Engine and Transmission Controls

Overview

New Eagle has the following experience:

• Powertrain and vehicle modeling

• Engine calibration

• Model based controls development methods

• Engine control algorithm development including port and direct injected fuel delivery, spark advance, bypass air, torque management, electronic throttle positioning, cylinder deactivation, cam phaser positioning, and all associated diagnostics.

• Interactive transmission controls for conventional automatic transmissions, CVT, and DCTs

• Extensive experience working to OEM production requirements, and utilizing industry best practice development methods and processes.

• Experience working in partnership with Tier 1 suppliers, both domestically and internationally.

• Supplier development, evaluation, and selection

Integrated Powertrain Control

The New Eagle Engine Management Control System uses MotoHawk model-based developed tools, process, and libraries. This is carried through from prototype through production. New Eagle has utilized the basic building blocks provided in this tool to create a set of high level function libraries, which can be used to construct a complete powertrain management system to customer specifications.

Engine Control Library Blocks

The high level building blocks in the New Eagle function library are shown below, along with a brief description of the functionality contained within:

Sensors The hardware interface to all sensors, including resource assignments and basic ADC to engineering units conversions are performed here. Functions in this block include:

• analog inputs (pressures, temperatures, voltages, positions, flow rates, switch states, etc.)
• CAN inputs (same as above, but via CAN interface)

Actuators The hardware interface to all actuators, including resource assignments and basic scaling to ADC units are performed here. Functions in this block include:

• primary actuators (spark plugs, throttle body, fuel injectors, fuel pumps, "hardwired" lamps, etc.)
• secondary actuators / accessories (alternator, fan , AC compressor, etc.)

Virtual Sensors Within this block are the modeled sensors. The modeled sensors are state variables that have been created from available actual sensor information. This modeled sensor information is available to the higher level control algorithms. Examples of functionality contained within this block include:

• modeled air charge
• engine running timers
• engine state determination (cranking, running, stall, etc.)
• steady state determination
• modeled temperatures
• Lambda (wide range O2 and switch type sensors)

Diagnostics Sensors Overrides This block provides a means of replacing the sensor value with a default value when the diagnostic algorithms deem it appropriate, based on the severity of the fault that has been identified.

Base Algorithm controller This block contains the core high level functionality of the control system. It contains most of the functions required for basic engine operation. Some examples of functions contained within this block include:

• Pedal Interpretation as a torque requestor
• Cruise Control
• PTO Control
• Torque limiting functions (over-speed, over-rev, interface to transmission limiting requests, and ABS limiting requests)
• Torque arbitration
• open loop fuel control
• closed loop fuel control
• Upstream control (wide-band and switch type control available)
• Downstream control (switch type control only)
• intake airflow characterizations and dynamics
• idle control (utilizing slow and fast path torque actuators)
• Deceleration Fuel Cutoff and safety fuel cut (DFCO/FC)
• ignition angle and energy characterization as a function of speed, load, temperatures, pressures, knock, etc.
• engine torque characterization – forward path (friction and pumping losses, indicated engine torque to air charge characterization, modifiers for ignition retard from MBT as scheduled from base spark control, temperature and pressure modifiers, equivalence ratio modifier, ignition angle offset request based on fast path torque, torque reserve request and slow path / fast path coordination, DFCO/FC)
• engine torque characterization – reverse path (frictional and pumping losses, air charge to torque characterization, modifiers for ignition retard from MBT, equivalence ratio modifier, temperature and pressure modifiers, DFCO/FC).
• accessory control (fan, AC, alternator, etc.)

Component Control This block contains control algorithms linked to specific actuator hardware. functions contained within this block include:

• throttle position controller
  • throttle learning algorithm
  • ice breaking algorithm
• certain customer specific actuators
• HEGO heater control

Diagnostics Actuators Overrides This block provides a means of replacing the commanded value with a default value when the diagnostic algorithms deem it appropriate, based on the severity of the fault that has been identified.

