Electronic control system

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Lynette Gertrude McLaughlin
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1 Electronic control system Date 28 March 2013 Vico de Bres Customer Service Department Yanmar Europe B.V. Content 1. Overview 2. ECU connections 3. Sensors Page1

2 Overview Page2 Engine sensors and actuators DOC out DOC in DPF Press. : On the engine : On DPF ITV EGRT IAT Injector s EGT EGR Press. AT EGR ECU Crank speed Rail Press. CWT HPP FT Cam speed Page3

3 Tier 4 harness concept DPF bracket Switch Lamp Key Relays Fuse Glow CAN Starter, Alternator OEM machine side [Harness A] Engine bracket (AMP seal16) 12p 8p 12p 12p DPF bracket [Harness A] EGT HPP Crank speed FT DPF press. IAT EGR Press. Engine side IA Throttle EGR Injector s AT EGRT [Harness C] [Harness B] CWT Cam speed Rail press. Battery DOC in DOC out Yanmar provides Page4 Supply policy of harness Harness Monitor Engine Sample Engine Mass-Production Harness A Supply Supply (Only the first engine) Not-Supply Harness B Supply Supply Supply Harness C Supply Supply Supply Harness A Harness A is prepared by the customer because it is affected by machine layout. Harness A will be supplied with the first sample engine for troubleshooting of the harness the customer prepared. Harness B,C Harness B and C is supplied by Yanmar in order to guarantee quality of engine performance and electronic devices. Page5

Sensor concept for Tier 4 engines T2(In.Mani.) T_ambient P2(In.Mani.) CWT T_EGR P P_ambient atmospheric P (SF) Sensors for Tier4 engine 4 press. sensors 7 temp.

) P2 (Intake mani.) EGR high press sensor EGR correction, intake pressure governor P3 (Exhaust mani.

correction (injection) T2 (Intake mani.) Intake manifold temp sensor Air mass calculation, EGR correction T3 (Exhaust mani.) Exhaust gas temp sensor Air mass calculation, EGR correction, temp.

4 Sensor concept for Tier 4 engines T2(In.Mani.) T_ambient P2(In.Mani.) CWT T_EGR P P_ambient atmospheric P (SF) Sensors for Tier4 engine 4 press. sensors 7 temp. sensors 4 CR sensors 15 sensors in total P3(Exh.Mani.) T3(Exh.Mani.) T4(DOC in) T5(SF in) Sensor name Usage P atmospheric Atmospheric press sensor Atmospheric press correction (injection, etc.) P2 (Intake mani.) EGR high press sensor EGR correction, intake pressure governor P3 (Exhaust mani.) EGR low press sensor EGR correction P (SF) DPF differential press sensor P-method T_ambient Ambient temp sensor Intake temp. correction (injection, etc.) CWT CW water temp sensor Coolant temp. correction (injection) T2 (Intake mani.) Intake manifold temp sensor Air mass calculation, EGR correction T3 (Exhaust mani.) Exhaust gas temp sensor Air mass calculation, EGR correction, temp. governor T_EGR EGR temperature sensor Air mass calculation, EGR correction T4 ( Before DOC) DPF inlet temp sensor C-method, temp. governor T5 (Before SF ) The information and figures DPF in inside this document temp are the sensor exclusive property of YANMAR Corporation. C-method, temp. governor Page6 ECU connections Page7

5 Diagram overview Page8 Analog input Page9

6 Low side digital input Page10 High side digital input Page11

7 Digital output High side output Low side output Page12 Pulse I/O & CAN communication Page13

8 Common rail system digital output Page14 Power supply & grounding Page15

9 Sensors Page16 Sensor types and measure principles (1) Temperature (2) Pressure (3) Speed (4) Position (angle) Page17

10 ENGINEECUSensor outline figure Physical value Chemical value Speed Temp Pressure Acceleration Moisture etc. Electrical Value Sensor Voltage UCurrent Resistance Digital input Digital output Page18 Temperature sensor types and sensing principles Sensor name Usable temp. range [ C] Fuel temp. sensor -40 to 150 CW temp. sensor -30 to 120 Ambient temp. sensor -40 to 150 Intake mani. temp. sensor -40 to 200 EGR gas temp. sensor -40 to 325 DPF inlet temp. sensor -40 to 1000 (diag 700) DPF inside temp. sensor -40 to 1000 (diag 700) Ex. gas temp. sensor -40 to 1000 Thermistor Sensing principle Resistance Temperature Temp.: High Resistance value: Small Platinum resistor Resistance Temperature Temp.: High Resistance value: High Page19

