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1 ELECTRONIC FUEL PUMP CONTROLLER FOR RETROFIT EFI SYSTEM MOTORCYCLE MUHAMMAD ZULKHAIRI BIN ZULKIFLI UNIVERSITI TEKNOLOGI MALAYSIA

2 UNIVERSITI TEKNOLOGI MALAYSIA DECLARATION OF THESIS / UNDERGRADUATE PROJECT PAPER AND COPYRIGHT Author s full name : MUHAMMAD ZULKHAIRI BIN ZULKIFLI Date of birth : 30 TH NOVEMBER 1990 Title : ELECTRONIC FUEL PUMP CONTROLLER FOR EFI SYSTEM MOTORCYCLE Academic Session : 2013/2014 I declare that this thesis is classified as: CONFIDENTIAL RESTRICTED (Contains confidential information under the Official Secret Act 1972)* (Contains restricted information as specified by the organization where research was done)* OPEN ACCESS I agree that my thesis to be published as online open access (full text) I acknowledged that Universiti Teknologi Malaysia reserves the right as follows: 1. The thesis is the property of Universiti Teknologi Malaysia. 2. The Library of Universiti Teknologi Malaysia has the right to make copies for the purpose of research only. 3. The Library has the right to make copies of the thesis for academic exchange. Certified by: ASSOC PROF IR DR HAZLINA SELAMAT (NEW IC NO. /PASSPORT NO.) (NAME OF SUPERVISOR) Date : 20 th JUNE 2014 Date : 20 TH JUNE 2014 NOTES : * If the thesis is CONFIDENTAL or RESTRICTED, please attach with the letter from the organization with period and reasons for confidentiality or restriction.

3 I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in terms of scope and quality for the award of the degree of Bachelor of Engineering (Electrical - Control & Instrumentation) Signature : Name : ASSOC PROF IR DR HAZLINA SELAMAT Date : 20 th JUNE 2014

4 ELECTRONIC FUEL PUMP CONTROLLER FOR RETROFIT EFI SYSTEM MOTORCYCLE MUHAMMAD ZULKHAIRI BIN ZULKIFLI A report submitted in partial fulfillment of the requirements for the award of the degree of Bachelor of Engineering (Electrical Control & Instrumentation) Faculty of Electrical Engineering Universiti Teknologi Malaysia JUNE 2014

5 ii I declare that this thesis entitled Electronic Fuel Pump Controller for Retrofit EFI System Motorcycle is the results of my own research except as cited in the references. The thesis has not been accepted for any degree and is not concurrently Signature : submitted in candidature of any other degree. Name : MUHAMMAD ZULKHAIRI BIN ZULKIFLI Date : 20 th JUNE 2014

6 iii Dedicated to my beloved parents, Mr. Zulkifli Ishak & Mrs. Razimah Wahab.

7 iv ACKNOWLEDGEMENT First and foremost, I would like to express my gratitude towards my supervisor, Assoc. Prof. Ir. Dr. Hazlina Selamat, who has given me guidance and has offered valuable advices for this project. I am very grateful as I have learnt a lot from this work. Her critics helped me to do the project in a different way and show some uniqueness in my project. I would like to thank all my friends who had helped me in this project by giving suggestion and moral support. Without them, I would be difficult to finish my project as it today. Lastly, thanks to all my family members which is my siblings that encourages me to work hard so that I can be their idol. Thank you.

8 v ABSTRACT In Malaysia, motorcycle with the capacity of 250cc below has become the main daily transportation because of the increase in gasoline price recently. Most of the motorcycle below 250cc use low technology carburetor that contribute to low operating efficiency, high fuel consumption and high exhaust emission. To overcome this problem, Retrofit Fuel Injection System has been introduced by replacing the carburetor with a fuel injection system as the fuel delivery system. The electronic fuel pump controller is part of the Retrofit Fuel Injection System that uses Proportional-Integral-Derivative (PID) controller to maintain the pressure supplied to the fuel injector at 2.5 bars for all engine operating conditions as the fuel injector needs pressure to operate efficiently. PID controller is used to eliminate the steady state error and increase the stability of the system as well as to reduce the current consumption of the fuel pump. Fuel pressure will be the control variable and the manipulated variable is the voltage that is supplied to the fuel pump. MATLAB/Simulink software has been used to verify the performance of the PID controller. The results show that the output pressure of the systems follows the desired pressure or reference pressure with good dynamic performance.