Characterization This block provides conversions from engineering units to the hardware level units

• fuel mass to injector pulse width conversion (with appropriate temperature, pressure, voltage corrections)
• ignition angle and spark energy to ignition coil start and stop angles

Drive By Wire Redundant Calculations and Diagnostics This block contains all of the functionality required to validate all inputs and calculations resulting in the positioning of the throttle blade. These functions include:

• sensor rationalities with redundant and modeled sensors
• torque path calculations with redundant sensor set
• main micro checking with secondary checking micro (cross checking by each micro to monitor the state of health of the other micro)
• 3 level torque safety structure

OBD II Diagnostics OBD blockset integration aiming to be compliant with OBD II 1968.2

• Sensors: input high, input low, rate high, rate low
• Actuators: open/shorted
• CAN inputs: rate

OBD II Major Monitors and Rationalities This block contains the major monitors and rationalities. Examples of functions contained within this block include:

• fuel system monitor
• catalyst monitor
• simple misfire
• catalyst temperature model (utilized by the catalyst monitor and certain base algorithm functions).
• engine coolant temperature monitor

Communications and Reporting This block includes the interfaces required for J1939 communications, freeze frames, etc. as required for diagnostics tools and customer specific tools such as "in-plant" and "end of line". Communications interfaces to other systems are also provided, such as:

• cluster
• body controller
• transmission controller
• chassis controller
• CCP support

Standard Engine Controller

Standard Engine Controller In Development

Spark Ignited Engines

• Automotive quality and prices for components including sensors, throttles, and engine controllers
• Enhanced user interface for engine control and system installation and setup
• Auto Start / Stop features for scheduled duty cycle or remote engine and load control
• Fuel efficiency advantages by utilizing automotive style torque control algorithms
• OBD diagnostics to protect engine and other system components
• Adaptive to multiple fuel usage
• Adaptable controls for mobile and stationary applications
• Experience with vapor lock handling and purge routines

Compression Ignition Engines

Fire Protection Systems

Electronic Engines

Electronic Engine Fire Control System Diagram

An electronic engine fire control system integrates an engine control unit with additional I/O and logic to perform fire control functions. Communication with the engine control unit is done over a data bus such as the J1939 CAN bus interface.

System Inputs and Outputs

Typical system I/O for the electronic engine consists of:

• SCB Replacement
  • Valve output
  • Current feedback of the valve output
  • General fault alarm output
  • Thermistor in pump - ambient temperature
  • Bypass valve output - optional
  • Thermistor input - raw water - optional
• Suction Pressure Alarm
  • Alarm output
• ECM Supervisory Switch
  • ECM switch driver
  • Alarm - Primary/Alternate ECM failure, Engine Running Alarm

Mechanical Engines

A diagram for a mechanical engine fire control system. The picture includes an integrated fire pump controller, two batteries, an engine, a pump and a check valve.

Mechanical Engine Fire Control System Diagram

A Mechanical Engine Fire Control System does not interface with a data bus and therefore requires control and signal inputs and outputs.

System Inputs and Outputs

Typical system I/O for the mechanical engine consists of:

• Remote start/stop
• COM pumphouse trouble
• Emergency stop
• Sprinkler (interlock)
• Charger failure
• Access lock
• Oil pressure sender
• Water temperature sender
• Pressure sensor
• Mag pickup
• Engine running
• Fuel solenoid
• Horn
• Starters 1 and 2
• Engine/Pumphouse trouble

Heavy Fueled Engines

Optimax JP

Members of New Eagle's engineering team have been working on applying the electronic fuel injection (EFI) system built in MotoHawk on UAV engines. The benefit of the MotoHawk system to the UAV is that the electronics and software have millions of hours of operation including use on the JP Marine heavy fuel engine.

One unique feature of the New Eagle EFI system is that it burns heavy fuels, JP5, JP8, and Jet A fuel. Derivatives of the EFI system have run on the UEL Rotary engine, and the xRDI Heavy Fuel engine.

