Team Harley ECU

1. Team Harley ECU Larry Sawhill Mat Stein Justin Clark Sponsor: Biketronics Inc. Advisor: Chris Wagner

2. Project Definition MicroSquirt Stock ECU The 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 Interface Board Breakout Board - MicroSquirt Output - Sensor Input - Stock ECU Output

3. 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

4. Milestones and GoalsSemester 1 • Get the bike running on the MicroSquirt • Communicate with the MicroSquirt • Run bike on stock ECU and adjust settings on MicroSquirt to match • 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

5. Milestones and GoalsSemester 2 • 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 • Refine MicroSquirt code for motorcycle use • Make a flow chart of the MicroSquirt code • Determine branches that are not used that could simplify operation • Prepare project for future development • Start converting code used with the MicroSquirt to code for the Atmel microcontroller.

6. 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

7. Our Design Function • 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

8. 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)

9. Issues Encountered • Timing appears to be in the ballpark but…. • We hope to have this resolved and have a running bike before Expo

10. 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

11. Questions?