Capstone Design Document
Contents
1. TRL Vanguard Engineering Group Problem Statement The Vanguard Engineering Group is dedicated to optimizing transmission performance through the development of an after market electronic control system for automatic transmissions Functional Requirements These functional requirements are the features that we must design and implement into the TORC Transmission Controller These range from the basic functionality of an electronic transmission controller to other features beyond shifting gears which will add value and set this transmission controller apart Functional Requirements e Transmission Control Functionallity e Quick Logic System e Alternate Mode Operation e End User Configurability e Intuitive User Interface e Rugged Packaging e User Friendly Installation Figure 1 Functional Requirements Transmission Control Functionality This device will properly operate and control the functionality of the GM 4L60E automatic transmission using an electronic control system with data from the necessary sensors Quick Logic System The controller will contain shifting algorithms that provide for the optimum performance of the transmission Alternate Mode Operation A benefit of having an electronic transmission controller is that you can create alternate transmission modes This allows the user to be able to change the shift timings to suit their current needs Some basic modes that can be included are race2. Conditioning DIO e Efficient Software Architecture and Timing e User Input System e System Feedback To User e Alternate Shift Timing Algorithms e Executable Software Package e Serial Communications RS 232 DB9 Cable e Reprogrammability of Controller e Character of Graphical LCD Display e PMP Communications With Controller e Display Unit Enclosure e Attractive Enclosure e Environmental System Testing e Proper Hardware Specifications e Color Coded Wiring Harnesses e Installation Manual e Installation Video Guide February 29 2008 Project TORC Page 4 TRL Vanguard Engineering Group Technology Survey Assessment Transmission Control Functionality gt Microcontroller based system Pros e Contains several on chip peripherals e Development team is most familiar with these devices Cons e Less customization ability gt ASIC based system Pros e Extremely customized system e Faster operation Cons e Expensive e Time consuming gt FPGA based system Pros e Faster operation Cons e Development team has little experience with these devices Vanguard Engineering has chosen to use a microcontroller based system A microcontroller based system will provide all of the needed functionality and a low price and with the least amount of learning curve for the development team February 29 2008 Project TORC Page 5 TRL Vanguard Engineering Group o Quick Logic System g
3. shifting Some of the main sensors that are used to determine gear selection are engine speed vehicle speed and throttle position Using these inputs along with the shifter position digital input we can select the proper gear Once the controller has selected the proper gear that the transmission needs to be in it will output to the proper shift solenoids which will mechanically force the transmission into the proper gear Another portion of the transmission that we must control besides the gear selection is the torque converter or TCC One benefit of controlling the TCC is the ability to improve the gas mileage of the car This can be done by disabling the torque converter when it is no longer needed thus improving gas mileage Using this controller we will also be able to include an LCD module for a useful and attractive user interface Along with this module we will include a way for the user to select which shifting mode they would like to use such as race mode or efficiency mode February 29 2008 Project TORC Page 11 TRL Vanguard Engineering Group Deliverables Deliverables are the elements that we will present to the project stakeholders to demonstrate the growing value of this project These are markers of achievements like milestones only these markers have specific value to the stakeholders and are actual tangible elements that prove the design group is making progress It is important that these deliverables are p
4. the high level goals that VEG has set to accomplish throughout the course of this design project Whenever a milestone is reached it will mark a significant stage of completion in the development process The final milestone is the only milestone that really counts but setting several milestones will keep the project on track and allow for the development of a better product e Completion of Research e Development Environment Established e Hardware Design Specification e Hardware Prototyping e PCB Design and Implementation e Transmission Control Software e User Configuration Software e Hardware Testing e Software Testing e Initial Prototype e System Testing e Pre Production Prototype Figure 6 Milestones Completion of Research Although research will continue throughout the entire process there is still a milestone when all of the necessary research is done so that the team can begin to move to the design phase Development Environment Established Determining the software environment and the main hardware with which we will be working with will be one of the first steps in starting the design phase February 29 2008 Project TORC Page 15 TRL Vanguard Engineering Group Hardware Design Specifications Completed At this milestone we will have determined all of the sensors that we will be using and all of the necessary circuitry and hardware needed to complete our design Hardware specifications such as wiring an