9 vi ABSTRAK Di Malaysia, motosikal dengan kapasiti 250cc ke bawah telah menjadi pengangkutan utama setiap hari kerana harga petrol yang semakin meningkat barubaru ini. Kebanyakan motosikal di bawah 250cc menggunakan karburetor berteknologi rendah yang menyumbang kepada penggunaan bahan api yang tinggi dan pencemaran ekzos yang tinggi. Untuk mengatasi masalah ini, Sistem Suntikan Bahan Api retrofit telah diperkenalkan dengan mengubah motosikal yang menggunakan karburetor kepada sistem suntikan bahan api (FI). Pengawal Pam bahan api elektronik adalah sebahagian daripada Sistem Suntikan Bahan Api Retrofit yang menggunakan pengawal Proportional-Integral-Derivative (PID) untuk mengawal tekanan yang dibekalkan kepada penyuntik bahan api pada kadar 2.5 bar untuk setiap keadaan enjin kerana penyuntik bahan api memerlukan tekanan untuk beroperasi dengan cekap. Pengawal PID digunakan untuk meningkatkan kestabilan dan juga untuk mengurangkan penggunaan bahan api. Perisian MATLAB/Simulink digunakan untuk menjalankan simulasi keatas pengawal PID. Perisisan MATLAB/Simulink menunjukkan bahawa tekanan yang dihasilkan oleh sistem berada pada tekanan yg diperlukan.

10 vii TABLE OF CONTENTS CHAPTER TITLE PAGE TITLE DECLARATION DEDICATION ACKNOWLEDGMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLE LIST OF ABBREVIATIONS LIST OF APPENDICES 1 INTRODUCTION Background Problem Statement Objective Scope of Work Thesis Outline 5 i ii iii iv v vi viii x xii xiii xiv 2 LITERATURE REVIEW Introduction Development of Fuel Injector and Fuel Pump for Small Engine Motorcycle 7

11 viii 2.3 Modeling of Pump Drive Motor Method of Controlling Fuel Pump Sliding Mode Control Method Active Disturbance Rejection Fuzzy Controller Returnless Fuel Supply Control System Digitally Controlled Fuel Metering Pump Low Pressure Fuel Pump Control Smart Automotive Switch (SAS) Conclusion 14 3 METHODOLOGY Introduction Project Flow Mathematical Modeling of Fuel Pump Proportional Integral Derivative Controller Ziegler-Nichols Tuning Method MATLAB/Simulink Simulation Software Proteus Circuit Simulation Software Circuit Development 25 4 RESULT AND DISCUSSION Introduction Result of Mathematical Modeling Simulation Result 32 5 CONCLUSION AND FUTURE WORK Conclusion Future Work 37

12 ix 6 PROJECT MANAGEMENT Introduction Project Schedule Cost Estimation 40 REFERENCES Appendices

13 x LIST OF FIGURES FIGURE NO TITLE PAGE 1.1 Malaysia Vehicle Distribution In Year Motorcycle that converted into Retrofit Fuel Injection System Comparison Between Current Product With Newly Develop Product Block Diagram for SMC System MTG With ADRC System Fuel Injection Pressure and Pump Rotational Speed After Implement SMC Metering Pump Design Configuration Flowchart of The Whole Project Fuel Pump Block Diagram Closed Loop System Block Diagram Simulink Library Browser MATLAB/Simulink User Interface Simulation Output Panel MATLAB/Simulink Programming Language Configuration Proteus Circuit User Interface Load C Programming Into Microcontroller In Proteus Full Schematic Diagram PCB Layout from Eagle Software Finished PCB 27

14 xi 3.13 Complete Circuit with Component on The PCB Power up The Complete Circuit Graph of Current vs. Voltage Graph of RMS Current vs. RMS Voltage Graph of Pressure vs. Voltage System Block diagram Output Response Using PID controller Output Response Using PI controller 34

15 xii LIST OF TABLES TABLE NO TITLE PAGE 1.1 Specification of the motorcycle engine Description of motor parameter Effect of PID controller gain on system response Ziegler-Nichols tuning chart Parameter value of the fuel pump Result of PID and PI controller tuning Comparison between PID and PI controller Project Gantt chart (semester one) Project Gantt chart (semester two) Cost estimation for electronic board 41

16 xiii LIST OF ABBREVIATIONS EFI CDI SI SMC ADRFC PID PI PCB MATLAB AC DC RMS EMF ECU FMV PWM PCU SAS A V Psi Pa Electronic Fuel Injection Capacitive Discharge Ignition Spark Ignition Sliding Mode Control Active Disturbance Rejection Fuzzy Controller Proportional Integral Derivative Proportional Integral Printed Circuit Board Math Laboratory Alternating Current Direct Current Root Mean Square Electromagnetic Field Electronic Control Unit Fuel Metering Valve Pulse Width Modulation Pump Control Unit Smart Automotive Switch Ampere Voltage Pound per square inch Pascal

17 xiv LIST OF APPENDICES APPENDIX TITLE PAGE A MATLAB/Simulink Block Diagram 44 B Schematic Diagram of Electronic Board 45

18 CHAPTER Background INTRODUCTION In Malaysia, motorcycles are one of the main transportation in our daily life. Most of the time, motorcycle become the first choice for daily transportation to work compared to car because of the rise in fuel price recently. According to the Malaysian Road Transport Department report in year 2008, more than 8 million motorcycles have been registered and the number of the motorcycles registered increased annually by 500,000 units. This number covered 47% of all vehicles in Malaysia [1, 2].