11 Example of characteristic curve for temperature sensor (1) 30 Thermistor 6 Resistance 抵抗値 value [kω] Resistance value Sensor voltage 冷却水温度 CW temp [ ] Sensor センサ電圧 voltage [V] Characteristic curve for CW temperature sensor Page20 Example of characteristic curve for temperature sensor (2) Platinum resistor 6 5 Resistance 抵抗値 value [Ω] Resistance value DPF DPF inlet 入口温度 temp [ ] Sensor voltage Sensor センサ電圧 voltage [V] Characteristic curve for DPF inlet temperature sensor Page21

12 ECU interface circuit of temperature sensor ECU Sensor power supply E (5 V) Determine the inner resistance value using the resistance characteristics of the temperature sensor. Microprocessor Digital signal AD converter Analog signal V sig R 0 Sensor signal R Temp. sensor Sensor GND Temperature Characteristic curve Relationship between V and C V sig = E x R 0 R + R Voltage input to microprocessor is converted to temperature value using characteristic curve. Page22 Pressure sensor types and sensing principles Sensor name Rail pressure sensor Detected pressure range 0 to 1,800,000 hpa Sensing principle DPF differential pressure sensor EGR pressure sensor EGR high-press. side (ex. mani. pressure) EGR low-press. side (in. mani. pressure) Ambient pressure sensor 0 to 50 kpa 40 to 300 kpa abs 40 to 300 kpa abs 40 to 110 kpa abs Strain gage Change in electrical resistance value caused when the resistor is deformed by external force (pressure) Page23

ECU interface circuit of pressure sensors ECU Sensor power supply E (5 V) Sensor 5 V Pressure sensor Microprocessor Digital signal AD converter R 0 Analog signal V sig Sensor signal

Page24 DPF differential pressure sensor structure gage sensor High press side (before SF) gage sensor Import press Low press side (after SF) before SF after SF absolute press

13 ECU interface circuit of pressure sensors ECU Sensor power supply E (5 V) Sensor 5 V Pressure sensor Microprocessor Digital signal AD converter R 0 Analog signal V sig Sensor signal Sensor GND Pressure Characteristic curve Relationship between V and Pa Voltage input to microprocessor is converted to pressure value using characteristic curve. Page24 DPF differential pressure sensor structure gage sensor High press side (before SF) gage sensor Import press Low press side (after SF) before SF after SF absolute press absolute press Digital ADJ absolute press differentia l press Two gage sensors are adopted, and difference of absolute pressure values is calculated in the sensor to output DPF differential pressure. Page25

14 Speed sensor types and their sensing principle Sensor name Crank speed sensor Sensing principle Electromagnetic pickup Cam speed sensor Magnetic resistance element (Hall element) Page26 Principles of speed measurement with electromagnetic pickup Electromagnetic induction. Electricity is generated by magnetic flux change. gap: near large gap: far small Microcomputer (counter) Electromagnetic pickup type sensor comparator 18 gear teeth (rotors) Calculation by microcomputer Input waveform Threshold Output signal time Engine speed is min -1. Engine speed Count by microcomputer Time of 1cycle period Reciprocal at the cycle is a frequency. Page27

Principle of speed measurement with electromagnetic pickup Internal structure of crank speed sensor (Bosch) Page28 Operating principle of Hall element Magnetic resistance element (Hall element) is an

