« Reply #5 on: March 22, 2006, 04:49:46 AM »
why not MAP sensor?
E30 318is M42
E36 318is M44

Zoso

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« Reply #6 on: March 22, 2006, 08:05:45 AM »
I have a few questions just out of curiousity.  My knowledge base in this area isn't deep so feel free to fill me in with the correct info.

I know a Mass Air Flow sensor converts the amount of air drawn into the engine into a voltage signal and the ECU needs this information so it knows injection duration, etc.  I know a MAF im principle operates by using a thermister, power transistor, and a comparator.

I'll try to break all the questions into bite size chunks.

1)  What does the car have in stock form?  A Vane Air Flow Meter (potentiometer, return spring, etc)?

2)  Both types output a voltage/air mass curve.  How do you know what kind of curve the stock ECU is expecting?

3)  If the curves don't compare nicely, how do you know you're not telling the engine to use too much or too little fuel?  I'm assuming you have to rewrite the ECU's fuel curves?

4)  If not rewriting the ECU's fuel curves, how are you converting the MAF's output voltage curve into one that the stock ECU can use?

5)  If you are rewriting the ECU's fuel curves, are you using megasquirt?

6)  If rewriting the fuel curves, how do you know what a good fuel curve for the M42 is?  Is it a trial and error thing or is there an easy ratio that you always try to obtain?

7)  What makes the MAF so much better than the stock sensor?  Will it respond quicker?

8)  What is that MAF from?


It looks like an interesting senior project.  Nice work so far.

My senior project wasn't as practical.  It was sponsered by a company who makes transducers and I used a bank of different frequency narrowband transducers to send out an ultrasonic signal and then monitored for a response.  I then did an analytical cross correlation between the output signal and the received signal.  With that and the speed of sound in the medium (which was air at this point), I could calculate the distance.  If there was more time I would have added hardware that would allow it to calculate it's own sound of speed so it could be placed in any medium (water, air, thin air, dense air, space, etc) and it would accurately calculate distance.  It used 4 pairs of transducers with the lower frequency ones calculating long distances and the higher ones doing short distances.  The system would automatically pick the most optimum frequency transducer for the distance.

It was a good project overall and included a lot of electrical engineering aspects including signals, power electronics (transducers need to be fed hundreds of volt pulses), filter design, digital electronics (I had an FPGA doing system controlling, buffering data and having it accessible to a uP bus for a CPU), and software design.

Senior projects are fun when they're over :D
« Last Edit: March 22, 2006, 08:08:04 AM by Zoso »

kowalski

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« Reply #7 on: March 22, 2006, 10:48:57 AM »
that was quite the mouthful.
sounds like you took on quite the interesting project.

to answere one fo your questions the benefits would be:
no flaper, or spring which means less restriction which means more flow, significantly better throttle response and a little more power.

i think he's trying to get ahold of the stock fuel maps so that he can remap the stock chip? i know hes atleast looking for the stock maps... i'm not really sure what hes gona do if he can't find them, or get them to workt ho.

as for figuring out fuel maps, for the best results you would have the car on a dyno and play arround with the maps, but i'm pretty sure there is an optimum A/F ration depending on combustion chamber shape, piston head, compression, and all that good stuff.
« Last Edit: March 22, 2006, 10:54:00 AM by kowalski »
Sale:
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Send $ to: kroeker.michael @ gmail.com

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bmwman91

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« Reply #8 on: March 22, 2006, 03:12:41 PM »
Actually, there is no chip reprogramming at all.  This will be pure plug-n-play when it is done.  I mapped the voltage output of each sensor at various flow rates and modeled them mathematically.  I made an equivalence table & stuck it on a microcontroller.  The DME will not need any work, and will think the AFM is still there.  You just get all the MAF benefits on top of that.

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kowalski

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« Reply #9 on: March 22, 2006, 03:20:47 PM »
Quote from: bmwman91
Actually, there is no chip reprogramming at all.  This will be pure plug-n-play when it is done.  I mapped the voltage output of each sensor at various flow rates and modeled them mathematically.  I made an equivalence table & stuck it on a microcontroller.  The DME will not need any work, and will think the AFM is still there.  You just get all the MAF benefits on top of that.


and what is one of these units gona cost?
Sale:
EBC Green stuff pads = $60 shipped front and rear set available


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bmwman91

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« Reply #10 on: March 22, 2006, 05:59:32 PM »
I will work out pricing once I have a fully working & reliable prototype, and I have worked out a deal with an electronics fabber to produce the circuits (I will have PCB's made & hopefully surface mount components).  I would probably say in the $250 range.  The sensor would NOT be included (it is a very easy part to get through Kragen's for like $50, or a wrecker for $20).  I do not like the idea of shipping the sensor as it has breakable stuff in it, and it just adds to the cost of everything.