19 2 Figure 1.1: Malaysia vehicle distributions in year 2010 [2] Most of the motorcycle in Malaysia use small engine capacity about 90cc to 150cc that equipped with low technology carburetor. This will contribute to low operating efficiency, high fuel consumption and high exhaust emission. The problem can be solved by using the low-cost retrofit fuel injection system as shown in Figure 1.2. The system modified the motorcycle with the carbureted system into retrofit fuel injection system. All conventional part of the motorcycle is retained except for carburetor and manifold part that needs to be changed to fit into fuel injection system [3]. Figure 1.2: Motorcycle that converted into Retrofit Fuel Injection System

20 3 To implement the system with small engine motorcycle, retrofit fuel injection system has to be compact, low energy consuming and low cost [4]. Fuel pump is an important part in the fuel injection system. It will pump the fuel in the fuel tank and maintain the fuel pressure to the fuel injector. For the retrofit fuel injection system, fuel injector needs pressure at 2.5 bars to operate efficiently and in-tank fuel pump is used. 1.2 Problem statement Motorcycle fuel pump consumes high power to operate and this has become a problem for small engine motorcycle that uses small capacity battery. Usually, fuel pressure regulator is used to maintain pressure in the fuel rail. Fuel pump will always run at high speed regardless the load of motorcycle engine when using fuel pressure regulator [5]. Automotive fuel pump required 10A average current to operate. Meanwhile, motorcycle fuel pump required only quarter of the current to operate. By using pressure regulator, the fuel pump is quite inefficient and most of the power will contribute to heat loss. As a result, it will reduce the life expectancy of the fuel pump [5]. 1.3 Objectives The objectives of this project are: I. To control the pressure delivered to fuel injector using closed loop system. II. To reduce current consumption by the fuel pump.

21 4 III. To improve the motorcycle performance by supplying fuel according to the fuel injection flow rate for all engine operating condition. 1.4 Scope of Work Electronic fuel pump controller only applicable for small engine motorcycle that using retrofit fuel injection system. The specifications of the motorcycle engine are shows in Table 1.1. The retrofit fuel injection system is designed for 4-stroke 1 cylinder small gasoline spark ignition (SI) engine [3]. The electronic fuel pump controller consists of 3 major parts, which are hardware (electrical circuit), software programming to implement digital control system and system analysis. Table 1.1: Specifications of the motorcycle engine Engine Parameter Engine cycle Bore and stroke Specification 4 Cycle OHC mm Engine displacement cc Ignition system CDI 1.5 Thesis Outline This thesis consists of 5 chapters which are: i. Chapter 1: Introduction ii. Chapter 2: Literature Review iii. Chapter 3: Methodology

22 5 iv. Chapter 4: Results and Discussion v. Chapter 5: Conclusion and Recommendation Introduction consists of background of study, problem statement, objectives, scope of work and thesis outline. Literature reviews consist of previous research that has been made about the fuel pressure control system. Methodology of the project explains about how the project has been organized and the method that has been used in detail. Result and Discussion discuss about the final result obtained from this project. Lastly, Conclusion and Recommendation will discuss the overall project gain and ways to improve it.

23 CHAPTER Introduction LITERATURE REVIEW Fuel pressure regulator can be used in the Retrofit Fuel Injection System to ensure the correct amount of pressure delivered to the fuel injector. Fuel pump efficiency will decrease when using fuel pressure regulator because most of the power will lead to heat loss. To overcome this problem, electronic fuel pump controller is proposed to replace the function of the fuel pressure regulator. There are many methods to control the fuel pressure electronically. In this chapter, the related work that similar to this project is discussed to develop the controller for fuel pressure control system.

24 7 2.2 Development of Fuel Injector and Fuel Pump for Small Engine Motorcycles In order to apply fuel injection system for the small engine motorcycle, there are two important parts, which are fuel injector and fuel pump. Conventional parts are excessively bulky and restrict the flexibility to mount on the small engine motorcycle. The conventional parts were not convenience to use on the small motorcycle. Therefore, the development of a compact fuel injector and compact fuel injector was studied [6]. To produce compact fuel injector, there are several aspects that need to be improved to achieve desired performance. The aspects are: I. Simplification of plunger stopper system II. III. Optimization of magnetic circuit Reduction of pressure loss in fuel passages By improving these three aspects, the compact fuel injector system can be produced. Figure 2.1 shows the comparison between conventional products and newly develop product.

25 8 Figure 2.1: Comparison between Current Product with Newly Develop Product 2.3 Modeling of Pump Drive Motor To develop the closed loop system, mathematical modeling of the system needs to be identified. Fuel pump is driven by DC motor and the electrical characteristic can be obtained as shown in the following equation. (2.1) From equation of the electromagnetic torque,, the motion of the fuel pump system equation can be derived. By according to Newton s laws of motion the equation below was obtained. (2.2)

26 9 By substituting equation (1) into equation (2), the following equation is obtained[7, 8]. Table 2.1: Parameter Description L J D Θ or Description of Motor Parameters Input Voltage Armature Current Armature inductance Armature Resistance Rotor Inertia Viscous Friction Co-efficient Coulomb Friction Induced Voltage Constant Cam Rotational Angle Total Load Torque Motor Torque Constant (2.3) 2.4 Method for controlling Fuel Pump In order to control the fuel pump, there are many methods that can be used. In this section the techniques to control fuel pump are discussed briefly to gain knowledge of current technology of fuel pump control method.

