[info] Proteus - Waterproof, High-feature ECU!

[mck1117]

Hello everyone!

Introducing rusEfi's most fully-featured ECU: Proteus

(photos to be updated as boards are assembled/tested)





Why does this board exist?
I have an LS-swapped Volvo 240, and the ECU sits in the front corner of the engine bay. When it rains, the ECU gets wet. I'd like to run rusEfi, but a wet ECU is a sad ECU (if not sealed!).

The goals started like this:

• Can run my v8 (later expanded to able to run a sequential fire, dual electronic throttle V12)
• IP68 waterproof

So, what can it do?

• 16 low-side outputs, limited to 3 amps each (injectors, relays, check engine light, etc)
• 12x ignition outputs (or general purpose 5v, 100mA push-pull)
• Dual electronic throttles
• 4x High-side 12v drivers, 1 amp each
• 4 thermistor analog inputs (2.7k pull up resistor)
• 12 General purpose analog inputs
• Dual VR sensors (crank position, wheel speed)
• 6 digital inputs (hall cam/crank position, wheel speed, clutch/brake switch, etc)
• TE Ampseal connectors: 2x 35 pin, 1x 23 pin

(Andrey edit) boards available for sale - see https://rusefi.com/forum/viewtopic.php?p=44274#p44274

[mck1117]

GitHub repository for board design: https://github.com/mck1117/proteus/

Readme on GitHub: https://github.com/mck1117/proteus/blob/master/readme.md

v0.1 Schematic, gerbers, bill-of-materials, and board PDF: https://github.com/mck1117/proteus/tree/master/export/v0.1
v0.2 Schematic, gerbers, ibom, bill-of-materials, and board PDF: https://github.com/mck1117/proteus/tree/master/export/v0.2

[mck1117]

Project progress will be logged below:

2019-12-04: Boards, BOM and connectors are in-hand. Assembly, testing, and running engine(s) soon!
2019-12-05: First board assembled!
2019-12-09: Cut the connectors off of my engine harness in my V8 Volvo, crimped on some AMPSEAL pins, and started the engine!



I hadn't yet connected any sensor pins (other than crank position...) when I shot this, so it's running completely in the blind, locked to 3.5ms fuel and 20 degrees of timing.

2020-03-03: v0.2 has been fabbed, assembled, and run an engine successfully. I've logged a few hundred miles of daily-ish driving between v0.1 and v0.2. Two more assembled boards are in the hands of @AndreyB, with plans to run his BMW M70 V12. @Crazy Striker also has boards in hand, and is nearly complete with assembly. Revision v0.3 is mostly complete, with optimizations made for nearly-complete assembly by JLCPCB's assembly service, and added silkscreen for on-board documentation.

[mck1117]

Media:

[AndreyB]

wow! subscribed!

[kb1gtt]

Very nice, very nice. I need to find some time to review the circuit.

[mck1117]

Very nice, very nice. I need to find some time to review the circuit.

There isn't a whole lot that's new here, mostly the tighter integration and focus on a small, waterproof form factor.

The most novel electrical part is the power supply, which is an Infineon TLE9471. It's a 2.2mhz buck converter, CAN transceiver, power management state machine, watchdog, etc. I think this supply is price competitive (and more efficient and smaller) than the supply currently used on Frankenso.

The injector drivers are SOIC8 drivers (two channels per package), from the same family of protected smart low side drivers as are used on Frankenso.

Ignition drivers are identical to Frankenso.

Digital inputs are buffered with a 74AHCV17 hex buffer to protect the MCU inputs, along with a diode clamp/series resistor on the input.

The board is wired for a 4-channel high-side driver, but I managed to screw up the footprint, so I can't test that on this rev of the board.

[AndreyB]

Just mentioning IWISS SN-28B Crimping Tool for AWG28-18 Dupont Pins https://www.amazon.com/gp/product/B00OMM4YUY since it's relevant to the connector used on this board.

[kb1gtt]

I just wanted to share my experience with a similar but different crimp tool at a place I worked. It was an industrial environment on equipment installed inside a building so it had a controlled dry humidity and close to 70F (23C). We had electrical fires after the equipment was in service for around 1 to 5 years. It was a huge liability to the company. I was brought in on this issue to resolve issues caused by a person who worked there before me.

