3D Re-Map Box
An exciting new product is about to be launched in the next few weeks – here is a brief technical insight for the trade, there will be more to follow soon for the end user.
Eddie Zyla the owner of F1 Automotive is also the Technical Director of Mobilizer Limited whose CRD Technology division in conjunction with F1 Automotive have carried out research and development on what was originally a project to develop a control system specifically to allow Common Rail Diesels to be run on a blend of LPG or CNG and Diesel.
In order to help reach emission requirements it was necessary to develop a 3 dimensional mapping method to electronically reduce the amount of diesel being injected. This unique and patented method not only allows for diesel reduction but also increased fuelling if required.
"This development work has turned the CRD Technologies Dual Fuel Controller (DFC) into what is probably the most advanced CRD diesel tuning box in the world" says Eddie
There is a new Mobilizer Limited/CRD Technology website and technical brochure being worked on which will be finished soon, but for now the following will give you a preview of the unit and its functionality.
3D RE-MAP BOX
PRODUCT DESCRIPTION
- A unique electronic fuel controller.
- Patented technology developed in the UK.
- Provides precise single or simultaneous dual fuel control during all engine speed and load conditions.
- The only product available with this infinite adjustment capability.
- Enables fuel delivery to be accurately set to the optimum for any demand combination of speed and load or operator preference.
- Delivers a choice of applications including (CNG or LPG) dual fuel/diesel blend, plus engine tuning with power reduction or enhancement.
- Universal application and versatility.
- Easily installed using smart technology.
APPLICATION 1 – PERFORMANCE TUNING
- The only available universal product that gives you a choice of ‘maps’ with up to 5 different power selections. Pre-programmed units are supplied complete with 3 maps. Map 1 is set to standard power, map 2 has increased torque at low RPM and reduced power at high RPM (for economy) map 3 has increased torque at low RPM and increased power at high RPM (for high performance) The maps can be easily and instantly switched using the remote control fob with the ignition on and engine static or idling.
- The only available universal product that allows specialist mapping in addition to the unique 3 pre-set map programme. Maps 4 and 5 can be customised by the installer to suit any other customer requirement eg low power setting for inexperienced drivers or highest power possible for track day use.
- Built in adjustable fuel rail pressure parameters ensure the unit does not interfere with or compromise the vehicles own engine management system parameters.
- Easily installed and calibrated in less than an hour on a plug and play basis.
- Unique adjustable built in torque reduction feature, ensuring maximum performance under all conditions.
- Universal application to most common rail diesel engine in cars, vans, mobile homes, boats, buses etc.
Tuner Protect
Note: Since 2009 most vehicle manufacturers have introduced the ‘tuner protect’ feature that effectively prevents specialist re-mapping of the ECU via the normal route through the vehicles standard 16 pin OBD diagnostic port.
Applications 1 & 2 allow re-mapping specialists to make economy or performance changes without having to resort to difficult removal, dismantling and bench programming of the on-board electronic control unit (ECU).
Although this practice is perfectly acceptable when carried out properly as is done routinely at F1 Automotive, it can raise serious concerns that in the event of any warranty repairs requiring a dealer visit, the changes could be discovered by either the dealer or manufacturer. They may then restore the ECU to its original settings or even refuse to honour the repair under warranty.
Traditional tuning boxes rely on introducing additional fuel and therefore can only increase and not decrease power and do so without any reference to variations in engine speed and load. This has resulted in a high incidence of Diesel Particulate Filter blockage which has resulted in tuning box manufacturers reducing the amount of added fuel in an attempt to prevent this consequence, but in doing so are restricting the amount of power gain available.
The CRD Technology 3D re-map box does not suffer from this major concern because in addition to measuring fuel rail pressure it also measures injector opening times. By monitoring just one of the injectors it calculates engine speed and load enabling it to create an engine specific 3D fuel map.
This map then controls a precise amount of additional (or reduced) fuel that is introduced to exactly meet fuelling requirements under varying engine speed and load conditions, thus ensuring there is no excess fuelling and therefore no additional contamination of the diesel particulate filter.