27 Sliding Mode Control Method (SMC) Fuel pressure in the fuel supply system may vary because of the fuel temperature or the fuel injection flow rate. The conventional proportional-integralderivative (PID) control is difficult to applied in the system because fuel supply system is non linear that make the system parameter to fluctuate. Moreover, when the system of parameter is fluctuate, the gain of PID control will also changed simultaneously with the fluctuated system parameter. In order to overcome this problem, the sliding mode control method was used. This method is deemed to be robust against system parameter fluctuations and applicable to linear and non- linear systems. Fuel pressure in supply control system is controlled by fuel injection flow rate and the pump shaft rotational speed, this parameter is observed by a pressure sensor [8]. Figure 2.2: Block diagram for SMC system From the figure above, the error of the system is expressed by,, where is the target pressure in the non-linear system. From SMC method, the energy consumption of the fuel pump reduced significantly during high-speed engine operation, hence improving the overall engine performing.

28 Active Disturbance Rejection Fuzzy Controller (ADRFC) Micro turbine generator system needs a certain fuel pressure to operate. The fuel pressure is control by its own system that received command signal from the engine control system and the feedback signal from the pressure sensor. For simple process control, Proportional-integral-derivative controller (PID) was easy to implement but for MTG system PID controller is not effective. The output of the MTG system changed in large range such as loading and unloading. This will contribute interference to the input and output signal of the system. By combining the active disturbance rejection controller (ADRC) and fuzzy control, the active disturbance rejection fuzzy controller is proposed (ADRFC). The non-linear PID controller is replaced by Fuzzy PID controller while the tracking differentiator (TD) and extended state observer (ESO) are remaining unchanged [9]. MTG system using ADRFC are show in Figure 2.3. Figure 2.3: MTG with ADRC system

29 Returnless Fuel Supply Control System Returnless fuel supply control system will eliminates the excessive fuel from the fuel injector flowing to the supply tank through a return line. The system only supplies the fuel according to the fuel injection flow rate that need by the fuel injector to operate. The system used sliding mode control (SMC) as a controller because it is robust against system modeling error and disturbance. Figure 2.4: Fuel injection pressures and pump rotational speed after implement SMC From the Figure 2.4, the pressure of the fuel injection was constant at 3 MPa. The rotational speed of the motor shows that when the pressure in the fuel rail meets the required pressure, the pump will stop. The fuel pump will start operates when the pressure in the fuel rail is decreased.

30 Digitally Controlled Fuel Metering Pump Digital controller fuel pump use microstepping driver to control stepper motor that driven the fuel pump. Stepper motor fuel pump is used because it can be control by using digital signal as well perform the function of fuel pump control unit. The system is simple as it is not required the feedback loop in order to determine the fuel pressure in the rail [10]. Figure 2.5 shows the fuel metering pump configuration. Figure 2.5: Metering Pump Design Configuration[10] The advantage of the system is the pressure of the fuel can be estimated based on the speed of the stepper motor in the fuel pump. Meanwhile, the disadvantage of this type of control method is that the stepper motor driver is too expensive Low Pressure Fuel Pump Control In car engine, there are two types of pump, which are low pressure pump and high pressure pump. Low pressure pump always run at the maximum fuel rate regardless the engine fuel request. Meanwhile the high pressure pump is control by the Fuel Metering Valve (FMV) based on the signal from the Electronic Control Unit (ECU). In order to minimize the fuel consumption, the fuel flow of low pressure

31 14 pump is varied by controlling the low pressure fuel pump speed trough Pulse Width Modulation (PWM) technique [11]. To overcome the problem of energy lost caused by the circulated fuel in the fuel rail, the fuel rate from low pressure fuel pump is controlled by using motor speed regulation technique [11]. This technique is performed using Pump Control Unit (PCU) by regulating the fuel pump speed in order to deliver the correct amount of fuel that required by the engine Smart Automotive Switch (SAS) In the conventional fuel pump system, the fuel pump will start to operate continuously when the engine is started. This will lead to a waste of electrical power. By introducing the SAS system, the efficient power consumption is achieved. The pressure, current and power of the fuel pump is controlled using PWM, so that the fuel pump motor will operates consumption is minimized [12]. in the region where the power 2.5 Conclusion Based on the system from the previous research, there are several techniques that can be adapted in the electronic fuel pump controller. The control method using PWM is widely used in the previous research in order to control the fuel pump. There are several high level technologies of controller used in order to control the fuel in the fuel rail. The technologies applied for multiple fuel injectors. Therefore,

32 15 the techniques are not suitable for the Electronic Fuel Pump controller because the pressure is supplied to the single fuel injector. Thus, a simpler PID controller is proposed with the used of PWM to control the current, power consumption and pressure of the fuel pump.