We had an engineering department of about 15 engineers and the normal USA quality controls in a reputable company and we had quality well trained good assemblers. Before my time at that company, someone in engineering probably gave the OK to use the amazon crimp tool. We started getting electrical fires as soon as 2 years but more likely after 5 years of service. Our customer did an inspection and found obvious issues with the insulation after as less than 1 years of service. Some time between 2 and 5 years the heat got high enough to set fire to the component it was attached to.

It was after we had 3 fires that I was involved in this issue. At that time, we had something like 25 of this equipment in the field, each was sold for something like $20k usd. We used quality stranded tin coated Belden 12 AWG wire, the crimp device was from TE and rated for 25A. We were running 20 amps through the wire, which it was all rated for. The materials were all rated to be used with each other. The equipment that failed was run under full load for 24 hours before we shipped it. Part of our quality procedures was to inspect with a thermal camera to see if there were any abnormal hot spots. Usually this would detect a contractor which was not properly torqued. So there were no obvious issues when we shipped.

I had our production persons make several sample wires with our standard procedures. I found the generic quality ratcheting crimped devices pulled off with about 20 lbs to 30 lbs of force, while the OEM datasheet claimed they should hold something like 80 lbs. I had the crimped samples tested and we found they had a higher mOhm's than the one which were crimped with the OEM tool. I also found that the OEM crimped devices pulled off with 80 lbs to 90 lbs.

What was happening was over the course of a couple years, the mOhms was increasing as the elevated heat at the connector was causing corrosion that migrated into the crimped part of the connector. Basically the OEM crimp smashes them together cold welding the metals together, which prevents corrosion from propagating as well the OEM tool provides a lower ohm connection, which prevents watts from being generated in the connector. While the quality generic tool was not achieving that same level of quality in the connection. The results were that the connector was over heating causing electrical fires after a period of time.

If done correctly, crimped connections are among the most reliable connections you can make.

You can of course do what you want, but I would like to encourage OEM crimp tools be used. My house, my car will not burn down because I was to cheap to by the $300 OEM crimp tool. From my point of view that's cheap insurance. As well who wants your ECU to over heat and shut down during a race because you were cheap on the crimp tool.

[AndreyB]

https://rusefi.com/build_server/ now has a bundle for this Proteus board.

[AndreyB]

0.2 has happened - pictured with UB-20PMFP-LC7002 waterproof USB connector and Hammond 1590XXFL/1590wxxfl metal enclosure
Silkscreen is desired https://github.com/mck1117/proteus/issues/25

[Boostonabudget]

Any updates? I really wanna find out more info on its capabilities for my project. Can it read wideband? What files do i need to send of to have the pcb made? Also the BOM isnt very specific atm. Doesnt tell you the quantity of each indevidual part and no pricing is listed either. The more info i can get the better as i wanna build one asap.

Edit: figured out bom was trying to view on a phone when i needed my pc. Found all the gerber files and such but when i upload them to jlcpcb they only detect 2 layers? When you clearly stated 4 layers. Any idea why?

[AndreyB]

Sounds like board owner is not very available to answer questions

[Boostonabudget]

Sounds like board owner is not very available to answer questions

Damn hopefully he comes back online soon. Really want to get the ball rolling and have some boards ordered. I have all the files and firmware ready but seem to be having issues getting the pcb design correct to send off. Keeps telling me 2 layer not 4 and all sorts of other wierd things like not letting me view the design and such. Super exited to have this hooked up to my 1uz in full sequential. Just need to figure out ordering a set of pcbs and the parts i need to solder. Are there any others who have managed to get a proper 8x8 board working as of yet?

[Simon@FutureProof]

At this time the ecu has run exactly one engine and is only at rev 0.3, I have a few rev 0.2 boards arriving soon but won't have any on a car for several weeks.

The board is believed to be OK so feel free to take the plunge if you want, however frankenso is more proven and can handle V8 sequential just fine.

