MEDUSA
Methane Engine Design for Unmanned Small Aircraft
Test Readiness Review
University of Colorado at Boulder
03/05/2015
Customer: Dr. Ryan Starkey
Daniel Frazier
Christopher Jirucha
Alexander Truskowski
Team
Nathan Genrich
Crawford Leeds
Carlos Torres
Advisor: Dr. Jelliffe Jackson
Abram Jorgenson
Huikang Ma
Corey Wilson
Outline
2
• Overview
Project Overview Corey Wilson
and Schedule
Mechanical
Daniel Frazier
• Schedule
Software and
Electronic
Budget
• Testing
• Budget
Project
Overview
Mechanical
Software and
Electronic
Crawford Leeds
Crawford Leeds
Engine
Integration
Budget
Project Statement
3
Project Description: Modify a JetCat P90-RXi mini turbo jet engine to
run on gaseous methane fuel to address the USAF’s interest in the
possible use of the methane gas as fuel.
Functional Requirements
Engine Control Unit
(ECU)
Fuel Delivery System
(FDS)
Project
Overview
Start, run, and shut down engine
Maintain JetCat recommended safe operation conditions
Log data
Deliver up to 4.2g/s of methane to combustion can
Deliver kerosene/oil mix to bearings at stock rates
Mechanical
Software and
Electronic
Engine
Integration
Budget
4
PROJECT OVERVIEW
Project CONOPS and Objective
RC Signal
RC Receiver
5
Current Stock Engine: JetCat P90-RXI
JetCat
ECU
RPM and Temperature
from Engine Sensor
Board
Commands to
pump/solenoids
Injection point
RPM < 130,000
Shaft
Lubrication Line
Kerosene
Fuel/Lubricant
Exhaust
Temp < 700oC
Project CONOPS and Objective
Mass Flow Safety
Controller Valves
Commands to Controller
Student
ECU
Fuel
Commands
to
RPM and Temperature
Manifold
pump/solenoids
from Engine Sensor
Board
6
Pressure
Regulator
Methane Tank
RPM < 130,000
Student
Engine
Board
Use stock
lubrication
hardware
Will use stock
sensors
Six Student
injectors
Exhaust
Temp < 700oC
Fuel System
Methane
Tank
RC Controller
Kerosene
Tank
Throttle
Command
Key
Physical Contact
Electrical Signal
Data
0.9 - 4.2 g/s
Mass Flow
Controller
Fuel Pump
Provided
Purchased
Designed
Lubrication System
PWM
Lubrication
Solenoid
Logic
Algorithms
Command
Outputs
Starter
Motor
Injectors
Combustion
Compressor Bearings
Can
ESB
PWM
Input Receivers
Engine
PWM
ECU
RS-232
Receiver
0-2500 Hz
SPI
T5 < 700oC
Turbine
Nozzle
Injectors
Hall Effect
Sensor
Cold Junction Compensation
& Amplification
7
8
Critical Project Requirements
Requirement Subsystem
Description
CPR.1
FDS
The FDS shall deliver 0.9-4.2g/s ± 5% of methane to the combustion chamber
CPR.2
FDS
The FDS shall deliver lubricant to the bearings at rates equal to or greater than
stock rates
CPR.3
ESB
The ESB shall read data from the existing thermocouple and hall effect sensor
CPR.4
ESB
The ESB shall transmit sensor data to the ECU
CPR.5
ESB
The ESB shall drive signals to engine hardware components
CPR.6
ECU
The ECU shall implement open loop control to control fuel flow rate
CPR.7
ECU
The ECU shall shutdown the engine should the exhaust temperature exceed 700oC
or the RPM exceed 130,000
CPR.8
ECU
The ECU shall detect an ignition failure, shutoff fuel flow, and drive compressor
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
9
SCHEDULE
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
MEDUSA Current Work Plan
Where We Are
10
Week 10
ECU phase II
ECU phase I (Completed)
Week 12
Week 14
FDS
IIIIII:
(In
progress):
ECU
Phase
III(Completed):
(Completed):
(In
progress):
FinalPhase
System
Test:
FDS
components
ordered,
received
and
ECU&
revision
ESB:Board
Finished
bothwith
prototypes,
ECU
&ESB
ESB
Board
manufacturing
Integrating
ECU
and
FDS
engine
manufactured
FDS
sealfunctional
and flow
rate
manufacturing
if necessary
passed
testsverification test
Software:
Individual
functions
ECU
& software
Integration
Mockhardware
engine
test
with
hardware
Lubrication
rate
date collection
ECU
and ESBflow
board
verified
for engine
complete
test
integration
Simulator:
LabView
complete
Engine
simulator
testcode
- verify
ECU and
Methane
engine
test
run
– validate
the
verified.