5. the system This system will also be able to function in other ways than just the alternate mode selection End User Configurability gt PC Configuration software Pros e Most robust system e Easily upgradeable Cons e Requires user to have a PC e More extensive implementation process gt Control unit hardware based configuration Pros e Cheap e Easy to use e Easier implementation for design team Cons e Not upgradeable e Limited by control unit dimensions gt Configuration through user interface Pros e Adds functionality to the user interface e Allows user to configure in car Cons e Depends upon user interface implementation e Limited with small screen and form of input February 29 2008 Project TORC Page 7 TRL Vanguard Engineering Group Vanguard Engineering has chosen to develop a software executable for the configuration method This will allow for more options and upgradability for the system It will also be more user friendly Intuitive User Interface gt Graphic LCD Pros e More robust display e More attractive Cons e Expensive e More difficult implementation gt Character LCD Pros e Cheap e Easy to use Cons e Less Attractive gt Touch screen Pros e Most user friendly interface e Allows for more options Cons e Cost prohibitive e Development time outweighs benefits For the TORC user interface our design group will most likely implement a graphical LCD disp
6. 1 1 9 2008 Completion of Research 10 17 2008 system Tecan Transmission Control Software i 11 14 2008 Hardware Testing 9 19 2008 Hardware Prototyping 8 25 2008 12 2 2008 9 12 2008 Hardware Design Specification oe SODE 1 A n m 11 7 2008 Pre Production Prototype 10 10 2008 o a Software Testing PCB Design and Implementation Figure 7 Functional Requirements February 29 2008 Project TORC Page 17
7. Our printed circuit board will contain all of the hardware necessary for our final prototype in an efficient package This PCB will allow for the concise and easy fabrication of our hardware and will fit in the enclosure that we design Commented Source Code In the creation of our controller we will also create the source code for both the transmission control and the user configuration software This source code will contain the algorithms that allow the controller to read the sensor data and control the shifting of the transmission s gears User Configuration Program The user configuration program is the software executable that the end user will use to configure the controller This software will be provided in its final form and will be able to be used with the final prototype to customize certain features Flow Chart and Algorithm Pseudo Code Along with our final source code our team will also provide a flow chart and pseudo code of the source code explaining the algorithms used and how the program functions Cost Analysis Included with the rest of the deliverables will be a cost analysis of the project The cost analysis will ensure that the cost of design and production fall in line with what the stakeholders deem suitable for the TORC control system Test Plan and Test Data Including the test plan and the test data in our deliverables will allow the stakeholders to see how we have tested our design and what the results are fro
8. age 2 TORG Vanguard Engineering Group Conceptual Block Diagram The conceptual block diagram is a high level representation of the system that we will implement for the transmission control In the center we have the enclosure containing the microcontroller and the heart of the system The microcontroller takes in data from the necessary sensors and makes decisions as to which gear the automobile needs to be in by outputting to the mechanical control portion of the transmission controller We have also included an overview of how the user will interface with the controller When the controller is installed in the vehicle we will have some form of display and an interface for selecting the current mode you want the transmission to be in such as race tow or economy Also displayed is the high level representation of how the user will be able to configure the controller using a home computer Figure 2 Conceptual Block Diagram February 29 2008 Project TORC Page 3 Performance Requirements Transmission Control Functionality Quick Logic System Alternate Mode Operation End User Configurability Intuitive User Interface Rugged Packaging User Freindly Installation VEG Vanguard Engineering Group e Controls overall operation of the automatic transmission e Provides reliable service that is robust and handles errors e Processing power e 16 bit processor e Sensor Readind A D Signal