15 Principle of speed measurement with electromagnetic pickup Internal structure of crank speed sensor (Bosch) Page28 Operating principle of Hall element Magnetic resistance element (Hall element) is an element which detects a magnetic field using the Hall effect. It converts a magnetic field generated by a magnet or that generated by a current into an electric signal, and output it. The Hall effect is a phenomenon that when a magnetic field is applied to an object through which a current is flowing in a direction perpendicular to the electric current, an electromotive force appears in a direction orthogonal to both the current and magnetic field. V H = R H IC B V H : Hall output voltage R H : Hall coefficient (depends on material or temperature) I C : Control current B: Magnetic flux density Hall element V H : Hall output voltage B: Magnetic flux density I C : Control current From the above principles, the Hall element output power is proportional to the magnetic flux density. Sensor power supply Page29

Principle of speed measurement with Hall element Hall element Internal structure of cam speed sensor (Bosch) Page30 Principle of speed measurement with Hall element Pulsar Pulsar Gap between

16 Principle of speed measurement with Hall element Hall element Internal structure of cam speed sensor (Bosch) Page30 Principle of speed measurement with Hall element Pulsar Pulsar Gap between sensor and pulser: Large Gap between sensor and pulser: Small Magnetic flux density: None Magnetic flux density: Occurs Output voltage: Zero Output voltage: Occurs Cam speed sensor output voltage Page31

17 Principle of speed measurement with Hall element ECU Cam speed sensor Vcc Pulser Hall S N Amplifier Sig : On/Off output GND Time count by microprocessor T Based on the sensor voltage input from the cam speed sensor to ECU, the microprocessor counts the time from the sensor voltage leading edge up to the next leading edge. Page32 Difference between electromagnetic & Hall sensor Page33

Minimum measurement speed Starter ON Key switch terminal voltage Cam speed sensor pulse Speed pulse of 0 to 5 V is output not depending on the speed.

18 Minimum measurement speed Starter ON Key switch terminal voltage Cam speed sensor pulse Speed pulse of 0 to 5 V is output not depending on the speed. Crank speed sensor pulse Low speed, small magnetic flux Voltage necessary for speed pulse detection is not generated. ECU cannot detect the speed. Page34 Position sensor types and their sensing principle Sensor name Accelerator sensor Intake throttle position sensor Exhaust throttle position sensor Sensing principle - Potentiometer (sliding resistance) - Contact type - Magnetic resistance element (Hall element) - Non-contact type Page35

19 Principle of position measurement with potentiometer A sliding brush moves on a resistor, and rotation amount is considered as a change in the resistance value. Assuming that the total angle of the resistor is θf, the output voltage Eo when the rotational axis turns by θ is E o = E θ θf Base element cermet gear cutter capped electrode resistive element sliding brush shaft Input/output terminal sliding brush sliding brush Cermet layer support material A/D converter Microcomputer Page36 Operating principle of Hall element Magnetic resistance element (Hall element) is an element which detects a magnetic field using the Hall effect. It converts a magnetic field generated by a magnet or that generated by a current into an electric signal, and output it. The Hall effect is a phenomenon that when a magnetic field is applied to an object through which a current is flowing in a direction perpendicular to the electric current, an electromotive force appears in a direction orthogonal to both the current and magnetic field. V H = R H I C B V H : Hall output voltage R H : Hall coefficient (depends on material or temperature) I C : Control current B: Magnetic flux density Hall element V H : Hall output voltage From the above principles, the Hall element can obtain an output power supply proportional to the magnetic flux density. B: Magnetic flux density I C : Control current Page37

Operating principle of Hall element Output 出力電圧 voltage [V] 5 4 3 2 1 0 0 10 20 30 40 50 60 70 80 90 100 Throttle open スロットル開度 [ ] position Internal structure of Sensor characteristics intake

20 Operating principle of Hall element Output 出力電圧 voltage [V] Throttle open スロットル開度 [ ] position Internal structure of Sensor characteristics intake throttle position sensor Place a magnet so that the magnet flux density proportional to the travel of an object to be measured (throttle) is applied to the Hall element. Obtain the Hall output voltage proportional to the travel. Page38 Crankshaft speed/camshaft position sensor Crankshaft Camshaft No.1 Firing-TDC No.4 Firing-TDC For Illustration Purpose Only Cam Angle (CA) Page39