requirements
project requirments
Spring Break
FDS phase I (Completed)
Electrical
Software
MSR
Labview
ECU Integration
Fuel Delivery
Lubrication
Engine Integration
ECU phase III
TRR
Final system Test
FDS phase II
SFR
Testing Architecture & Presentation Layout
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Fully integrated
engine test
Level 2
Drive mechanical components
with ECU/ESB
Mock engine test
with hardware
Lubrication Flowrate
Data Collection
TRR
MSR
11
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Integration
ECU/ESB
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
Engine simulation
with Labview
Verification Test
Budget
Testing Architecture & Presentation Progress
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Fully integrated
engine test
Level 2
Drive mechanical components
with ECU/ESB
Mock engine test
with hardware
Lubrication Flowrate
Data Collection
TRR
MSR
12
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Construction
ECU/ESB
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
Engine simulation
with Labview
Verification Test
Budget
Methane Delivery: Flow Rate Verification
13
Run Engine With Methane
CPR.1
Deliver methane from
0.9 - 4.2 g/s (Idle to Full Thrust)
Must validate system and
predictive models
Pressure vs Flow Rate Flow rate vs Temp
CPR.1
Meet flow rate command
within 5%
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
Methane Delivery: Seal Verification
14
• Goal: Verify system has leak rate below 4% of commanded flow rate
Performed with air at Boulder Municipal with a blast tunnel
125 PSI (Maximum operational pressure)
Air
Compressor
Safety
Valves
Mass Flow
Controller
Fuel Injectors
Check Valve
Pressure
Gauge
∆𝐺𝑎𝑢𝑔𝑒
5% total mass in tubes
= 𝐿𝑒𝑎𝑘𝑎𝑔𝑒 <
𝐼𝑑𝑒𝑎𝑙 𝐺𝑎𝑠 𝐿𝑎𝑤 𝑤𝑖𝑡ℎ 𝑎𝑖𝑟: 5𝑝𝑠𝑖/ 𝑠 𝑎𝑡 125𝑃𝑆𝐼
𝑇𝑖𝑚𝑒
Equivalent methane leak within OSHA standards
Jan 30 8hr Remain
Mar 10
Methane: Pressurized Delivery Verification
15
• Goal: Verify systems delivers methane within 5% of commanded rate (CPR.1)
Performed with air at Boulder Municipal with a blast tunnel
Manual Control
0.9-4.2g/s
Flowrate
Delivered
Error < 1% of Commanded Rate
Relief Valve at
operational
engine pressure
Check Valve
Safety Valves
Air Compressor
Mass Flow
Controller
Fuel
Injectors
Pressure
Vessel
Methane: Pressurized Delivery Verification
15
• Goal: Verify systems delivers methane within 5% of commanded rate (CPR.1)
Performed with air at Boulder Municipal with a blast tunnel
Command Error
Manual Control
Flowrate
0.9-4.2g/s
Delivered
Total Delivery Error
< 5% Commanded
Leak Error
from controller
to injectors
Check Valve
Safety Valves
Air Compressor
Mass Flow
Controller
Fuel
Injectors
Relief Valve at
operational
Pressure engine pressure
Vessel
Mar 4 10hr Remain
Mar 15
Testing Architecture & Presentation Progress
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Fully integrated
engine test
Level 2
Drive mechanical components
with ECU/ESB
Mock engine test
with hardware
Lubrication Flowrate
