FYP Taufiqurrahman 7540 Final Report
FYP Taufiqurrahman 7540 Final Report
FYP Taufiqurrahman 7540 Final Report
INTRODUCTION
“Fuel driver injection is a quick, responsive, reliable way to meter the right
amount of fuel and spark for a given volume of air to an engine” [4]. Early
automotive engines found on 1983-84 Celica‟s use an analog system. For a given
volume of air, an appropriate amount of fuel is metered into the engine by the
injectors. This signal is amplified by input from other sensors, but for analog system,
resistance is used to control its operation.
Direct fuel injectors are just simple solenoid devices that allow pressurized
fuel to be squirted into the engine in a fine spray for a predetermined period of time
[4]. An injector's size is measured in how much volume of fuel it can flow in a given
period of time. United States domestic injectors are usually measured in pounds per
hour (lbs/hr), while injectors for import engines are usually measured in cubic
centimeters per minute (cc/min) [4]. Injectors come in two types which are low
impedance (typically less than 3 ohms) and high impedance (typically more than 12
ohms) known respectively as “peak-and-hold” and “saturated” injector.
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1.2 Problem Statement
The current required to open a solenoid is several times greater than the
current necessary merely to hold it open, therefore the injector driver by directly
sensing the actual solenoid current, initially saturates the driver until the „peak‟
injector current is 4 times that of the idle or „hold‟ current. This guarantees opening of
the injector [3].
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CHAPTER 2
LITERATURE REVIEW
Peak and hold injectors may also be called current sensing or current limiting
driver. These types of injectors are more expensive and complex than saturated circuit
drivers, and are not generally used with domestic production ECUs. Besides, these
injectors primarily used in aftermarket high performance systems. It was shown that
“most high flow injectors are low resistance (2-5 ohms) and use a peak and hold
driver to activate them” [8]. The “peak” current is the amount required to quickly
open the injector, and then the lower “hold” current rating is used to keep it open for
as long as the input signal. These require the extra kick from the higher current to
keep the opening and closing time of the injector stable at the higher fuel flow rate.
With this type of driver, 12 volts is still delivered to the injector, but due to its low
resistance, the current in the driver circuit is high. This is substantial current flow and
a high impedance injector cannot handle it. The drivers usually come in two values
which are 4 amp peak/1 amp hold, and 2 amp peak/0.5 amp hold. Even though 6
amps may be available to operate the injector, the maximum it is allowed to reach is 2
or 4 amps, depending on the driver‟s current limit.
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2.1.2 Saturated Circuit Injector (High impedance: 10-16 ohm)
Fuel flow specifications are given in grams per minute (g/min), as this is an
internationally accepted standard at vehicle manufacturing level. As vehicle
development engineer deal with the weight or mass of air inducted by an engine not
its expected power rating, the weight of fuel that an injector can provide is the pivotal
measurement.
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Figure 2 shows the design of full connection using LM1949 injector drive
controller chip. This circuit is one of many different variations of peak and hold
circuit but still have the same function. From the start of an injector pulse, the circuit
works about the same. The analog circuit relays the logic 'high' signal to the base of
the transistor, which fully saturates it, causing the collector too short to the emitter.
One difference in this circuit is the 0.1 ohm resistor in series with the emitter. This
voltage is proportional to the current through the injector and is monitored by the
analog circuit. From this point on, a much smaller amount of current is needed to hold
the injector open.
RT and CT connected between pin 7 and 8 is used to limit the power dissipated
by the injector under certain condition. Value of resistor and capacitor will set the
timer period to just less than 5ms. This timer is used during periods where the current
through the injector doesn‟t reach 386mV peak threshold voltage. This can happen
during cranking periods where the battery voltage is too low to get 3.86A through the
injector coil. When one time cycle is reach (4.6ms) the controller drops into hold
mode. The timer is reset at the end of each input pulses. If the timer function is not
used, it can be disabled by grounding the TIMER pin (Pin 8).
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2.2.3 Compensation (CC)
Figure 4 shows the typical waveform under normal battery voltage and low
battery voltage. The injector peak and hold current can be determined by the value of
sense resistor, Rs. With the sense resistor set to 0.1Ω, it makes thing simple to
calculate. 100mV voltage drops across Rs equals 1A through the injector. The
LM1949 trips into hold mode when the voltage across the sense resistor reaches
386mV and gives 3.86A through injector. During hold mode, the controller acts like
an op-amp holding the voltage across Rs to 94mV. The injector current will remain at
hold level for the duration of the input signal at pin 1 [1].
