Gasoline Engine Management

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Gertrude Rosemary Wheeler
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1 Powertrain Control Gasoline Engine Management Overview The basic design principles of the fourstroke internal combustion engine has remained basically the same since patented in However, the engine control electronics have changed dramatically. The primary motivation is the need to meet legislative exhaust emission levels, provide competitive fuel economy, and meet customer quality expectations. For example, electronic fuel control is an enabler for meeting emissions and fuel economy goals. It also provides a variety of customer comfort features like cruise control, cold startability, fuel shutoff safety feature, and security lockout on startup. Today s vehicles have features such as Gasoline Direct Injection (GDI), knock detection, catalytic converters, oxygen sensors, Exhaust Gas Recirculation (EGR), evaporative emission control systems (canister purge and vent solenoid), misfire detection, and secondary air systems. Tomorrow s vehicles will feature Electronic Throttle Control (ETC), variable valve timing, cylinder deactivation, camless engines, in-cylinder combustion control, electronic stability, collision avoidance, and remote starting. These features will spawn new methods such as autocoding, autocalibration, generic operating systems, floating point math, DSP algorithms, and model-based control. Freescale Semiconductor microprocessors continue to meet these future demands. Key Benefits > Meets legislative exhaust emission levels, provides competitive fuel economy, and meets customer quality expectations > Provides engine subsystems CPU performance that meets EPA regulations, fuel economy, and customer driving satisfaction > Positions vehicle for future applications such as autocoding, autocalibration, generic operating systems, floating point math, DSP algorithms, and model-based control

2 ENGINE CONTROL SYSTEM BLOCK DIAGRAM Voltage Regulators Transient Protection + 12 V Crank Position Vehicle Speed MPC500/ MPC5500 MCU RESET MCU Reset Control Engine Temp. Fuel Injector Ambient Temp. Manifold Absolute Pressure Input Signal Conditioning Application Code Fuel Injector Fuel Injector Throttle Position Mass Air Flow Knock Sensor O2 Sensor API Diagnostic Code API Ignition Coil Ignition Coil Ignition Coil Oil Pressure Sensor Fuel Pressure Sensor Analog Inputs Analog Outputs Amplifier Switch Sensor Output SPI Operating System SCI/CAN/FlexRay Solenoid Driver Solenoid Driver Diagnostic BUS Driver EGR Valve Idle Speed Valve Diagnostic Bus Input Devices Output Devices Freescale Ordering Information Note Part Number Product Highlights Additional Information MC Input Multiple Switch Detection Interface with Suppressed Wake-Up MC33975 MC33993 MPC500 family Note: Search on the listed part number. 22 Input Multiple Switch Detection Interface with Higher Wetting Current 22 Input Multiple Switch Detection Interface Floating Point Unit; 40 MHz or 56 MHz CPU; Compatible with the PowerPC ISA; Available with Code Compression; Up to 1 MB Flash Memory SG2024-2

3 Design Challenges As the demands for better emissions, smoother driving, and fuel economy increase, the complexity of the control strategies increase within the vehicle, affecting the amount of power a microprocessor requires. Engine control applications operate in both time and angle domains. A majority of the processing occurs in various time loops, but some of the most critical functions occur in the time domain. For example, calculating how much fuel to deliver occurs in the time domain, but scheduling the pulses to occur at the proper engine position occurs in the angle domain. Fuel delivery, which began with a simple carburetor, is controlled by Central Port Injection (CPI), Multi-Port Injection (MPI), and Gasoline Direct Injection (GDI). Each injection method, while delivering fuel more accurately, also requires finer control and more sophisticated electronics. To complement the finer fuel control, spark systems have increased in functionality and complexity, from a simple distributor to Coil On Plug (COP) and dual spark systems. Spark systems require feedback to measure nominal current and fault detection. To control fuel and spark with high accuracy, the engine position information must be delivered faster and more accurately. Instead of a crank tooth every 60 degrees, it is common to see crank teeth every 10 degrees or 6 degrees. The CAM signals are becoming more sophisticated, so a vehicle can drive longer on CAM if the crank is lost. Updating fuel and spark pulses on every tooth edge allows fine tuning to occur until the last moment. This level of performance requires a powerful control system. New tools such as autocode generators allow engineers to quickly and easily build more complicated algorithms. These tools have built-in features that enable more advanced math functions and floating point algorithms to be applied. Whether it is engine position, fuel, spark, misfire, knock, or one of the many other subsystems, it is clear that control strategies are demanding more power from the engine controller processor, in both time domain processing and angle domain delivery. Freescale Semiconductor Solution As the leader in the engine controller market, Freescale Semiconductor has developed the MPC500 family of embedded controllers. This family offers the high performance of a 56 MHz PowerPC ISA-compatible core, advanced peripherals, integrated Flash memory (up to 1MB) and fast static RAM (up to 36K) in a single silicon chip. The CPU contains an advanced floating point unit that is essential in the model-based strategies and autocoded control algorithms. The MPC500 family contains built-in calibration support with flexible overlay RAM. The QSMCM modules handle off-chip serial communications for UART and SPI functionality, while vehicle networking is supported with up to three TouCAN modules (CAN version 2.0b) and a J1850 interface. To meet the wide variety of performance and cost targets, the family offers many members that range from a low-end flashless device to a high-end 112 MIPS device with 1MB of integrated Flash. Additional computing power is added to the MPC500 with the Time Processor Unit (TPU3) (up to 3 on MPC565). These units have a 32-bit MicroRISC engine capable of processing 28 million instructions per second. The TPU runs independently and in parallel to the CPU. The TPU/CPU shares data through a dual-access RAM. Specifically designed for scheduling pulses in a circular system, the TPU is ideal for handling the angle domain operation. Each TPU contains 16 channels with independent match and capture hardware, multiple time bases, and a priority round-robin hardware scheduler, to ensure that no task is locked out. The TPU is capable of running an engine even when the CPU has stopped running. Freescale Semiconductor, as the authority in the automotive industry, continues to develop and improve engine controllers. Microprocessors of the future will contain features such as hundreds of megahertz, 100+ K-bytes of RAM, several megabytes of Flash (both on/off the main MCU), DSP support, caches (data and instruction), sophisticated branch predictors, large and powerful pipelines, and coprocessors for timer system, communications, etc. Freescale supports the input signal conditioning and switch sensor outputs with a series of analog devices: MC33972, MC33975, and MC SG2024-3