Data Collection
TRR
MSR
16
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Construction
ECU/ESB
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
Engine simulation
with Labview
Verification Test
Budget
Lubrication: Experimental Test
17
Run Engine With Methane
CPR.2
Lubricate bearings to
prevent seizing
Will use stock rates, but
these are unknown
No documentation, determine
experimentally
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
Lubrication: Experimental Test
18
• Goal: Find flow through Lubrication Solenoid
Performed with kerosene at Boulder Municipal with a blast tunnel
Flowmeter
Flowmeter
2
1
Pump
Fuel Can
1
2
Bearing
Lubrication
Lubrication
Solenoid
Bearings
Fuel
Solenoid
Injectors
On Hold because of weather
Jan 20 5hr Remain
Mar 14
Lubrication: Calibration & Error Test Results
• Goal: Calibrate flowmeters and calculate test error
Performed in Dr. Starkey’s lab with fire extinguisher
Fuel Can
250ml
Graduated
Cylinder
1-3V Power Supply
Flowmeters
Filter
1
2
Pump
Pulses/Quantity=Calibration Factor
1
2
Relative
Flowmeter
Error
Omega 601b
Equflow 0045
29000
116000
Manufacturer 36000
110000
Tested
19
Lubrication: Calibration & Error Test Results
• Goal: Calibrate flowmeters and calculate test error
Performed in Dr. Starkey’s lab with fire extinguisher
Fuel Can
250ml
Graduated
Cylinder
1-3V Power Supply
Flowmeters
Filter
1
2
Pump
Relative Error Calibration Error
𝝈
1
2
𝑵
Error
Pulses/Quantity=Calibration Factor
Omega 601b
Equflow 0045
29000
116000
Manufacturer 36000
110000
Tested
19
Lubrication: Calibration & Error Test Results
19
• Goal: Calibrate flowmeters and calculate test error
Performed in Dr. Starkey’s lab with fire extinguisher
Fuel Can
1-3V Power Supply
Flowmeters
Filter
1
Pump
Relative Error
0.001±0.046mL/s
Calibration Error
0.014±0.011mL/s
2
45 Tests, 6 most
refined procedures
250ml
Graduated
Cylinder
0.07mL/s
2% of Max Achievable Throttle
Jan 20 10hr Remain
Mar 14
Lubrication: Remaining Work
• Complete Engine Testing
• Analyze data
• Prove ECU can operate
lubrication system (CPR.2)
• Drive pump with ECU
• Check flow rate produced
• Test in Dr. Starkey Lab with
fire extinguisher
ECU
Filter
250ml
Graduated
Cylinder
• Predicted 30 hours, has taken 60 so far
• 15 hours to go
• Not a scheduling problem
20
Pump
Lubrication
Solenoid
𝐹𝑢𝑒𝑙 𝐷𝑒𝑙𝑖𝑣𝑒𝑟𝑒𝑑
= 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒
𝑇𝑖𝑚𝑒
Engine
Lubrication
Tubing
Testing Architecture & Presentation Progress
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Fully integrated
engine test
Level 2
Drive mechanical components
with ECU/ESB
Mock engine test
with hardware
Lubrication Flowrate
Data Collection
TRR
MSR
21
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Construction
ECU/ESB
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
Engine simulation
with Labview
Verification Test
Budget
Software/Electronics: Command Testing
22
Engine
Control
Unit
Run Engine With Methane
Engine Control Unit
Engine Sensor Board
CPRs.
