Team Harley ECU

Larry Sawhill Mat Stein Justin Clark

Sponsor: Biketronics Inc. Advisor: Chris Wagner

Project DefinitionThe Problem• Customers want to customize their bikes

• Doing so with the stock ECU presents risk:– Reduced fuel efficiency– Reduced engine life

The Solution• Use the MicroSquirt

• Connect the MicroSquirt to the bike via a custom interface board

• Use the bike’s J1850 bus to communicate with the gauges

• Use the previously-designed breakout board to switch between stock ECU and MicroSquirt control

MicroSquirt Stock ECU

Interface Board

Breakout Board

- MicroSquirt Output- Sensor Input- Stock ECU Output

Specifications• Communicate bike operation data on

instrument J1850 network

• Communicate diagnostic data between MicroSquirt and interface board

• Implement interface with a processor capable of handling all ECU function

• Provide protected power to interface board and MicroSquirt module to avoid interference

• All boards must fit in stock ECU container

• Design must safely process high-voltage output from reluctance sensor

Milestones and GoalsSemester 1

1. Get the bike running on the MicroSquirt– Communicate with the MicroSquirt – Run bike on stock ECU and adjust settings on

MicroSquirt to match

2. Build interface board– Determine appropriate micro processor to use on

our interface board– Determine communication IC’s needed for

interface board– Complete schematic of our interface board– Test communication with transceivers to ensure

proper operation with our microcontroller– Capture data sent to the instrument cluster to

determine what needs to be sent– Pull needed data from the MicroSquirt using CAN

bus

Milestones and GoalsSemester 2

3. Get gauges working– Connect our interface board to the

J1850 network on the motorcycle– Ensure proper communication through

the bus– Send proper data to the instrument

cluster and verify correct operation

4. Refine MicroSquirt code for motorcycle use– Make a flow chart of the MicroSquirt

code– Determine branches that are not used

that could simplify operation

5. Prepare project for future development– Start converting code used with the

MicroSquirt to code for the Atmel microcontroller.

The MicroSquirt• EFI controller that features:

– Freely available code

– Support documentation

– User configurability

– CAN communication support

– Compact size• Designed to be “plugged in” to other

projects

– A relatively low price• $249

Our DesignFunction• Receives and routes sensor input to MicroSquirt

• Communicates CAN information to the MicroSquirt– RPMs and other instrument data– Debug information

• Communicates operation data to instrument panel via J1850 bus

• Will someday replace the MicroSquirt entirely– Will function as ECU

Design• Microcontroller:

– Atmel AT90CAN128

• Communication:– Freescale MC33390 J1850 transceiver– Microchip MCP2551 CAN transceiver

• Debug:– Header pin for every I/O

Project Summary

Status• We have half an engine running

– Our settings for the MicroSquirt seem to be our biggest issue

– We can run one cylinder fine, but have trouble getting timing right while cranking

• We have the schematic of our interface board

• We’re in the process of writing code for our microcontroller to communicate with the transceivers

Expenses to Date• MicroSquirt Module: $249.00

• Atmel CAN controller: $13.55

• J1850 transceiver: $1.64

• CAN transceiver: $1.12

• Connectors: $100.00

• PCB breakout board: $83.00

• Total: $448.31

(All product prices retail)

Issues Encountered• Timing appears to be in the ballpark

but….

• We hope to have this resolved and have a running bike before Expo

Continuing Work• Finish setting up the MicroSquirt and ensure proper operation running the engine

• Finish and test code for communication between CAN and J1850 networks– Verify using logic analyzer message capture

• Finish board layout

• Print the first version of our PCB and test for proper operation

• Attach interface board to MicroSquirt and J1850 bus and test

Questions?