33 CHAPTER Introduction METHODOLOGY This chapter will explain the flow operation of this project from the beginning. In this chapter, the development of the Electronic Fuel Pump controller is discussed based on the previous research by others in the literature review. In addition, the techniques that are used in this project will also be discussed. This chapter also includes the appropriate project flows that need to fulfill in order to achieve the actual result. 3.2 Project Workflow The research involved mathematical modeling and the simulation of the fuel pressure controller. The research is initiated by collecting and documenting knowledge of previous research regarding the fuel pump controller. The sources are

34 17 obtained from books, journals, conferences and thesis. Figure 3.1 shows the flow of the whole project from the beginning until the end. Figure 3.1: Flowchart of the whole Project The system needs to be able to maintain constant pressure in the fuel line at 43 Psi. The value of the pressure is important to ensure the fuel injector will work efficiently. In order to achieve this requirement, the closed loop system that employs PID controller is designed.

35 Mathematical Modeling of Fuel Pump To run the simulation of the system, the mathematical modeling that represents the actual system need to be identified. Fuel pump consists of DC motor and rotor blade to deliver the gasoline to the fuel injector. The mathematical modeling of the fuel pump is deriving based on the DC motor equation[8]. (3.1) Where, I a is armature current, R a is armature resistance, L is armature inductance, U a is voltage supply and K e the back emf constants. Torque that produce by the motor can be obtained based on the equation below: (3.2) Where, T is torque produce by the motor, K t motor torque constant and I a armature current. The relationship between the voltage and pressure of the fuel pump are assumed to be linearly proportional The block diagram of the fuel pump model was shown in figure 3.2., where K x is pressure constant. Figure 3.2: Fuel Pump Block Diagram

36 Proportional-Integral-Derivative (PID) Controller In this project, fuel pump will control by the closed loop system. The PID controller can be implementing in this project as close loop system. PID controller use proportional, derivative and integral operation in order to correct the system error and to obtain the desired output. Each operation has respective gain that typically labeled as. These controls are modeled by the following equation: (3.3) Where the e(t) is the input error at the output and τ is simply used as integration variable. Each controller has different effect to the system. The effect of each system will be discussed in the Table 3.1 [13]. Table 3.1: Effect of PID controller gain on system response Parameter Rise Time Overshoot Settling Time Decrease Increase Little Changed Steady-state Error Decrease Stability Degrade Decrease Increase Increase Eliminate Degrade Minor Decrease Decrease No Effect Improve for Changed is small 3.5 Ziegler-Nichols Tuning Method For tuning the PID controller, Ziegler-Nichols tuning method was used to determine the value of K p, t i, and t d. By Laplace the equation (3), the transfer function of the PID controller was obtained[14].

37 20 (3.4) From the simulation of the closed loop system, the value of the critical gain K u, and critical period P u was obtained. The simulation was performed using Matlab/Simulink software that easy and user friendly. To get the PID tuning value for K p, t i, and t d, the equation of the Ziegler-Nichols chart from Table 3.2 was used. Table 3.2: P control K u /2 Ziegler-Nichols Tuning Chart K c t i t d PI control K u /2.2 P u /1.2 PID control K u /1.7 P u /2 P u /8 To perform the Ziegler-Nichols tuning method, the closed loop system transfer function need to be identified [15]. The closed loop system represent the electronic fuel controller are show in Figure 3.3 and the transfer function of the closed loop are shown below: (3.5) Figure 3.3: Closed Loop System Block Diagram

38 MATLAB/Simulink Simulation Software In order to perform system simulation, MATLAB/Simulink software was used. The simulation software was used because of the interface of the software that easy to be understand, user friendly and the software can produce the C programming that will be used with the Arduino Microcontroller. MATLAB/Simulink software support the Arduino package that can be easy to integrated between both hardware and software for further development. Simulink provide user with block diagram environment in order to do multidomain simulation and model based design. MATLAB/Simulink is used in this research because it supports simulation, continuous test, automatic code generation and ability to verify the embedded systems. Figure 3.4 shows the library browser of the simulink that provide various function based on block diagram. The function include the mathematical operation, continues system, and many more. Simulink also provided support package for Arduino Uno and Mega Figure 3.4: Simulink Library Browsers

39 22 User interface of the MATLAB/Simulink was shows in Figure 3.5. In order to simulate the mathematical model, the model needs to build using the block diagram function in the MATLAB/simulink library browser. Block diagram is build by using drag and drop the block diagram into user interface panel. Figure 3.5: MATLAB/Simulink User Interface Scope block diagram was used to display the output of the mathematical model that has been build. Example of the scope interface was shows in Figure 3.6. By selecting Run the simulation will started and the result will show in the scope interface. Meanwhile, to interface the MATLAB/simulink with microcontroller such as Arduino, the Build button is used to compile the entire block diagram into.hex file and upload it into microcontroller.