3-8
Control engine state
Check safety conditions
Test functionality without risking
engine damage
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
Electrical/Software: Command Flow
Raw
Sensor Data
Processed
Sensor Data
23
Key
Raw Data
Processed Data
Command
Component
Stock Engine
Components
Student Engine
Sensor Board
(ESB)
Methane
Delivery System
Component
Commands
Student Engine
Control Unit
(ECU)
RC Command
Electrical/Software: Command Flow
23
Key
Raw Data
Electronic Data
and Commands
Signals from/to
Stock Hardware
RPM Sensor
Thermocouple
RPM
Processed Data
TEMP
Command
Component
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Combustor
Flow Control
Methane
Delivery System
Student Engine
Control Unit
(ECU)
RC Command
Software Test & Integration Status
Item
Signal Type
PWM
Electronic Data
and Commands
Individual
Individual
simulated test
RPMHardware Test
24
Integration
and Test
TEMP
PWM
On/Off
On/Off
On/Off
Complete
Complete
f Modulation
SPI
Time Remaining
Starter Motor
Pump
Solenoid
Glow Plug
RS-232
Complete
RC Command
Complete
Complete
Complete
Complete
5 Hours Remaining
PredictedFlow
92 Hours,
Control Spent 60
Jan 1
8hr Remain
Mar 7
24
Testing Architecture & Presentation Progress
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Fully integrated
engine test
Level 2
Drive mechanical components
with ECU/ESB
Mock engine test
with hardware
Lubrication Flowrate
Data Collection
TRR
MSR
25
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Construction
ECU/ESB
Complete
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
Engine
LabView
simulation
Engine
Simulator
with Labview
Test
Verification Test
Budget
Electrical/Software: Command Flow
Key
Raw Data
Processed Data
Electronic Data
and Commands
RPM
Signals from/to
Stock Hardware
RPM Sensor
26
Command
Component
TEMP
Thermocouple
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Injectors
Flow Controller
Methane
Delivery System
Student Engine
Control Unit
(ECU)
RC Command
LabView Simulation Test
26
• Goal: Verify CPRs 3-8 are met in a simulated environment without danger to the engine
Performed in a computer lab
Electronic Data
Signals from/to
and Commands
Stock Hardware
RPM Sensor
RPM
Key
Raw Data
Processed Data
Component
TEMP
Thermocouple
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Flow Controller
Command
Student Engine
Control Unit
(ECU)
RC Command
Full Engine Simulator Test
• Goal: Verify CPRs 3-8 are met in a simulated environment without danger to the engine
Performed in a computer lab
RPM Sensor
Thermocouple
Starter Motor
Pump
Solenoid
Glow Plug
Flow Controller
26
Full Engine Simulator Test
27
• Goal: Verify CPRs 3-8 are met in a simulated environment without danger to the engine
Performed in a computer lab
Signals from/to
stock hardware
Expected Signal
Acceptable
0-2400Hz (0-144,000 RPM)
Simulated
Thermocouple
0-41mV (0-1000oC)
Simulated
Starter Motor
0-8V PWM, 555kHz,
39% Duty Cycle
±0.5V, ±5kHz
±1% Duty Cycle
0.5V
±0.01V
Solenoid
10V
±1V
Glow Plug
10V
±1V
RS-232 ASCII From ECU
<3% Baud Rate Error
RPM Sensor
Pump
Flow Controller
Engine Run Sequence
Wait For
User
Command
Startup
Shutdown
Engine
Running
Control
Loop
Emergency
Shutdown
Mar 9 25hr Remain
Mar 23
Testing Architecture & Presentation Progress
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Integrated
Engine Test
Level 2
Drive mechanical components
with ECU/ESB
Mock Engine
Test
Lubrication Flowrate
Data Collection
TRR
MSR
28
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Construction
ECU/ESB
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
LabView Engine
Simulator Test
Verification Test
Budget
LabView Simulation Test
29
• Goal: Verify CPRs 3-8 are met in a simulated environment without danger to the engine
Performed in a computer lab
Electronic Data
Signals from/to
and Commands
Stock Hardware
RPM Sensor
RPM
Key
Raw Data
Processed Data
Component
TEMP
Thermocouple
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Flow Controller
Command
Student Engine
Control Unit
(ECU)
RC Command
Mock Engine Test
29
• Goal: Verify CPRs 3-8 are met using engine hardware without danger to the engine
Performed with air at Boulder Municipal with a blast tunnel
Electronic Data
Signals from/to
and Commands
Stock Hardware
RPM Sensor
RPM
Not
Connected
to each
other or the
engine
Processed Data
Command
Component
TEMP
Thermocouple
Run as in
engine
operation
Key
Raw Data
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Pressure Vessel
Flow Controller
Methane
Delivery System
Student Engine
Control Unit
(ECU)
RC Command
Mock Engine Test
• Goal: Verify CPRs 3-8 are met using engine hardware without danger to the engine
Performed with air at Boulder Municipal with a blast tunnel
RPM Sensor
Thermocouple