ENGINEECUCrankshaft speed/camshaft position sensor 3 cylinder engine 18⁰ 1⁰ 90⁰ CA Crank sensor position at TDC #3 360⁰ CA 360⁰ CA 0 5 10 15 20 25 30 35 40 45 50 55 0 5 10 15 20 25 30 35 40 45 50 55

21 ENGINEECUCrankshaft speed/camshaft position sensor 3 cylinder engine 18⁰ 1⁰ 90⁰ CA Crank sensor position at TDC #3 360⁰ CA 360⁰ CA Cam sensor position at TDC #3 124⁰ CA Crank shaft pulse 176⁰ CA 132⁰ CA 48⁰ CA 184⁰ CA 124⁰ CA 56⁰ CA 176⁰ CA Cam shaft pulse rotor for Bosch CR Cam shaft pulse 4 cylinder engine 18⁰ 1⁰ 108⁰ CA Combustion #1 Crank sensor position at TDC #4 360⁰ CA Combustion #3 Combustion #4 Combustion #2 360⁰ CA Cam sensor position at TDC #4 Crank shaft pulse 124⁰ CA 176⁰ CA 132⁰ CA 48⁰ CA 184⁰ CA 124⁰ CA 56⁰ CA 176⁰ CA Cam shaft pulse Page40 Concept diagram of actuators Actuator Electrical Value Driving power Operation power Voltage Current Electric equipment Oil pressure Air pressure Page41

Actuator types and operating principles Injector Sensor name Supply pump Intake throttle Exhaust throttle (optional part) EGR valve Operating principle Solenoid control (Pull, Hold)

core sprin g Windin g number N core S Friction force bail forc e Current I Strength of magnetic field : W The iron core is moved by a magnetic field generated when the coil is

22 Actuator types and operating principles Injector Sensor name Supply pump Intake throttle Exhaust throttle (optional part) EGR valve Operating principle Solenoid control (Pull, Hold) PWM control (Duty ratio) DC motor (with brush) control DC brushless motor control Page42 Solenoid injector operation principle Principles of solenoid coil magnetic field Moving iron core sprin g Windin g number N core S Friction force bail forc e Current I Strength of magnetic field : W The iron core is moved by a magnetic field generated when the coil is energized. Because there is a friction force, it is necessary to apply a larger current through the coil to make the magnetic field stronger in order to move the iron core quickly. Page43

23 Injector current (1) (2) Pull Hold Injector current 100 µs Time (1) To pull quickly, apply a large current. Because of heat generation, the same current cannot be applied continuously. (2) To hold the lifting position, apply the minimum required current. Apply the injector current in 2 stages. Page44 Supply pump operating principle t / T: Duty ratio solenoid Stroke I/O port (ECU) transisto r PWM control = Voltage waveform Current Fuel discharge Current ON OFF ON OFF ON OFF ON Image figure of voltage waveform and current Current Outline figure of pump characteristics Page45

24 Intake Throttle Special features - Non-contact type position sensor is integrated. Durability is ensured. Bore size associated to 76mm ball bearing has seal function spring Non-contact type Position sensor is integrated -The valve is fully opened by the integrated spring when non-energized. Failsafe is considered dry bearing -The energizing time etc. are calculated and controlled from the present valve position and the target valve position to the motor. ECU controls intake throttle. DC motor gasket Motor and sensor connector Internal structure of intake throttle Page46 EGR valve Special features Hall IC - The motor has no brushes. No risk of sticking of brush contact point rotor magnet bearing - Valve position is fed back by non-contact sensor. No loss of synchronization. Quicker response speed Motor shaft Valve shaft Return spring close -EGR valve is controlled by the ECU based on stroke open a target position as instructed by the ECU. ECU send target valve position to EGR valve. ECU controls EGR valve only by CAN communication. Internal structure of EGR valve Page47

25 THANK YOU FOR YOUR ATTENTION 年 3 月 22 日

MULTIPORT FUEL SYSTEM (MFI) <2.4L ENGINE>

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