APPLICATION 2 – SINGLE FUEL CONTROL
- Infinite control of fuel delivery under all engine speed and load conditions.
- Can be easily ‘re-mapped’ to suit specific journey and load conditions or operator requirements. (eg: deliver less fuel and reduce power when empty).
- Can be easily ‘re-mapped’ to increase power at lower revs and decrease at higher revs which means the vehicles improved overall performance actually encourages less aggressive driving.
- Delivers a minimum of 10% reduction in fuel usage plus NOx and CO2 and particulate emissions.
- Universal application for Cars, LCVs, HGVs, Buses and most common rail diesel applications.
Rolling Road print out showing Diesel mapping capability
APPLICATION 3 - NITROUS OXIDE CONTROL
The 3D re-map box also has an optional nitrous oxide control feature that can be used in conjunction with a dry nitrous system, not only for common rail diesel engines but also FSI petrol applications.
Dry nitrous oxide systems deliver only nitrous into the engines air intake (not additional fuel) and therefore rely on a surplus of fuel being present in the combustion chamber.
This is combined with the nitrous to create extra horsepower. Most modern diesel engines run with some available excess fuel and therefore still smoke (unless fitted with a DPF) but modern FSI engines usually have full closed loop control with very little excess fuel when accelerating for the nitrous to combine with during acceleration.
One solution when running petrol engines with nitrous is to use a wet system, this involves breaking into the engines regulated fuel supply and using an extra solenoid and jet to inject additional petrol into the intake along with the nitrous.
Whilst this procedure is often difficult on high pressure petrol FSI systems it is not at all possible on compression ignition diesel engines as diesel will only ignite when atomised and injected at high pressure inside the cylinder.
The 3D re-map box enables either diesel or petrol quantity to be increased at all different engine speeds and loads whilst simultaneously injecting the nitrous. The 3D Box, using an additional solenoid driver interface, now drives the nitrous solenoid to deliver the correct amount of nitrous into the engines intake without any excess waste.
The 3D box’s nitrous map outputs a switching frequency and duty cycle (pulse width) to the nitrous solenoid that is directly proportional as to how much diesel or petrol is being injected into the engine in real time. This frequency is directly controlled by the engine’s 4-stroke cycle i.e. 6hz @ 720 rpm, (720 rpm divided by 60 secs = 6 firing strokes per second) or 30hz @3600 rpm, (3600 rpm divided by 60 secs = 30 firing strokes per second).
The duty cycle range (nitrous solenoid on time) of between 20% and 100% is dependent on the map setting and can easily be altered by the installer as can the nitrous quantity by also changing the jet sizes. This level of control allows more frequent economical use of the nitrous by the user as only the correct amount of nitrous is injected when needed at full load (mid rpm) and none wasted at higher RPM when there is less load and therefore less nitrous requirement.
Some wet systems tend to increase the amount of nitrous injected at higher engine speeds, this works well because these systems also control and add the correct amount of petrol. Diesel engines develop their maximum power at much lower speeds so there is no need for a secondary fuel or to operate the engine at a higher RPM.
Another useful unique feature of the 3D Box is its ability to switch between any one of its 5 fuel maps even with the engine running and to automatically switch to an excess fuelling map specifically intended for nitrous use.
By connecting it’s auxiliary sensing wire to the live side of the nitrous arming switch the 3D Box selects map 4 (set to excess fuel) and then reverts back to map 5 (standard fuel) or its previously selected map when the system is disarmed.
APPLICATION 4 - DUAL FUEL CONTROL
- The only available universal product that allows fully sequential and accurate delivery of two fuels simultaneously (eg: LPG or CNG) to compliment the primary fuel (Diesel)
- The only available universal product that allows infinite adjustment and combination blend of diesel fuel and LPG/CNG.
- Designed to work with any make of either liquid or vapour LPG multipoint installation.
- The only available universal product that is easily programmed to suit most common rail diesel engine applications with the facility to make minor adjustments to suit specific vehicles or operating conditions.