9. d harnesses will be completed for this milestone Hardware Prototyping Completed After the specification we will piece together a rough prototype in which we can determine if our designs will function as required This milestone will be considered completed when all of the hardware that we have specified for design has been implemented in a rough from PCB Design and Implementation Completed The rough prototype will need to be developed into a PCB design which will be our final hardware schematic and design This design will then be what we work with in testing and software development for the remainder of the project Transmission Control Software Completed This milestone marks the completion of the transmission control software This will be all of the software that is required to read the transmission sensors and control the operation of the transmission successfully User Configuration Software Completed The user configuration software is a separate entity from the transmission control software and is aseparate milestone This will require a different style of programming that our group has little experience with and it will be a great accomplishment Hardware Testing Completed Testing is a necessary phase in our process When the hardware design that we have implemented is done being tested we will be one major step closer to an initial prototype Software Testing Completed It is necessary that our control software and con
10. figuration software is tested extensively before the system testing is done We may be testing this device on an actual transmission and anything but minor errors could cause expensive damage If the software is tested extensively then we can eliminate this chance and will have created a functioning program that we can further test as a system February 29 2008 Project TORC Page 16 Vanguard Engineering Group Initial Prototype Completed Combining all of the software and hardware that we have created into an initial prototype will be a great achievement for our team This will mark a closing to the majority of the design and implementation work and the beginning of our system testing System Testing Completed This testing stage will be the benchmark for determining whether or not our system is going to function as required When this stage is completed our only step will be to create a final prototype and make sure that we have finished all of our work packages Pre Production Prototype Completed This milestone will mark the closing of our project It is at this point that our team will have created a device that is to our satisfaction and that we feel will please our stakeholders It may not mark the end of our team s work but it will be the end of all design and implementation for this final prototype Milestones Timeline 3 29 2008 Development Environment Complete 10 24 2008 8 29 2008 User Configuration Software 1
11. lay This allows for a more pleasant and diverse interface while still maintaining low cost levels and development times Rugged Packaging gt Custom Enclosure Pros e Can allow for better fit e Adds aesthetic value Cons e Expensive e Requires increased design time gt Existing Enclosure Pros February 29 2008 Project TORC Page 8 TRL Vanguard Engineering Group e Cheap e Less design time required Cons e Less custom appearance of device e Could be hard to track down a proper fitting enclosure gt No Enclosure Pros e Cheapest method Cons e Leaves device with little protection e Extra detail will be needed for mounting and placement of the device in a vehicle Vanguard Engineering plans to investigate further the custom enclosure option so that we can give TORC a custom feel that we feel will help the device appeal in the after market arena If this is too cost prohibitive we will acquire a pre built enclosure for our system User Friendly Installation gt User s Manual Pros e Can be included with retail package e Requires no other materials Cons e Can be more confusing than a live video gt Installation Video Pros e Provides better visual aids e Can be provided on a website Cons e Requires some hardware such as computer or DVD player gt Live Help Pros e Can help solve problems e Provides better service to the customer Cons e Expensive e The development tea
12. m those tests February 29 2008 Project TORC Page 13 Vanguard Engineering Group User s Manual and Installation Video A copy of the user s manual and installation video will be delivered to the stakeholders This manual will give a technical description of the device as far as the end user is concerned This will allow them to gain an understanding of what the device does and a little bit of how it functions Pre Production Prototype The final prototype will be one of the last deliverables This deliverable will include our final design along with its enclosure and all of the wiring necessary to install the controller to a GM 4L60E Project Documentation and Final Report Along with the final prototype we will also include the final report and documentation covering the entire scope of the design project and the final design 6 29 2008 11 28 2008 Functional Block Diagram and Hardware Schematics User s Manual and Installation Video 11 28 2008 Pre Production Prototype 12 1 2008 10 31 2008 Final Report Commented Source Code 10 31 2008 9 26 2008 User Configuration Program Parts List 6 25 2008 i J 12 2 2008 10 17 2008 Cost Analysis 9 12 2008 Flow Chart Algorithm Pseudo Code a 11 21 2008 11 7 2008 Test Data Test Plan 10 3 2008 PCB Layout Design Figure 5 Deliverables Timeline February 29 2008 Project TORC Page 14 TORG Vanguard Engineering Group Milestones The project milestones are
