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EControls
Software Design
EControls designs, writes, and qualifies its own software for both embedded
(engine control) and interface (PC / handheld / remote monitoring) platforms.
EControls’ unique approach to software brings together the theoretical
control system design phase, software coding, physical implementation and
testing, validation, and calibration. In less nimble companies, this chain
is broken into its individual links with the result of slow development
cycles and tedious calibration procedures culminating in production software
that is difficult to fully validate. EControls maintains the continuity
of the chain by utilizing small groups of highly qualified engineers formally
trained and experienced in control systems, mechanical engineering, and
software development. The result is better software in less time than any
other company in the world. This is an EControls’ core technology that
separates us from all others.
EControls’ embedded software integrates real-time, engineering-based
physical models of the engine and its associated dynamic systems into the
engine controller. This includes models for:
- instantaneous air flow at the throttle
- instantaneous air flow at the engine intake ports
- EGR flow at the introduction point and the intake ports
- transport (time) delay models for fuel and EGR
- spark advance compensation for effective in-cylinder conditions at
the time of ignition including temperature and EGR
- modeling of many temperatures throughout the engine system including
air temperatures at the intake port, temperatures at TDC compression,
exhaust temperature, and catalytic converter bed temperature
- speed governor compensation for engine load and speed sensitivity
- liquid-fuel wall-wetting and vaporization
These models allow the software to compute or accurately estimate thousands
of parameters that would normally require manual calibration. Instead of
requiring an engine calibrator to enter thousands of values into tables,
the calibrator often only has to enter a few physical (and easily measurable)
parameters such as intake manifold volume, exhaust volume, and compression
ratio. From these types of basic physical constants and a small set of sensor
input data, the engine controller automatically generates the remaining
information required to operate the engine at all speeds, loads, and temperatures.
Not only is this approach to calibration easier, quicker, and cheaper than
a manual point-by-point approach, it is also more accurate over the entire
engine operating envelope due to the inability of the calibrator to hold
certain (typically transient) operating conditions long enough for proper
calibration.
In addition to pure engine control functions such as air, fuel, spark, and
speed control, EControls’ software provides support for a vast array
of auxiliary functions:
- CAN (J1939), J1708, RS-485, and RS-232 data links
configurable ancillary device control such as gauge/tachometer control,
oil makeup, …
- digital inputs for switch selectable features and operating mode
control
- support for auxiliary analog inputs, such as additional pressures
or temperatures
EControls supplies user-friendly, Windows 9x/2000/XP based PC interface
software to all of its control module customers at no cost. This software
is truly world class offering:
- graphical gauge emulations of all types
- built-in data logging of any number of user-defined variables
- strip chart or ‘oscilloscope’ graphing in real-time of
user-defined variables
- simple page reconfiguration and parameter addition/deletion
- scroll bar support for all screen sizes
- integrated ECM calibration upload and download
- full field reprogramming support
- multi-level password access as described below
This software supports a virtually unlimited number of levels of password
access to features and information – for both access to a particular
customer’s full line of products or as refined as access to only a
single serial number unit. All of this functionality is included in a single,
web-distributable and updateable package with easy automated PC installation
on the target computer.
EControls also integrates world-class diagnostic systems into the control
package. This includes:
- support for 2, 3, or 4-digit customer defined fault codes
- support for field extractable fault information using a laptop PC,
a handheld display, a remote data link connection for stationary engines
(CAN, RS-485, …), or simply by blinking the fault codes on the
MIL (malfunction indicator lamp)
- automatic control system state snapshot storage at the time of occurrence
of a fault with user definable parameter storage support
- automatic flight-data-recorder information stored at the time of
occurrence of a fault with both pre- and post-fault data capture with
user definable parameter storage support
- integrated ‘hypertext’ embedded fault diagnosis help screens
accessible by clicking directly on the fault indication
In addition to a PC-based diagnostic interface, EControls also offers a
low-cost handheld interface. This tool is small, durable, and highly portable
— and offers many of the same features of our full PC-based package.
This is an excellent tool for field support personnel.
The combination of leading-edge embedded control software, ease of calibration,
user-friendly interface tool software on multiple platforms, and a rich
set of auxiliary functions truly sets EControls apart from competitors.
Our software reflects our commitment to giving our customers a competitive
advantage in the market place and exceeding their customer’s expectations.
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