40 23 Figure 3.6: Simulation Output Panel MATLAB/Simulink support various programming language, thus code generation configuration need to be made. This configuration was used to select desired language code that suitable for the microcontroller used in the system. Figure 3.7 shows the configuration parameter panel that need filled before build the.hex file. Since this research only involve in simulation, the.hex file that produce will be used in the Proteus Circuit simulation software. Figure 3.7: MATLAB/Simulink Programming Language Configurations

41 Proteus Circuit Simulation Software Circuit simulation was important to verify circuit functioning before developed the actual circuit. Proteus software was able to simulate SPICE (Simulation Program with Integrated Circuit Emphasis), animated components and various microcontroller models. Proteus support many electronic component package that produce by electronic company such as Microchip, Fairchild, Texas Instruments and others. Moreover, the Proteus software has the ability to convert the schematic diagram into printed circuit board (PCB) layout. Figure 3.8 shows the user interface of the Proteus software. The ability of the software to do simulation on the microcontroller make the circuit design becomes easy and simple. Hence the circuit schematic has finished developed,.hex file obtained from the MATLAB/Simulink software was loaded into the virtual microcontroller before circuit simulation can be made. Figure 3.9 shows how to load.hex file into virtual PIC18F2520. Figure 3.8: Proteus Circuit User Interface

42 25 Figure 3.9: 3.8 Circuit Development Load C programming into Microcontroller in Proteus After satisfied with the simulation result, the actual circuit is developed. There several ways to build the actual circuit, through Proto board, Donut board or using Printed circuit board (PCB). In this research, circuit using PCB was chosen because troubleshooting the circuit becomes easy by using PCB. Meanwhile, the circuit will be put on the motorcycle, so that the circuit must be rugged enough in any condition. Figure 3.10 shows schematic diagram using Eagle s Software before converted into PCB layout.

43 26 Figure 3.10: Full Schematic Diagram There are two ways to convert schematic circuit into PCB layout. First method by using auto route function that provided by the Eagle s software and second method by using manual method. Manual method is more accurate, where the user can choose the best size of copper but limited for simple circuit that can be easy routed manually. While, by using auto route function, the complex circuit will become easy to convert into PCB layout. Figure 3.11 shows the complete PB layout that will use in the PCB making. Figure 3.11: PCB Layouts from Eagle Software

44 27 From the software, the PCB layout will convert into PCB board. There are many process involve to make the PCB board. The process will be explain briefly, the finished PCB layout must be printed on the glossy paper and attach to the copper board. The attach PCB layout on the copper board are then inserted into laminating machine until the printed PCB layout on the glossy paper stick to the copper board. After that the etching process will take over to remove the unwanted copper on the copper board, the etching process take about 10 to 15 minutes. To complete the process, the PCB board will undergo drilling process using PCB stand drill. Figure 3.12 shows the condition of the complete PCB board after undergo process stated above. Figure 3.12: Finished PCB Before putting the electronic component on the PCB board, the continuity test needs is done using multimeter. Continuity test is important to make sure all connection on the PCB connected to the correct location. The circuit complete when the entire component fit in and solder on the PCB board. Before inserted the microcontroller chip into IC base, voltage at each of the IC base was tested to make sure the voltage across the base not exceed 5V, because microcontroller chip is operated at 5V to 0V voltage ranges. The complete PCB board is shows in Figure 3.13.

45 28 Figure 3.13: Complete circuits with components on the PCB After done with troubleshooting process, the electronic board was power up and the programming in the.hex file will load into the microcontroller. Figure 3.14 shows the complete electronic board with the programming. Figure 3.14: Power up the Complete Circuit

46 CHAPTER Introduction RESULTS AND DISSCUSIONS In this chapter, the result mathematical modeling of the fuel pump and the result of the simulation of the Electronic Fuel Pump controller are given in detail. The simulation results were obtained from MATLAB/Simulink software that has been discussed in Chapter Result of Mathematical Modeling To obtain the mathematical modeling of the fuel pump, certain parameters need to be identified. Before proceed to the mathematical modeling result, the transfer function of the fuel pump was derived. (4.1)

47 30 The value of armature resistance, was determined from the gradient of the graph in figure 4.1. The result of the graph was determined by experiment where the fuel pump current (I) is measure while the supply voltage (V) is increase. Current, (A) Figure 4.1: Graph of Current (I) vs. Voltage (V) The inductance value of the fuel pump is obtained through the experiment using AC supply. By using low voltage AC source to the armature winding of the DC motor in the fuel pump the value of inductance was defined. The AC current that flow through the armature is recoded while the AC voltage source increased. Graph in Figure 4.2 is plotted based on the result obtained. From the gradient of the graph, the inductance value Fuel Pump DC Experiment Voltage (V) is obtained from the equation below. Current (I) (4.2) Where Z is impedance value of the armature winding and ω is radian per seconds obtain using frequency value of 50Hz.

