He351ve stand alone Arduino controller code for 2nd Gen Cummins

[Me78569]

Getting married in a couple days so this is on the back back back burner.  I will be towing with the setup this weekend so I can report how it acts.

 

 

I will say that thanks to lillb.com and hakcenter overthere, I have added a turbo accel variable that tells the arduino if the turbo is speeding up or slowing down.  I use this in the top end controls of the turbo.  This resolves the issue of the vanes opening causing a huge drop in shaft rpms, then repeating.  I am watching shaft speed and accel, if speed is increasing beyond 130,000 rpm I will open the vanes slightly, but if the shaft speed is above 130,000 but decreasing I hold the current position or reduce the housing size

        if (curveb){  //End pos of 16cm start 11cm
                 if (turbo_rpm <= 120000) { vane_position = 645 - TPS_range;} //************************
            else if (turbo_rpm <= 128000) { vane_position = 624 - TPS_range;} //************************
            else if (turbo_rpm <= 140000) {
                     if (turbo_accel[2] > 20){vane_position = last_vane_position - 5;} // if shaft accel is Positive then open by 5
                else if (turbo_accel[2] > 40){vane_position = last_vane_position - 10;} //if shaft accel is postive and large, open by 10
                else if (turbo_accel[2] < -20){vane_position = last_vane_position + 5;} // if shaft accel is decreasing minus size by 5
                else if (turbo_accel[2] < -40){vane_position = last_vane_position + 10;} //if shaft accel is decreasing largely minus by 10
                else {vane_position = last_vane_position;}
          }
        }
//Overrun
      if (turbo_rpm > 140000){  // 145,000 rpms is where I get worried about shaft speed.  
        if (turbo_accel[2] > 0) {vane_position -= 5;}         //this will creep the vane position more open each code cycle if turbo rpms are above 150,000 if not in curvea ( perf mode defined by "F_watchpot" tab) 
        else {vane_position = last_vane_position;}
      } 

[Vais01]

Getting married in a couple days so this is on the back back back burner. I will be towing with the setup this weekend so I can report how it acts.

I will say that thanks to lillb.com and hakcenter overthere, I have added a turbo accel variable that tells the arduino if the turbo is speeding up or slowing down. I use this in the top end controls of the turbo. This resolves the issue of the vanes opening causing a huge drop in shaft rpms, then repeating. I am watching shaft speed and accel, if speed is increasing beyond 130,000 rpm I will open the vanes slightly, but if the shaft speed is above 130,000 but decreasing I hold the current position.

        if (curveb){  //End pos of 16cm start 11cm
                 if (turbo_rpm <= 120000) { vane_position = 645 - TPS_range;} //************************
            else if (turbo_rpm <= 128000) { vane_position = 624 - TPS_range;} //************************
            else if (turbo_rpm <= 140000) {
                     if (turbo_accel[2] > 20){vane_position = last_vane_position - 5;} // if shaft accel is Positive then open by 5
                else if (turbo_accel[2] > 40){vane_position = last_vane_position - 10;} //if shaft accel is postive and large, open by 10
                else if (turbo_accel[2] < -20){vane_position = last_vane_position + 5;} // if shaft accel is decreasing minus size by 5
                else if (turbo_accel[2] < -40){vane_position = last_vane_position + 10;} //if shaft accel is decreasing largely minus by 10
                else {vane_position = last_vane_position;}
          }
        }
//Overrun
      if (turbo_rpm > 140000){  // 145,000 rpms is where I get worried about shaft speed.  
        if (turbo_accel[2] > 0) {vane_position -= 5;}         //this will creep the vane position more open each code cycle if turbo rpms are above 150,000 if not in curvea ( perf mode defined by "F_watchpot" tab) 
        else {vane_position = last_vane_position;}
      } 

Very nice. Congratulations and let us know how everything goes.

[Me78569]

well like I told her, 

 

 

With the amount of time and money put into this wedding, we are doing it regardless, snow, rain. hail, doesn't matter.  I paid for it, I am doing it.

[Vais01]

well like I told her,

With the amount of time and money put into this wedding, we are doing it regardless, snow, rain. hail, doesn't matter. I paid for it, I am doing it.