4 Development Tools Note Vendor MPC555 MPC561 MPC562 MPC563 MPC564 MPC565 MPC566 TPU Metrowerks CodeWarrior for Embedded PowerPC ISA!!!!!!! CodeWarrior for OSEK RTOS!!!!!!! CodeWarrior Development Systems!! OSEKturbo (RTOS)!!!! TPU Low-Level Driver Library Flash Programming CodeWarrior for Embedded PowerPC ISA Flash Programming CodeWarrior for OSEK RTOS Wind River Systems!!!!!!!!!! BDM Debugger SingleStep!!!! BDM Debugger SingleStep with Vision!!!! Flash Programming SingleStep!!! BDM Debugger VisionCLICK!!!! Nexus Debugger VisionCLICK!!! Nexus Debugger SingleStep with Vision!!! Flash Programming VisionCLICK!!! Compiler DiabData!!!!!!! MATRIXX!!!! Simulator SingleStep!!!!!!! Lauterbach BDM Debugger Trace32!!!!!!!! Nexus Debugger Trace32!!!!!!! Code Trace (with Bus access)!!!!!!! Code Trace (Nexus)!!!!!!! Axiom Manufacturing Low-Cost Evaluation Board!! Mid-Range Evaluation Board!! Full-Feature Evaluation Board!!!!!!! Ashling Microsystems BDM Debugger Opella, Genia, and Vitra!!!!!!! Nexus Debugger Vitra (w/trace)!!!! Nexus Debugger Opella, Genia!!! Green Hills Software IDE, Debugger Multi!!!! Compiler C/C++/EC++!!!! P&E Microcomputer Systems Low-Cost Debugger!!!! Flash Programming Tools!!! GNU Compiler/Debugger!!!! ASH WARE TPU Simulator Note: Search on the listed product name.!! SG2024-4

5 Development Tools (continued) Note Vendor MPC555 MPC561 MPC562 MPC563 MPC564 MPC565 MPC566 TPU ETAS ErCOSEK!!!! Calibration Tools (ETK)!!!! Calibration Tools (ETK) Nexus!!!! LabCar Calibration!!!!!!!! LabCar Autocode!!!!!!!! Simulink Hardware in the Loop!!!!!!!! Simulator Hardware in the Loop!!!!!!!! MicroAutobox Calibration (Nexus)!!!!!!!! dspace dli TargetLink!!!! Logic Analyzer!!!! Agilent Technologies Logic Analyzer!!!! Inverse Assembler, Source Correlation!!!! Emulation Probe (BDV)!!!! Tektronix Logic Analyzer!!!! Abatron AG BDM Support!!!! Accelerated Technology Nucleus (RTOS)!!!! Note: Search on the listed product name. Disclaimer This document may not include all the details necessary to completely develop this design. It is provided as a reference only and is intended to demonstrate the variety of applications for the device. Third Party Support Vendor Metrowerks Axiom Manufacturing Wind River Systems Green Hills Software Lauterbach Accelerated Technology Ashling Microsystems ASH WARE GNU ETAS dspace P&E Microcomputer Systems Contact Information ( ( ( ( ( ( ( ( ( ( ( ( SG2024-5

6 Online Topics Description Analog Automotive MPC500 MPC500 User Group TPU Microcoding Made Easy Location Related Documentation Note Document Number Description Additional Information APDPAK Analog Pitch Pak SG187 Automotive Product Selector Guide Note: Search on listed document number. Learn More: Contact the Technical Information Center at or For more information about Freescale products, please visit Freescale and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. Freescale Semiconductor, Inc All rights reserved. SG2024 REV 2 6/2005 June2005

Contents. Preface... xiii Introduction... xv. Chapter 1: The Systems Approach to Control and Instrumentation... 1

Contents. Preface... xiii Introduction... xv. Chapter 1: The Systems Approach to Control and Instrumentation... 1 Contents Preface... xiii Introduction... xv Chapter 1: The Systems Approach to Control and Instrumentation... 1 Chapter Overview...1 Concept of a System...2 Block Diagram Representation of a System...3