Starter Motor
Pump
Solenoid
Glow Plug
Flow Controller
29
Mock Engine Test
30
• Goal: Verify CPRs 3-8 are met in a simulated environment without danger to the engine
Performed with air at Boulder Municipal with a blast tunnel
Signals from/to
stock hardware
RPM Sensor
Thermocouple
Expected Operation
Passing Operation
Range
0-2400Hz (0-144,000 RPM)
Simulated
0-41mV (0-1000oC)
Simulated
Starter Motor
Pump
Solenoid
Results TBD
Results TBD
On/Off
On/Off
Engine Run Sequence
Wait For
User
Command
Startup
Shutdown
Glow Plug
Flow Controller
0.9-4.2 g/s
Engine
Running
Control
Loop
Emergency
Shutdown
±5% commanded
rate
Mar 20
40hr Remain
Apr 4
Testing Architecture & Presentation Progress
April 20
Spring
Break
Level 3
Engine Functions
With Methane
Fully integrated
engine test
Level 2
Drive mechanical components
with ECU/ESB
Mock engine test
with hardware
Lubrication Flowrate
Data Collection
TRR
MSR
31
Level 1
Seal & Flow
Rate Checks
Mechanical
Project
Overview
Mechanical
ECU/ESB Construction
ECU/ESB
Chip Tests
ECU Function
Development
Electrical
Software
Software and
Electronic
Engine
Integration
Engine simulation
with Labview
Verification Test
Budget
Mock Engine Test
32
• Goal: Verify CPRs 3-8 are met using engine hardware without danger to the engine
Performed with air at Boulder Municipal with a blast tunnel
Electronic Data
Signals from/to
and Commands
Stock Hardware
RPM Sensor
RPM
Not
Connected
to each
other or the
engine
Processed Data
Command
Component
TEMP
Thermocouple
Run as in
engine
operation
Key
Raw Data
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Pressure Vessel
Flow Controller
Methane
Delivery System
Student Engine
Control Unit
(ECU)
RC Command
Integrated Engine Test
32
• Goal: Successful operate engine with methane; Verify all requirements (CPR 1-8)
Performed with methane at Boulder Municipal with a blast tunnel
Electronic Data
Signals from/to
and Commands
Stock Hardware
RPM Sensor
RPM
Key
Raw Data
Processed Data
Command
Component
TEMP
Thermocouple
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Combustor
Flow Controller
Methane
Delivery System
Student Engine
Control Unit
(ECU)
RC Command
Integrated Engine Test
33
• Goal: Successful operate engine with methane; Verify all requirements (CPR 1-8)
Performed with methane at Boulder Municipal with a blast tunnel
Engine Process
Data Collected
Performance
Characterization
Engine Run Sequence
Startup
Objective 1
Startup
RPM
Maintain engine
speed above
35kRPM?
Objective 2
Shutdown &
Emergency
Shutdown
Shutdown &
Emergency
Shutdown
Engine shuts down
safely
Objective 3 Engine Running RPM & Temperature
Objective 4 Engine Running
Temperature, &
Mass Flow Rate
Wait For
User
Command
Shutdown
Below 130,000 RPM
Temperature below
700oC
Engine
Running
Control
Loop
Emergency
Shutdown
Flow Rate vs
Temperature
Apr
25hr Remain
Apr 19
34
Critical Project Requirements
Requirement Subsystem
Description
CPR.1
FDS
The FDS shall deliver 0.9-4.2g/s ± 5% of methane to the combustion chamber
CPR.2
FDS
The FDS shall deliver lubricant to the bearings at rates equal to or greater than
stock rates
CPR.3
ESB
The ESB shall read data from the existing thermocouple and hall effect sensor
CPR.4
ESB
The ESB shall transmit sensor data to the ECU
CPR.5
ESB
The ESB shall drive signals to engine hardware components
CPR.6
ECU
The ECU shall implement open loop control to control fuel flow rate
CPR.7
ECU
The ECU shall shutdown the engine should the exhaust temperature exceed 700oC
or the RPM exceed 130,000
CPR.8
ECU
The ECU shall detect an ignition failure, shutoff fuel flow, and drive compressor
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
35
BUDGET
Project
Overview
Mechanical
Software and
Electronic
Engine
Integration
Budget
Budget – MSR Recap
37
$3,500
$3,000
Total: $4,273
$350
$2,500
$2,000
$1,500
$2,697
$1,000
$700
$900
$500
$266
$0
ECU
$100
$111
$149
FDS
Already Spent (MSR)
Testing
Remaining (MSR)
Other
Budget – TRR Status
36
$3,500
$200
$3,000
Total: $5,044
$2,500
$2,000
$1,500
$2,945
$1,196
$740
$1,000
$500
$300
$517
$149
$0
ECU
FDS
Already Spent
Testing
Expected Future Expenses
$192
Other
Remaining Available
Budget – TRR Remaining
37
$1,400
$1,240
$1,196
$1,200
$1,000
$800
$600
$400
$200
$0
Future Costs
ECU, FDS, Other Expected
Remaining Available
50
BACKUP SLIDES
Methane: Delivery Verification (Detail)
• Goal: Verify methane delivery within error bounds (CPR 3)
Pressure Relief Valve
Manual
Control
Flowrate
Delivered
Relief Valve at
operational
engine pressure
Fuel Injectors
Methane
Cylinder
Shutoff
Solenoid
Mass Flow
Controller
Check
Valve
Pressure Vessel
Thermocouple Input Software Test
• Connect SPI interface to pins C4
throughC7
• Temperature transmitted through
SPI bus from ESB
• Interrupt based.