I hear that.

[Me78569]

Well hooked up to a trailer for the first time since the turbo.

I gotta say it is awesome. I am making 5-10 psi of boost before 1500 rpm in 2nd.

It's great

[Vais01]

Well hooked up to a trailer for the first time since the turbo.

I gotta say it is awesome. I am making 5-10 psi of boost before 1500 rpm in 2nd.

It's great

Very nice. So is that with the 14cm vane position and the new settings you added for the load sensing?

[Me78569]

That curve is from 6cm to about 13-14.

No load, but it takes into account turbo acceleration to buffer the top end.

But it is a monster now without going to crazy on shaft speeds.

[Vais01]

That curve is from 6cm to about 13-14.

No load, but it takes into account turbo acceleration to buffer the top end.

But it is a monster now without going to crazy on shaft speeds.

That's right shaft acceleration. That's good to hear I bet now you will see near the full potential of the turbo.

[Me78569]

It really screams when you have a trailer on.  Just a little bit of extra load really helps lite the turbo.  I was climbing a small hill in 2nd maybe 15-20 mph, look at my boost gauge and I was still at almost 10 psi, looked at my rpms and I was at like 1400 haha.

 

little more tweaking and I will be really happy with the setup.

[Vais01]

It really screams when you have a trailer on. Just a little bit of extra load really helps lite the turbo. I was climbing a small hill in 2nd maybe 15-20 mph, look at my boost gauge and I was still at almost 10 psi, looked at my rpms and I was at like 1400 haha.

little more tweaking and I will be really happy with the setup.

Load helps a diesel quite a bit. The harder they work the more power they produce. Once you exceed 80% to 85% load then you begin over working the engine and really produce alot of heat. Edited September 17, 2015 by Vais01

[Me78569]

well, I pulled about 10,000-12,000 up the pass today.  I can say the turbo loved it....My radiator, not so much haha.    I guess it is time to clean her our.

[Vais01]

well, I pulled about 10,000-12,000 up the pass today. I can say the turbo loved it....My radiator, not so much haha. I guess it is time to clean her our.

Get a little warm on you haha. It happens. How hot did your coolant temp get?

[Me78569]

coolant got somewhere around 230*f

 

Pass I was driving is is about a 3,000' elevation increase pretty good grade.  45mph speed limit with a kansas person doing 25mph ugh.  as soon as I was able to get going 35-40 mph temps dropped to 220f*  

[Vais01]

coolant got somewhere around 230*f

Pass I was driving is is about a 3,000' elevation increase pretty good grade. 45mph speed limit with a kansas person doing 25mph ugh. as soon as I was able to get going 35-40 mph temps dropped to 220f*

Just a tiny bit warmer than normal. Then again a Kansas driver was the reason I wrecked my first car.

I think that state has some of the very worst drivers I have seen. It's as if they don't pay attention.

Rant done.

I'm glad the turbo is working better. So far I think your on the right track now if only you could seamlessly have the controller and tunner together.

[Me78569]

 

 now if only you could seamlessly have the controller and tunner together.

 

[Me78569]

Well made another trip up the pass. Had about 3k less in the trailer and ambient Temps were about 30*f less.

Temps didn't come above 200*f

Dunno if it was me cleaning the radiator or Temps being lower. Oh well

[Me78569]

I really need to spend some time working on this again, but life has been too busy.  I keep thinking the top end control of the turbo needs to be more dynamic.

[Vais01]

I really need to spend some time working on this again, but life has been too busy. I keep thinking the top end control of the turbo needs to be more dynamic.

That will solely depend on what you mean my dynamic?

[Me78569]

No more at x turbo rpm be at x position. 

 

 

More so if turbo is gaining speed do this or slowing down do this.  

 

Not sure how I want to do that yet, but I have been thinking about it.

[Vais01]

No more at x turbo rpm be at x position.

More so if turbo is gaining speed do this or slowing down do this.

Not sure how I want to do that yet, but I have been thinking about it.

I would use turbine shaft speed RPM to dictate vane position at high engine RPM/load and boost levels.

Having it fluctuate to create optimal boost at higher RPM/load. The controller needs to see boost values to choreograph the vane fluctuation I would think.