Electronic Engine Controls

Why Electronic Controls?

Emissions Driven
No loss of economy
No loss of power
Lower emissions number
World market has regulation
Flexible Solutions
Same hardware
Custom software
Fast turn-around
Easier fix after sale

Standardized Elements

Demands in the marketplace.


Electronic Engine Controls
Functions Provided by a Cummins Electronic Control System

Fueling Calculation Startup Management
Timing Calculation Shutdown Management
Fuel System Management Engine Protection
Speed Governors Fault Management
High Speed Communications
Low Speed Application Features etc
All Speed
Operator Interface
Machinery Interface
Throttle Management
Data Logging
Diagnostics
Prognostics

Electronic Engine Controls
Electronic Control are inevitable on all Cummins Engines,

Product complexity increases over time inevitable (Emission regulations,
fuel economy, customer features and competition)
Mechanical technology costs are increasing.
Electronic technology costs are decreasing.
The feature of electronic engines are more than mechanical engines.


Electronic Engine Controls
Cummins Electronic Control Systems,

Hardware Standards
Electronic Control Module Interface
Sensors Coding
Actuators Configuration
Cable harness Testing
Software
Operating system
Feature programs
Diagnostics
Calibration information
Tools
Design automation
Software testing / validation
Configuration management
Systems integration




Electronic Engine Controls
Why so Many Controllers?

Specific solutions to specific problems
Evolution from Celect to CORE
CORE provides
Target of specific market
Target of specific fuel system
CORE is an approach to electronic control that uses largely common
elements in conjunction with custom elements to craft a custom
electronic controller.
CORE advantages
Basic engine control standard
Modifiable for specific market
Automotive - Marine - Industrial - Special etc.
Modifiable for specific fuel systems
Uses common tools
Uses standard interfaces
Can be run on any hardware




Electronic Engine Controls
Why a CORE Product?

Reliability - benefit from fixes / improvements to common system
Rapid first engine start
Economic leverage through reuse
Develop common features once
Implement changes and improvements once
Use common development process and tools

The computer based controller has the same elements as any personal
computer.
Input
Output
Storage
Control
Calculation etc.




Electronic Engine Controls
Micro-Controller Architecture

The input and output computer sections interface to the operator,
sensors and actuators systems.
The STORAGE section contains
Calibration data for sensors
Temporary values
Constants for calculations
Instructions
The CALCULATION section performs all mathematics operations.
The CONTROL section co-ordinates the flow of information and
instructions between all the other subsections.

ALGORITHMS AND CALCULATIONS
Fueling / Timing
Engine Speed Control
Engine Protection
Diagnostic Processing
Engine State Determination etc.




Electronic Engine Controls
Wiring Harness

The wiring harness connects the electronic control module to sensors,
actuators, electrical power and data communications.
The wiring harness provides electrical power and signals for
Sensors
Indicators
Operator Controls
Actuators
Data Communications
Power Connections etc.
The wiring harness provides not just connection between active
elements of the electronic engine system; it also provides the
following functions:
Mechanical protection for wiring
Ease of connection for optional components
Environmental protection for connections
Adequate current path for devices
EMI protection for conductors




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Electronic Engine Controls
Wiring Harness

Cross - talk protection for signal and power lines.
Each harness is unique to particular customer and application. The
harness philosophy reflects a commitment to have the engine system
stand-alone without mixing the engine control component harness
with the OEM component harness.
Typical engine harness contents;
Engine speed 1
Engine speed 2
Fuel rail actuator
Oil pressure
Engine block ground
Ambient air pressure
Fuel rail pressure
Timing rail pressure
Coolant temperature
Intake air temperature etc.




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Electronic Engine Controls
Sensors :

Sensors are the measurement devices which convert physical
phenomena into electrical signals.
The sensor electrical signal is converted into the numeric value by the
input sub system of the electronic control module.
Sensors are information gathering devices in the electronic control
system.
These devices convert physical phenomena to electrical signal. The
magnitude of the electrical signal has a repeatable and defined
relationship to the magnitude of the physical phenomena.
Analog sensor examples
Pressure
Temperature
Digital sensor examples
Level
Operator request




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Electronic Engine Controls
Sensors :

Frequency sensor examples
Speed
Flow
ECM Parameters: Gas and liquid pressures
Fuel
Intake manifold
Oil
Exhaust
Coolant
Gas and liquid temperatures
Fuel
Intake manifold
Oil
Exhaust
Coolant
Liquid level
Fuel - Coolant - Oil



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Electronic Engine Controls
Actuators:

Actuators are the action devices which affect the system under control
with the result of the control calculations performed by the electronic
control module.
These devices convert electrical signals into physical phenomena. The
magnitude of the electrical signal has a repeatable and defined
relationship to the magnitude of the physical phenomena.
ECM system actuators include the following electromagnetic devices
(EMDs):
Spool valves Flow control poppet valves
Lamp drivers Injectors Stepping motors
Rotary valves Servo positioners
Pressure controls etc.



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Electronic Engine Controls
Actuators:

Actuators can be controlled in on/off continuous or times based mode
On/off examples
Light switch
Sump pump
Washing machine
Fuel solenoid
Continuous examples
Industrial heaters
Control valves
Throttle positioner
Time based examples
Electrical heaters
Lamp dimmers
Fuel solenoid



Contd.
Electronic Engine Controls
Electronic Control System Block Diagram





Engine
Sensor
Actuator
Wiring Harness
Input System
Output System
Storage
Computation
Communication
ECM