• Runs continuously
• EGT used to regulate engine
safety – 700o max
Feb 20
2 Hours Remaining
Feb 28
Mass Flow Controller Output Software Test
• Connect through RX/TX on pins
C2, C3
• Mass flow data transmitted via
RS-232 communication protocol
• Function based
• Runs only when called
• Mass flow used to control the
engine throttle level
Feb 20
2 Hours Remaining
Feb 28
RC Controller Software Test
• Connect RC Receiver to pin D3
• D3 – RC Throttle Input
• Interrupt Based
• Throttle input used to set the
mass flow controller
Feb 20
2 Hours Remaining
Feb 28
RPM Input Software Test
• Connect RPM input to pin A6
• Interrupt based
• Must run continuously
• RPM used to regulate engine
safety – 130,000 max
• RPM used to regulate the
lubrication flow
Feb 20
2 Hours Remaining
Feb 28
Starter Motor Output Software Test
• Connect starter motor to pin E0
• Starter motor receives PWM signal
• Interrupt based
• Runs continuously
• Starter Motor used to start the
engine, as well as safely cool
engine in shut down
Feb 20
2 Hours Remaining
Feb 28
Electrical/Software: Command Flow
RPM Sensor
RPM
Thermocouple
TEMP
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Injectors
Flow Controller
Methane
Delivery System
RC Command
Student Engine
Control Unit
(ECU)
Key
Raw Data
Processed Data
Command
Component
Jan 1 5hr Remain
Feb 22
Electrical/Software: Integrated Testing Part 1
• Goal: Verify Engine Sensor Board reads and transmits engine status (CPR.8)
RPM Sensor
Student Engine
Thermocouple Sensor Board
(ESB)
Simulated Input:
Function Generator
DC Power Supply
LabView
RPM
TEMP
Recorded Output:
Oscilloscope
LabView
Key
Raw Data
Processed Data
Command
Component
Jan 1 5hr Remain
Feb 22
Electrical/Software: Integrated Testing Part 2
• Goal: Verify Engine Control Unit receives data and sends commands (CPR.X)
RPM
TEMP
Starter Motor
Pump
Solenoid
Glow Plug
Flow Controller
RC Command
Student Engine
Control Unit
(ECU)
Key
Raw Data
Processed Data
Command
Component
Jan 1 5hr Remain
Feb 22
Electrical/Software: Integrated Testing Part 3
• Goal: Verify Engine Control Unit functions with Engine Sensor Board (CPR X)
RPM Sensor
Student Engine
Thermocouple Sensor Board
(ESB)
RPM
TEMP
Starter Motor
Pump
Solenoid
Glow Plug
Flow Controller
RC Command
Student Engine
Control Unit
(ECU)
Key
Raw Data
Processed Data
Command
Component
Jan 1 5hr Remain
Feb 22
Electrical/Software: Integrated Testing Part 4
• Goal: Verify Engine Control Unit functions with Engine Sensor Board (CPR X)
RPM Sensor
RPM
Thermocouple
TEMP
Starter Motor Student Engine Starter Motor
Pump
Sensor Board
(ESB)
Pump
Solenoid
Solenoid
Glow Plug
Glow Plug
Flow Controller
RC Command
Student Engine
Control Unit
(ECU)
Key
Raw Data
Processed Data
Command
Component
Jan 1 5hr Remain
Feb 22