The issue you see with Gerber's files is quite common. If they are uploaded to jlc then they don't seem to work right, however after manual verification they are happy to make them.

[mck1117]

Sorry all, I've been busy with 85 other things at once!

Some updates:

• v0.2 is mostly a success. I have a few hundred miles of real-world driving on my v8 Volvo between 0.1 and 0.2, without any real issues detected on v0.2 (other than miswired SPI for the TLE9471, which isn't strictly required anyway).
• Work is underway on v0.3. The primary goal is to move all components to the front (non-connector) side of the board, which will make it possible to have JLCPCB (or similar) do nearly all of the assembly work for us.
• I sent a few v0.2 boards along with stencils to @SVeilleux9, and he plans to assemble at least one.

[mck1117]

Some answers to your more specific questions:

Can it read wideband?

Not internally, no. High quality external wideband controllers aren't very expensive, and it's one that most people want to have a standalone gauge for anyway. Both analog and CAN wideband controllers/gauges are supported by rusEfi, however.

What files do i need to send of to have the pcb made?

The files here should be everything you need: https://github.com/mck1117/proteus/tree/master/export/v0.2

The gerber.zip is the exact file I uploaded to JLC to fab the boards that I have.

[AndreyB]

[*] Work is underway on v0.3. The primary goal is to move all components to the front (non-connector) side of the board, which will make it possible to have JLCPCB (or similar) do nearly all of the assembly work for us.

The mostly-assembled from JLCPCB would be pretty amazing and probably worth waiting for?

Do you think it's a week or a month away? Do you plan to order pre-assembled yourself?

[SVeilleux9]

[*] I sent a few v0.2 boards along with stencils to @SVeilleux9, and he plans to assemble at least one.
[/list]

That is correct, I am starting with 1 build then will make the other 2 depending on the success of the first. I plan on using it for my turbo LS Mercedes build. Hoping to be able to get (a basic) 4l80e trans control algorithm up and running also.

And depending on the success with the Mercedes I would like to convert my Z31 to rusEFI instead of MS2.

[Boostonabudget]

At this time the ecu has run exactly one engine and is only at rev 0.3, I have a few rev 0.2 boards arriving soon but won't have any on a car for several weeks.

The board is believed to be OK so feel free to take the plunge if you want, however frankenso is more proven and can handle V8 sequential just fine.

The issue you see with Gerber's files is quite common. If they are uploaded to jlc then they don't seem to work right, however after manual verification they are happy to make them.

Awesome to here your still making improvements tho man! Ok sweet so nothing stopping me anymore thanks a bunch for the verification on that. As for wideband your very right and im more than happy with can or external wideband just thought id ask. Also as for frankenso as far as i was aware it only has 4 inj and 4 spark in full seq not all 16 or more. Is there a post I'm missing? Or is there a board type i can use to enable all 8 in seq. Thanks for your responses and hope things ease up for you

[Simon@FutureProof]

Cannot take the credit - It is mck1117 that built the board

However I can confirm that full sequential with COP works for 6 cylinders at least on Frankenso.

[Boostonabudget]

Cannot take the credit - It is mck1117 that built the board

However I can confirm that full sequential with COP works for 6 cylinders at least on Frankenso.

Agreed hes definitely built a serious ecu haha. And yeah thats what i thought too whereas proteus can handle 8x8 with extra outputs and inputs on top so definitely my pick for big i/o diy ecu. The only one close to this is a 3.5 teensy based board for speeduino software that can do 8x8 hardware wise but is stuck at 4x4 software wise. Something rusefi has already leaped ahead with too. Does proteus have its own version of the software to match the hardware or is it just the normal rusefi firmware?

[AndreyB]

Does proteus have its own version of the software to match the hardware or is it just the normal rusefi firmware?

Different binaries builds from same source code. Is it same or is it different?

https://rusefi.com/build_server/

[mck1117]

Also as for frankenso as far as i was aware it only has 4 inj and 4 spark in full seq not all 16 or more. Is there a post I'm missing? Or is there a board type i can use to enable all 8 in seq.