13. m will be unable to implement this system February 29 2008 Project TORC Page 9 TRL Vanguard Engineering Group Vanguard Engineering will provide both a manual and a video in their deliverables This gives the user two options of how they would like to learn the installation methods and it will not be difficult to implement both of these The customer satisfaction will most likely outweigh the time spent on developing both forms of installation instructions Functional Block Diagram The functional block diagram covers the design of our system in a more detailed level As shown in this diagram the PIC24FJ128GA010 is the microcontroller being used in our system This will be the controller that is used to control the transmission using the sensor data and digital inputs that it receives Signal Conditioning Signal Conditioning Signal Conditioning Signal Conditioning Signal Conditioning Signal Conditioning 81 TB 77 76 PIC24FJ128GA010 Microcontroller Signal Conditioning Signal Conditioning Signal Conditioning EE DIGITAL LINES ANAGLOG LINES PWM LIMES 12V LINES a INPUTS OUTPUTS 3 3v LINES E Figure 3 Functional Block Diagram February 29 2008 Project TORC Page 10 TRL Vanguard Engineering Group In the block diagram there are several inputs into the microcontroller Most of these inputs are sensors inputting the necessary data needed to determine proper
14. mode tow mode and efficiency mode This will change the timings to either increase a specific performance point or increase the gas mileage of the car February 29 2008 Project TORC Page 1 TRL Vanguard Engineering Group End User Configurability The end user will be able to configure certain aspects of the controller using his home computer some interface software and a communication link between the user s home computer and the transmission controller Some options that can be controlled can range from custom timing modes to display information on an included LCD display Intuitive User Interface This product will also include a user interface allowing for the display of statistics and diagnostic information The user will also be able to select operating modes and control features fluidly using this interface Rugged Packaging Although the optimum placement will be on the inside of the automobile the device will have a rugged and attractive enclosure to prevent damage from neglect abuse or improper placement User Friendly Installation It is imperative to the success of this device that it is easy for the user to install In order to support this ease of use we will insure throughout our design that we are taking the end user into account We will also create excellent documentation and installation instructions for the end user to insure the installation is easily done February 29 2008 Project TORC P
15. resented throughout the course of the project so that the stakeholders can make informed evaluations of the team s progress Deliverables e Parts List e Functional Diagram e Hardware Schematics e PCB Layout Design e Commented Source Code e User Configuration Program e Flow Chart and Algorithm Pseudo Code e Cost Analysis e Test Plan and Test Data e User s Manual and Installation Video e Pre Production Prototype e Project Documentation and Final Report Figure 4 Deliverables Parts List The parts list will contain in detail all of the parts that we use in our design This is valuable to our stakeholders so that they can determine the cost of each part and will know which parts to order to make more devices February 29 2008 Project TORC Page 12 TRL Vanguard Engineering Group Functional Diagram The functional diagram will be presented as a deliverable to the stakeholders This functional diagram will include the entire system schematic in a form that includes all of the components and how they are connected together The functional diagram is the best way to get quick information on the system design of the TORC transmission controller Hardware Schematics The hardware schematics will include the pin layouts connections and circuit drawings of the hardware we design This in addition to the parts list will include all the information one would need to replicate our hardware design PCB Layout Design
16. t AVR 8 bit microcontroller Pros e Cheap e Well supported Cons e Contains too few peripherals gt PIC 16 bit microcontroller Pros e Cheap e Well supported e Sponsor supports this device Cons e Slower than 32 bit micros gt PowerPC 32 bit microcontroller Pros e Fast operation e Team has previous experience with this device Cons e Expensive e Unnecessary for this implementation TORC will be developed using a 16 bit PIC microcontroller More specifically we plan to use a PIC24 This decision was based on the fact that PAINLESS our sponsor has built previous devices with this controller and would like to continue using it for new design projects Alternate Mode Operation gt Selected through separate interface device Cons e Expensive e Requires multiple enclosure designs Pros e User Friendly e Highly customizable gt Selected From Interface on Control Unit Cons e Less user friendly e Adds to control unit complexity February 29 2008 Project TORC Page 6 TRL Vanguard Engineering Group Pros e Cheaper gt Include selection of mode in configuration software Cons e Dependant on configuration software e Less user friendly Pros e Cheap e No extra hardware requirements For this functional requirement the TORC design group has decide to include the alternate mode operation selection in a separate user interface This makes our device more user friendly and will add value to
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