smart controller, S-HSV, flow sensor and vari-cool integration

[Coolingmist]

I wanted to show everyone what one of our customers recently did with our technology. I feel honored that he chose us, but also that he took the time to make this fantastic diagram and send to us. I make this thread to show each of you what possibilities you have with our technology. In this example the customer is using the following:

1 Coolingmist Smart Injection Controller
1 Coolingmist Vari-Cool 2D model (1.06 Flash)
2 Coolingmist S-HSV valves with 500 CC nozzles
1 Coolingmist Flow Sensor
1 Tank (underhood shown, however he is using our Trunkmount tank).

The customer has chosen to inject by using a custom map of 3 inputs. Using the smart controllers 8 X 8 Grid he mapped the following to create a 0-5V output. This 0-5V output will go to Vari-Cool as 2 of the 3 inputs for injection. Our new flow sensor is integrated and if flow, water level and other inputs are not within spec the failsafe will trip. He is also activating a fuel pump at a certain overboost level and has integrated his boost controller into our system. The project is below. As well as the diagram.

I will start this thread with pictures of some of the components. The next page I will show the diagram and talk about what he did and how he integrated into his vehicle.

SMART INJECTION UNIT and Vari-Cool:




S-HSV Valve

[Coolingmist]

Inputs in Smart Controllers 8 X 8 Grid:
RPM. He got the RPM from his ECU.
Air Temp. He used his stock Air temp sensor.

Vari-Cool inputs.
Boost: The boost signal is read from Vari-cool.
0-5V in (RPM and AIR signal from Smart Controller)

I. Coolingmist Smart Injection Unit

a. Assumptions/Estimates, i.e. these will change when we have measured values

1. MAP: 0 V = 0 psi, 5V = 26 psi and linear scale
2. Air Sensor: Air Temp 0 V = 65% and 5 V = 100% of max input temp
3. EVC Stepping Motor: 4 V = boost high enough to need 2nd fuel pump turned on
4. Fluid Flow Sensor: Calibrated in cc/min. Max output is approximately 1400
cc/min.

b. 0-5V OUT (Terminal 9)

1. 2-D mapping of RPM and Input Air Temp to 0 - 100% scale. The 2-D map is
shown in the attached table

c. Virtual Output #1 (provides conditions for real outputs)

1. Condition 1: 0-5V IN 4 (Terminal 15) is less that 2 V, i.e. the water/methanol
tank is not empty; AND
2. Condition 2: 0-5V OUT (Terminal 9) is less than 4.25 V, i.e. the RPM/AIR map
is less than 85%; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 1.9 V, i.e. less than 9.9 psi of
boost measured by MAP sensor

d. Virtual Output #2 (provides conditions for real outputs)

1. Condition 1: 0-5V IN 4 (Terminal 15) is less that 2 V, i.e. the water/methanol
tank is not empty; AND
2. Condition 2: 0-5V OUT (Terminal 9) is less than 4.25 V, i.e. the RPM/AIR map
is less than 85%; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 3.1 V, i.e. less than 16.1 psi of
boost measured by MAP sensor

e. Virtual Output #3 (provides conditions for real outputs)

1. Condition 1: 0-5V IN 4 (Terminal 15) is less that 2 V, i.e. the water/methanol
tank is not empty; AND
2. Condition 2: 0-5V OUT (Terminal 9) is less than 4.25 V, i.e. the RPM/AIR map
is less than 85%; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 3.7 V, i.e. less than 19.2 psi of
boost measured by MAP sensor

f. Ground Output #1

1. Condition 1: Virtual Output #1 greater than 0.8, i.e. conditions are all true - less
than 9.9 psi of boost; OR
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 240
cc/min; AND
3. Condition 3: 0-5V IN 1 (Terminal 11) is less that 2.5 V, i.e. less than 13.0 psi of
boost measured by MAP sensor

g. Ground Output #2

1. Condition 1: Virtual Output #2 greater than 0.8, i.e. conditions are all true - less
than 16.1 psi of boost; AND
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 360
cc/min

h. Ground Output #3

1. Condition 1: Virtual Output #3 greater than 0.8, i.e. conditions are all true - less
than 19.2 psi of boost; AND
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 600
cc/min
Page 3 of 3

i. Ground Output #4

1. Condition 1: 0-5V IN 1 (Terminal 11) is less that 4.7 V, i.e. less than 24.4 psi of
boost; AND
2. Condition 2: Counter 1 (Terminal 19) indicates a fluid flow greater than 840
cc/min

j. Ground Output #5

1. Condition 1: 0-5V IN 3 (Terminal 14) is greater that 4 V, i.e. we have very high
boost and we need the 2nd fuel pump on


II. Coolingmist Vari Cool Controller (Black Unit)
a. Min Duty Cycle = 34
b. Max Duty Cycle = 100
c. Tuning Factor = 10, i.e. the Duty Cycle to Boost curve is below linear
d. Boost as measured by the Vari Cool Controller vacuum/boost line
1. Boost Min = 8
2. Boost Max = 26
e. Average = 66%
1. this is the weight given to the 0-5V input (Blue 22 AWG) when being combined
with the boost input, i.e. the 0-5V In is given 66% weight, while the boost is given
34% weight. This effectively makes the system inject based on 3 inputs.

[cali]

lemme see you your charts...cmon...put up . Still watching u :-)