The purpose to have peak current 4 times than the hold current is to overcome
kinetic and constriction forces when working with solenoids. Power dissipated in
solenoids and transistor also can be reduced by holding injector current at ¼ of the
peak current. 4A peak current was chosen to make sure the injector operation over the
life and temperature range of the system [1]. By choosing 0.1Ω of Rs value, it will
give 3.86A peak and 0.94A hold current which is closed to the recommended value.
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Figure 5: Closed up peak and hold waveform
(Source image: Orbital documentation)
Figure 5 shows the closed up view of peak and hold current for direct injector
(reproduced from Orbital). This type of injector requires 3A to open the solenoid and
1A to keep the solenoid open while minimizing power dissipated. The waveform
show corresponding time taken for rise, peak, decay and hold state. Time cycle is the
time taken for one input pulse to set and reset. This time can be adjusted depend on
the input signal generated at pin 1 of the LM1949. Peak time is fixed and cannot be
changed unless there are modifications were made to the circuit. Hold time is always
depending on the input signal come from PC-based controller or function generator.
There have some oscillation during the hold state due to the Darlington power
device used. That‟s why there has compensation part connected at pin 2 and 3 of the
circuit to reduce the oscillation and provides stability.
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CHAPTER 3
METHODOLOGY
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3.2 Tools and Equipments Required
Software
This software was used to draw the schematic diagram and the layout for the
PCB board before it will be fabricated on the PCB. Eagle Layout Editor 5.0.1 was
chosen instead of other software because only this software was compatible with PCB
workstation at the PCB lab.
Hardware
The injector driver circuit requires two (2) power supplies. One is for the
injector (solenoid) which needs 12V/14V supply and another one is for the LM1949
IC. The IC requires 3V-5.5V of voltage supply to operate normally.
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3.2.5 Orbital Low Impedance Direct Injector
This type of injector driver was used because the resistance is less than 3 ohm
(1.4Ω, 3mH). For the injector driver circuit to operate, it need low impedance injector
driver so it can control the peak and hold current of the fuel injector (refer to
Appendix A).
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3.3 Research Methodology
3.3.2 Books
3.3.3 Internet
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3.4 Project Milestone
3 Seminar (compulsory)
5 Poster Exhibition
7 Oral Presentation
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CHAPTER 4
Figure 7 shows the setup of the injector with connection of other peripheral or
component such as fuse and controller. 8A fuse was chosen and connected in series
with Darlington transistor to protect it from blow due to the overrated of current flow.
The input of the LM1949 IC is come from external controller which is the function
generator. This controller is used to generate required input pulses to the IC. By using
function generator, variations of inputs pulses can be generated by manipulate the
frequency. In this case the square wave pulse was used.
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Figure 8: Circuit connection
The circuit on Figure 8 shows the initial design of the injector driver circuit
connection on breadboard. During this stage, the circuit cannot be tested with the
direct injector because that injector is high impedance type. This circuit is design for
use with low impedance injector only. If using a high impedance fuel injector, this
circuit cannot perform its peak and hold current control function. Thus this project is
stuck until suitable low impedance fuel injector is found.
Eventually there have one set of low impedance direct injector and injector
driver kit available at UTP laboratory, so the test to obtain data for benchmarking has
been done. The result is use for comparison between these two injector drivers.
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4.2 Fabrication and Testing
This project also involving comparison between the designed injector driver
circuits with another one that available in UTP laboratory. So the circuit has been
fabricated on PCB to make the component setup easier. Unfortunately the circuit
didn‟t work while doing the testing. Due to limited time left, this project only reach
this stage and the comparison cannot be done. The only data obtained is for the
injector driver that is available at UTP laboratory.
Figure 9 and Figure 10 show the PCB schematic diagram and layout of the
injector driver circuit. The schematic was draw using Eagle software. By using this
schematic diagram, the PCB layout can be drawn using the same software. Figure 11
show the complete connection of component and wiring on PCB.
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Figure 12 shows the setup for testing the designed circuit on actual
automotive direct injector. This circuit is connected with external peripheral such as
power supply, oscilloscope and PC-based controller for data acquisition and
generating input.
Figure 13 shows the “Orbital Low Side Injector Driver” was used to get the
benchmark for comparison with the designed injector driver. Both test using same
type of fuel injector which is the “Orbital Direct Injector”. The specification for the
direct injector is attached in Appendix A.
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4.3 Data Analysis
Test was done using Orbital direct injector and low impedance injector driver
kit. The result and analysis is shown in following graph.
Figure 14 shows the injector peak and hold current for input signal pulse
duration is set to 50ms. This value of peak and hold current is fixed for this injector
driver. Even if the pulse duration is changed, it will give the same value of 3.4A peak
and 1.05A hold current.