The other part that would cause a rise in price is adapters to make it fit.  I am trying to keep it all as simple as possible, and fitting it to the stock air box is not an option, at least not a cost effective one.  I just have to come up with a way to make it fit the air boot, and make a heat shield.  We shall see.  I have not really made too many plans for a mass produced product, but I guess if there is interest I could look more into it after the project is done.  Unfortunately, this will not be the $100 magic MAF solution some people may be wanting...it does not exist.  I will keep my progress posted though.

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royalflush313

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Almost ready to test MAF conversion...[PICS too]
« Reply #11 on: March 22, 2006, 08:58:42 PM »
what kind of increases are you expecting with this conversion?

Zoso

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« Reply #12 on: March 23, 2006, 11:11:03 AM »
Quote from: bmwman91
I will work out pricing once I have a fully working & reliable prototype, and I have worked out a deal with an electronics fabber to produce the circuits (I will have PCB's made & hopefully surface mount components).  I would probably say in the $250 range.  The sensor would NOT be included (it is a very easy part to get through Kragen's for like $50, or a wrecker for $20).  I do not like the idea of shipping the sensor as it has breakable stuff in it, and it just adds to the cost of everything.

The other part that would cause a rise in price is adapters to make it fit.  I am trying to keep it all as simple as possible, and fitting it to the stock air box is not an option, at least not a cost effective one.  I just have to come up with a way to make it fit the air boot, and make a heat shield.  We shall see.  I have not really made too many plans for a mass produced product, but I guess if there is interest I could look more into it after the project is done.  Unfortunately, this will not be the $100 magic MAF solution some people may be wanting...it does not exist.  I will keep my progress posted though.


So if it is a plug and play solution then you must have hardware to map the MAF curve to the stock curve.  The electronics part of the system sounds pretty basic then.  Perhaps I can give some advice how to keep the cost of electronics down.

You can do this:
ADC -> FPGA/CPLD -> DAC
You'll also need votlage regulator(s) and an oscillator.

From what I can tell, you don't need the cost or complexity of an microprocessor.  All you need is a lookup table to do the curve conversion.  

I'd have to look into it, but the FPGA or CPLD is inexpensive and DAC and ADC are also cheap because this system runs slowly.

I've been involved in making many PCBs and most of the time http://www.pcbexpress.com is the cheapest... especially if you can let them take a week or two to build it.  You just need to make sure that your PCB design file is correct because they just build it.

I've also done a lot of surface mount work... and it is easy enough for you to do at home provided you have several tools.  You can buy a stencil that will allow you to scrape on solder paste onto all the pads on the PCB.  Then you place the components on the solder paste covered pads.  This is very easy but it can be a bitch for fine pitch chips.  Still, I was able to do this for .5mm pitch CPLDs... and that's tiny.  Then you can bake them in a toaster over.  I've done this hundreds of times and it comes out great and it's much cheaper than having someone do it for you.

It may be too late in your senior project process, but I'd be happy to give some electronics advice.  At a minimum the advice above can help you reduce the cost and complexity of the electronics.  PM me about it if you'd prefer to keep your "special sauce" secret.  :D
« Last Edit: March 25, 2006, 07:10:26 PM by Zoso »

Febi Guibo

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« Reply #13 on: March 23, 2006, 11:50:09 AM »
you guys have some awesome synergy brewing... dare I say on the order of:

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bmwman91

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« Reply #14 on: March 24, 2006, 11:45:55 AM »
LOL!!!

Thanks for the advice Zoso.  I am looking into the FPGA/CPLD idea.  I definitely agree, a microcontroller is way overkill.  I had been hoping all that time that there was some sort of programmable lookup-table device, but being a mechanical engineer I have very limited electrical experince (at least class-wise).  And that is good to know about the surface mount bits.  Yup, I was using an ADC for the input and shot the digital output back through a DAC to the DME.

06/05/2011 - 212,354 miles
Visit HERE for a plethora of 318iS stuff and some other randomness.  Would you say I have a, plethora, of pinatas?