The New Eagle EFI system has been developed and tested on various airframes:

• AAI Shadow
• Raytheon KillerBee
• AeroMech SandDragon

xRDI

xRDI of Beaufort, South Carolina has a number of applications using the New Eagle EFI system.

Current xRDI Projects Include:

• Engine replacement for Unmanned Aerial Vehicle (UAV), 35 hp
• Auxiliary Power Unit (APU) for business jets, 17 hp with starter generator
• Flight demonstration and engine evaluation program with major airframe supplier, 17 hp
• Flight demonstration and engine evaluation program, 35 hp
• STUAS- Tier 2, Navy and Marine joint program for ship based UAV, 15 hp
• Unmanned Ground Vehicle, 6 hp with starter generator
• SBIR Darpa Program for a 10 hp Small Engine Designed for High Efficiency, High Power Density and Quiet Operations
• Development Program for a 3-Cylinder and 4-Cylinder Heavy Fuel Engine for UAV application

OBD Diagnostics

• Reduces service time from trouble shooting
• Protects engine from harmful conditions such as low oil
• Reduces engine and system component warranty costs through system protections
• Prognostics available for scheduled service intervals
• Remote communications for system status available
• Ability to meet and exceed emissions requirements based on application

Transmission Controls

New Eagle’s team of engineers has had vast experience in the development, integration and deployment of controls. With past experience - including and not limited to: Torque based Control, Chassis Powertrain Controls, Active Braking, ESP Stability, interaction based on Torque messaging, Powertrain coordination schemes optimization and more, for both diesel and gasoline engines - New Eagle, as Controls Integrators, seeks to accomplish even more challenging projects in future. We believe we have the correct solution to meet the needs of all our customers, whether it is a specific demand or a simpler challenge. Not only that, our experience over the years has given us the capabilities to ensure success with high quality of reliability, robustness, performance and support for our projects.

Gasoline/Gaseous & Diesel Fuels

Gaseous Fueled Engine Controls

• Automotive quality and prices for components including sensors, throttles, and engine controllers
• Enhanced user interface for engine control and system installation and setup
• Auto Start / Stop features for scheduled duty cycle or remote engine and load control
• Fuel efficiency advantages by utilizing automotive style torque control algorithms
• OBD diagnostics to protect engine and other system components
• Adaptive to multiple fuel usage
• Adaptable controls for mobile and stationary applications
• Experience with vapor lock handling and purge routines

Dual Fuel Systems

New Eagle engineers have worked to help customers build Dual-fuel (diesel / cng) control systems to reduce the fuel cost of stationary and mobile applications, both certified and non-certified. The MotoHawk tool chain is an ideal product for such an application.

• Allow existing diesel engines to safely substitute natural gas ranging from 65% to 80%
• Mileage dramatically increases due to burn rate and efficiency of diesel combustion
• Market payback: occurs within months, depending upon price of fuel
• Seamless integration with existing vehicle systems via CAN:
  • Transmission
  • Chassis
  • Body
  • Instrument Clusters

Engine Control Library Blocks

There are libraries that have been developed over time to help the customer implement On Board Diagnostics software for their production programs.

OBD II Diagnostics OBD blockset integration aiming to be compliant with OBD II 1968.2

• Sensors: input high, input low, rate high, rate low
• Actuators: open/shorted
• CAN inputs: rate

OBD II Major Monitors and Rationalities This block contains the major monitors and rationalities. Examples of functions contained within this block include:

• fuel system monitor
• catalyst monitor
• simple misfire
• catalyst temperature model (utilized by the catalyst monitor and certain base algorithm functions).
• engine coolant temperature monitor

Communications and Reporting This block includes the interfaces required for J1939 communications, freeze frames, etc. as required for diagnostics tools and customer specific tools such as "in-plant" and "end of line". Communications interfaces to other systems are also provided, such as:

• cluster
• body controller
• transmission controller
• chassis controller
• CCP support