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Figure 15: Injector current for 30ms pulse duration
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Figure 15 and Figure 16 show the injector current for 30ms and 10ms. It can
be seen that the value of peak and hold current not changing for different values of
pulse duration. This time cycle can be adjusted depending on the input signal pulses
from the PC-based controller.
Figure 17 shows the close up view for 10ms pulse duration. This is to show
that the peak time is fixed at 2.8ms. Although the pulse duration is reduced, the value
of peak time is not changing. Thus, although the hold time changes with the pulse
duration, the 2.8ms peak time remains the same. Besides, the peak and hold value for
current are maintained at 3.4A and 1.05A respectively, regardless of the pulse
duration.
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CHAPTER 5
5.1 Conclusions
At the end of this project, the injector driver circuit has been designed and
fabricated on PCB. But the testing on actual automotive direct injector is failed
because the circuit did not function properly. The data for Orbital direct injector and
low impedance injector driver has been obtained and analyzed. The comparison
cannot be done because there are no data on designed injector driver. Thus the project
only reaches this stage and no result was obtained for the designed injector driver.
5.2 Recommendations
It is recommended that for future work of the project, some modification will
be made to obtain different result. First is to make an adjustable peak and hold current
control injector driver. This mean the respective current can be adjust as required by
the user. Second recommendation is to modify the parameter value so that the peak
time can be changed to give longer hold current state. Another recommendation is to
make the circuit also work with high impedance fuel injector.
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REFERENCES
[2] Injectors. (1999). In Tomco Techtips Issue 38. Retrieved March 13, 2009,
from http://www.tomco-inc.com/Tech_Tips/ttt38.pdf
[3] Peak and Hold Injector Patterns. (2001). In Tomco Techtips Issue 40.
Retrieved March 15, 2009, from http://www.tomco-
inc.com/Tech_Tips/ttt40.pdf
[8] Fuel Injector Spotters Guide and Information. (2000). In RTR performance.
Retrieved August 10, 2009, from http://www./fuelinjectorguide.htm
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APPENDICES
25
APPENDIX A
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ABSTRACT
The objective of this project is to design and test a suitable driver circuit to
meet current control objectives. Injector drivers for automotive engines require peak-
and-hold current control for operation. For this project, the designed circuits need to
be tested and compared to an injector driver that is available in the market.
Implementation of the driver circuit will be done on PCB using an injector driver
chip, PCB maker and schematic capture software. At the end of this project, the
fabricated circuit will be tested with an actual automotive injector. Analog electronics
and microelectronics knowledge will be applied for designing the circuit and to
analyze the acquired data. As a conclusion, this project is to design, fabricate and test
an injector driver that can meet current control objectives: peak-and-hold current.
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ACKNOWLEDGMENT
First of all, thank God for this opportunity and seeing me through some truly
difficult times especially through the period of this FYP 1 and FYP 2. My highest
gratitude goes to all those who helped me towards the completion of this Final Year
Project either directly or indirectly. First up to my supervisor, Mr. Saiful Azrin, an
Electrical and Electronics lecturer, thanks for all the never-ending support and trust
given to me in order to carry out the project given. Besides, I appreciate all your
comments and remarks given to me with regards to my project as this is crucial for
me to take note when doing my FYP in the future. My further gratitude is to all the
lecturers, technicians and related staff who have assisted me in completing this
project. Last but not least, not to forget my family and friends who gave me the
supports towards the completion this course and project. Thank you very much for the
fully hearted support.
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TABLE OF CONTENT
ABSTRACT ................................................................................................................. iv
ACKNOWLEDGMENT ...............................................................................................v
LIST OF FIGURES ................................................................................................... viii
vi
CHAPTER 3 METHODOLOGY ................................................................................ 10
3.1 Procedure Identification ............................................................................ 10
3.2 Tools and Equipments Required ................................................................ 11
3.2.1 Eagle Layout Editor 5.1.0 ................................................................. 11
3.2.2 LabVIEW 7.1 .................................................................................... 11
3.2.3 Power Supply Unit ............................................................................ 11
3.2.4 Function Generator .......................................................................... 11
3.2.5 Orbital Low Impedance Direct Injector ............................................ 12
3.2.6 Orbital Low Side Injector Driver ...................................................... 12
3.2.7 Injector Driver (LM1949 IC) ............................................................ 12
3.3 Research Methodology .............................................................................. 13
3.3.1 Software and Hardware Manual ....................................................... 13
3.3.2 Books ................................................................................................ 13
3.3.3 Internet ............................................................................................. 13
3.4 Project Milestone ...................................................................................... 14
REFERENCES ............................................................................................................ 24
APPENDICES ............................................................................................................. 25
APPENDIX A: DIRECT INJECTOR SPECIFICATION.................................... 26
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LIST OF FIGURES
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