None of our boards have any limitations as to how many of the outputs can be used for sequential, or even which are used (any output can run any cylinder). Since we do all of the scheduling and "distribution" in software (unlike some other ECUs), you're only limited by the actual physical outputs on the board.

Frankenso has 12 injector/lowside outputs, and 8 ignition outputs, so it can run 12 cylinders of sequential fuel, and 8 cylinders of sequential ignition (which aren't tied together, btw - you can run combinations like sequential fuel but wasted spark or even distributor ignition).

Proteus has 16 injector/lowside outputs, and 12 ignition outputs, so you could run a fully sequential v12. I run my v8 on batch fuel (but individually wired - pairs of injectors fire together) and wasted spark (also individually wired - pairs fire together) only because I don't have the cam sensor plugged in.

[AndreyB]

Proteus has 16 injector/lowside outputs, and 12 ignition outputs, so you could run a fully sequential v12.

rusEfi can we also modified to run v16 or W16 as long as you can prove that you have one.

[mck1117]

rusEfi can we also modified to run v16 or W16 as long as you can prove that you have one.

Yes, exactly. There's really not a hard limit, but we haven't had a reason to go above 12

[Boostonabudget]

Does proteus have its own version of the software to match the hardware or is it just the normal rusefi firmware?

Different binaries builds from same source code. Is it same or is it different?

https://rusefi.com/build_server/

Ah ok so make sure I upload the proteus built one gotcha cheers.

[Boostonabudget]

Also as for frankenso as far as i was aware it only has 4 inj and 4 spark in full seq not all 16 or more. Is there a post I'm missing? Or is there a board type i can use to enable all 8 in seq.

None of our boards have any limitations as to how many of the outputs can be used for sequential, or even which are used (any output can run any cylinder). Since we do all of the scheduling and "distribution" in software (unlike some other ECUs), you're only limited by the actual physical outputs on the board.

Frankenso has 12 injector/lowside outputs, and 8 ignition outputs, so it can run 12 cylinders of sequential fuel, and 8 cylinders of sequential ignition (which aren't tied together, btw - you can run combinations like sequential fuel but wasted spark or even distributor ignition).

Proteus has 16 injector/lowside outputs, and 12 ignition outputs, so you could run a fully sequential v12. I run my v8 on batch fuel (but individually wired - pairs of injectors fire together) and wasted spark (also individually wired - pairs fire together) only because I don't have the cam sensor plugged in.

Oh awesome haha glad you cleared that up that makes heaps more sense. Didnt know how much more ahead of the other names you really were thats super impressive. One thing things thats got me a little confused tho about can. Ive always known it was a comunication type but how exactly does it work? How many seperate connections to 1 can connection can you have? Say like wideband over can along with egts and a digital dash or something? Or woould you need more than one can?

[Boostonabudget]

rusEfi can we also modified to run v16 or W16 as long as you can prove that you have one.

Yes, exactly. There's really not a hard limit, but we haven't had a reason to go above 12

Someone needs to get a toureg w16 or something to have some fun with then ay

[mck1117]

One thing things thats got me a little confused tho about can. Ive always known it was a comunication type but how exactly does it work? How many seperate connections to 1 can connection can you have? Say like wideband over can along with egts and a digital dash or something? Or woould you need more than one can?

CAN is a multi-master, broadcast bus. That means that multiple devices can be "in charge" (separated in time), and a message from any device is sent to and received by all other devices on the bus. Think of it like a party phone line, or whiteboard in a conference room. Anybody can stand up and write something on it (but one at a time), and everybody has a good view from their seat.

What does that mean in your car? Well, it means that many (as many as tens) of devices on the bus can operate safely without knowledge of one another, each broadcasting things that they know, and listening for things they care about*. The wideband controller might broadcast the current lambda value, which the ECU and dash both listen to. The ECU might broadcast other parameters like RPM and TPS, which the dash also listens to. In my car, I have the ECU, wideband controller, and a Banks iDash SuperGauge all on the CAN bus. My 2013 Focus has 3 CAN busses, each with 5-10 devices on it. Some newer things like Mercedes/Porsche/BMW have up to around 100 total CAN devices.

*provided that they all operate at the same bus speed