48 Fuel Pump AC Experiment Current, IRMS Figure 4.2: Graph of RMS Current (I) vs. RMS Voltage (V) Pressure and voltage was assumed to be linear, so that the experiment to find the relationship between voltage and pressure is conducted. The relationship obtain from the graph is P = K x V a, constant value of the pressure and voltage is obtained from the gradient of the in figure 4.3. Voltage, VRMS Pressure,Psi Finding Parameter KX I(mA) Pressure(Psi) Voltage, V Figure 4.3: Graph of Pressure (Psi) vs. Voltage (V) From the experiments conducted, the value of the parameters of the fuel pump was obtained. There were some parameters that been obtained through the datasheet of the motor that has similarity with the fuel pump such as 12V operating

49 32 voltage that consume about 1.8 Ampere. All the parameter of the fuel pump has been summarized in table 4.1. Table 4.1: Parameter Value of the Fuel Pump Fuel Pump Parameters Parameters Value Armature Resistance, Armature Inductance, 2.5 Ω 0.02 Henry Motor Inertia, 0.01 kg.m 2 Motor Friction Coefficient, Back EMF Constant, Motor Torque Constant, Pressure Voltage Constant, 0.1 N.m.s 0.01 V/rad/s 0.01 N.m/ amp 30 Kpa/V By substitute all the parameters in the table 4.1 into equation (1), the transfer function of the fuel pump was obtained as below: 4.3 Simulation Results (4.3) Block diagram of the Electronic Fuel Pressure Controller has build as shown in Figure 4.4. The simulation will demonstrate the condition of the pressure in the fuel rail to the fuel injector. When the fuel injector, inject the fuel into the motorcycle engine there are slightly drop of pressure in the fuel rail. This controller will make correction so that the output pressure maintain at desired pressure at 43Psi.

50 33 Figure 4.4: System Block Diagram PID and PI controller were tuned using Ziegler-Nichols tuning method that has been explained in chapter 3, the result of K p, t i, and t d of the PI and PID controller are shows in table 4.2. Table 4.2: Result of PID and PI Controller Tuning PI PID K p t i t d From the result in table 4.2, the transfer function of the PID and PI controller were obtained. (4.4) (4.5) By using the PID block diagram, all the value of PID and PI using Ziegler- Nichols was used as the controller in the system block diagram simulation. The result of the simulation obtained were shows in figure 4.5 and figure 4.6 respectively.

51 34 Figure 4.5: Output Response Using PID Controller Figure 4.6: Output Response Using PI Controller Comparison between these two controllers was calculated and shows in table 4.3. The result between the two controller was identical but in term of stability the PID controller more reliable because of the percentage overshoot (%OS) of the system is lower compared to PI controller. PI controller damping effect of the output response settle more quickly than PID controller but the response speed of the two controllers was same.

52 35 Table 4.3: Comparison between PID and PI Controller PI PID Percentage Overshoot, %OS 18% 4.65% Rise Time,Tr seconds seconds Settling Time, Ts seconds seconds Steady State Error 0 0

53 CHAPTER Conclusion CONCLUSION AND RECOMMENDATION The simulation result of the Electronic Fuel Pump controller shows that by using the PID controller the output response more stable with percentage overshoot less than 10 percent compared to the PI controller. The circuit for the electronic fuel pressure controller has designed properly and tested, but the real application test was not conducted. With the help of the electronic pressure controller the performance of the fuel injector will increase and the performance of the motorcycle engine also will increase significantly. The electronic fuel pressure controller can be integrated with the Electronic Control Unit (ECU) to save cost and space consumption, but the microcontroller that will be used must be fast enough to perform the tasks.

54 Future Work Currently the system only undergoes the simulation system because of the Retrofit Fuel Injection System still in the development process. It will be difficult to tune the motorcycle performance when the Electronic Fuel Pump controller is involved. To apply this system to the motorcycle, the motorcycle needs to be well tuned and in the stage of the final prototype. Microcontroller that used in this research can be converted to more powerful microcontroller such as ARM processor because of it operation speed is more faster. The faster the microcontroller speed the better for the system to operate efficiently because the micro controller needs to perform many tasks in one cycle of operation.

55 CHAPTER Introduction PROJECT MANAGEMENT The objective of the project management was to make sure the project achieved the entire target effectively. Project management consists of project planning, organizing and controlling all the resource, so that the project can be finished in a specified time period. The project scheduled can be tabulated on the Gantt chart that will give the clearly explanation about project activity. This will give clear guideline in time management. There are other aspect that important in project management, where is the cost estimation. Cost estimation is important in order to make sure all the resource where used effectively and efficiently.

56 Project Schedule Table 6.1 shows project Gantt chart for semester one. The progress of the Project start of the second week with a final year project briefing, most of the time were involved with observing retrofit fuel injection system development because the motorcycle prototype was still in development. It takes long delay to find the parts for the motorcycle, most of the motorcycle parts were custom made to fit the fuel injection system requirement. Table 6.1: Project Gantt chart (Semester One) Sep-13 Oct-13 Nov-13 Dec-13 Week Task FYP Briefing First meeting with supervisor Project Background Study Literature Review Observing Retrofit Fuel Injection system development Project Proposal And NABC Circuit Simulation And Programming Market Survey For Retrofit Fuel Injection Kit Preparation For FYP 1 Presentation Project Presentation FYP Table 6.2 shows the project Gantt chart for semester two. In semester two, long time delay was expected because most of the task needs more time to finish such as modeling the fuel pump and circuit troubleshooting.

57 40 Table 6.2: Project Gantt chart (Semester Two) Jan-14 Feb-14 Mar-14 Apr-14 May-14 Week Task Modeling the fuel pump Circuit Design and troubleshooting PID and PI controller tuning using Ziegler- Nichols System Simulation Analysis and collecting the data Preparation for FYP 2 Presentation MIRCED Exhibition (FYP 2 Presentation) Writing Thesis 6.3 Cost Estimation Table 6.3 shows the cost estimation to assemble circuit for Electronic Fuel Pressure Controller. The expensive part of the component was a microcontroller because of the semiconductor technology. While, the cost of the PCB board was reduced because the PCB board was design and manufacture using PCB laboratory equipment. Total cost for this project only RM not include the fuel pump and motorcycle cost.

58 41 Table 6.3: Cost Estimation for Electronic Board Item Quantity Unit price Total HL2527 DC plug (2.1mm) 2 RM 1.00 RM 2.00 Terminal Block KAR301-2way 2 RM 0.70 RM 1.40 Mini slide switch (PCB) 2 RM 0.80 RM x6x1 Push Button 4Pin 3 RM 0.50 RM ways straight Box header 1 RM 0.50 RM 0.50 Resistor 0.25W 5% (1k) 1 RM 0.05 RM 0.05 Resistor 0.25W 5% (10k) 4 RM 0.05 RM 0.20 Resistor 0.25W 5% (330R) 4 RM 0.05 RM 0.20 Resistor 0.25W 5% (1R) 1 RM 0.05 RM 0.05 Crystal H49S 10MHz 1 RM 2.00 RM 2.00 Straight Pin Header (male) 40ways 2 RM 0.60 RM 1.20 Straight Female Header 1x40 ways 1 RM 1.20 RM 1.20 Voltage Regulator 1 RM 1.00 RM 1.00 Diode 1N RM 0.20 RM 0.60 Diode 1N RM 0.20 RM 0.40 LED 3mm Green 1 RM 0.10 RM 0.10 LED 3mm Yellow 1 RM 0.10 RM 0.10 LED 3mm Orange 1 RM 0.10 RM 0.10 Electrolytic Capacitor 16V 330uF 2 RM 0.40 RM 0.80 Preset 5k 2 RM 0.50 RM 1.00 PIC18F RM RM IC socket 28pin 1 RM 0.55 RM 0.55 Drill Bit 0.8mm 1 RM 2.00 RM 2.00 Drill Bit 1.0mm 1 RM 2.00 RM 2.00 Multilayer Capacitor 33pF 2 RM 0.15 RM 0.30 Multilayer Capacitor 0.1uF 5 RM 0.15 RM 0.75 Grand Total RM 46.60

59 42 REFERENCES 1. Lee, J.H., et al., Development of Motorcycle Drive Cycles for Malaysia. 2010, SAE International. 2. Lee, J.H., C.L. Chong, and H. Gitano, Analysis of Motorcycle Fuel Consumption in Malaysia. 2010, SAE International. 3. Muslim, M.T., et al., Electronic Control Unit Design for a Retrofit Fuel Injection System of a 4-Stroke 1-Cylinder Small Engine. Applied Mechanics and Materials : p Alimin, A., et al., Experimental study on the application of fuel injection retrofitment kit for a small gasoline fuelled engine Sawut, U., et al., Identification and Robust Control of LPG Fuel Supply System. SAE Int. J. Fuels Lubr., (1): p Ujiie, T., et al., Development of Fuel Injector and Fuel Pump for a Fuel Injection System to Use in Small Motorcycles. 2005, SAE International. 7. Omar, M.H.B., Design And Implementation of PID Controller for DC Motor Using PIC Sawut, U., et al., Liquid LPG Injection System with Variable Fuel Injection Pressure Control. 2010, SAE International. 9. Shijie, Y. and W. Xu. Active disturbance rejection fuzzy control of MTG fuel pressure. in Mechatronics and Automation, ICMA International Conference on Krepec, T., A. Labbate, and M. Taylor, Digitally Controlled Fuel Metering Pump for Small Gas Turbine Engines. 1991, SAE International. 11. De Cesare, M., et al., Electric Low Pressure Fuel Pump Control for Fuel Saving. 2013, SAE International.

60 Park, I., et al., Smart Automotive Switch (SAS) for Improved Automotive Electronic Control Systems. 2008, SAE International. 13. Hufstetler, N., Implementing a PID Control System on a Microcontroller (PIC18F4550) Tang, W., et al., PID TUNING FOR DOMINANT POLES AND PHASE MARGIN. Asian Journal of Control, (4): p Yadaiah, N. and S. Malladi. An optimized relation between T<inf>i</inf> and T<inf>d</inf> in Modified Ziegler Nichols PID controller tuning. in Control Applications (CCA), 2013 IEEE International Conference on

61 44 APPENDIX A

62 45 APPENDIX B