- Diesel reduction map can be automatically activated when LPG/CNG is switched on and map selection returned to standard or economy map when gas is switched off.
- Universal application for Cars, LCVs, HGVs and Buses or any other common rail diesel application.
- Produces cleaner emissions with c35% NOx and c5% CO2 reduction.
- Results in fuel cost savings of approximately 10%-25% depending on application and local price of alternative fuel, (LPG/CNG) typically on a 60% diesel, 40% LPG mix.
Print out showing LPG Dieselblend mapping capability
APPLICATION 5 – ANTI HI-JACK SECURITY SYSTEM
- Optional anti hi-jack feature that can be integrated into any of the other applications and is automatically enabled every time the engine is switched off and is easily re-set by the driver. (by remote or switch)
- If the vehicle is driven off, for example if the keys are stolen, the system is automatically set and will gradually decrease engine speed/power to a reduced power condition rendering it difficult to drive.
- It is the only available product that can also be linked to a vehicle tracking system and be activated remotely to give safe and controlled engine speed degradation, in the event of unauthorised removal of vehicle.
- The unit safely and effectively, in all applications, reduces the engine’s power or forces the vehicle into limp mode (LOS, limited operating strategy) to slow the vehicle down without risk of losing engine assistance to brakes, steering or any other engine driven safety features.
APPLICATION 5 – COMMON RAIL DIESEL DIAGNOSTIC TOOL
- Identified by Frank Massey (ADS Preston) one of the leading diesel diagnostic trainers in the UK, as the only piece of equipment that gives him the necessary information for accurate and speedy diagnosis of certain faults that previously took lots of time and high levels of expertise.
- Frank says he can now build a diagnostics training course around the equipment enabling lesser skilled people to be trained in CRD diagnostics.
- The 3D Re-Map Box is to be packaged as a kit and will include:- Dealer Programming Handset, 6 Fuel Rail Pressure Connectors covering all makes, a Modified Diagnostic Harness and a Diagnostic Training Disc .
- This can, not only be used by garages as a diagnostic tool, but also as a demonstration 3D tuning box to generate additional tuning box sales.
- A unique additional feature is the built-in Diesel Particulate Filter (DPF) regeneration programme.
Autoinform
Apply for your free subscription of Autoinform written by Frank Massey and a brief introduction of the 3D Re-Map Box.
www.autoinform.co.uk
Dealers
We will be appointing dealers around the country soon; this would ideally suit any company already within the performance industry with specific benefit to tuners with rolling roads or those familiar with live “on the road” mapping.
Also welcome are existing tuning companies that already supply their own tuning boxes or ECU Re-Maps to their own customer base.
We are happy to supply un-programmed CRD Technology 3D Re-Map boxes for those companies to use as their own tuning platform and to re-badge them accordingly.
In the first instance please make any initial application by email to F1 Automotive and our Technical team will make contact with you on behalf of Mobilizer Ltd.
Dieselblend Overview
The following is an overview of the 3D Re-Map Box Dieselblend control written by Eddie Zyla
Dual Fuel Controller (DFC) for LPG / CNG Dieselblend
The engine management system of a commonrail diesel engine has two main functions, to switch open the diesel injectors at the correct time and for the correct duration, also to control pressure in the common rail.
The DFC inductively measures the injector opening times from one cylinder only; it also interrupts and measures the 0-5 volts varying pressure signal voltage from the fuel rail pressure sensor going to the ECU. It uses this information to quantify when, and how much diesel is being injected into all cylinders during the engines 720 degree 4-stroke cycle, regardless of the number of cylinders. The unit uses this data to calculate an assumed value which it then converts into sequential output signals, similar to those of a petrol injector. These 0-12v switching signals can now be used with any liquid or vapour LPG or CNG system. Selecting the number of cylinders using the dealer handset varies the outputs from between 180 degrees (4 cyl’) to 90 degrees (8 cyl’).
The DFC also generates an engine speed signal (RPM) this can be used by the gas system and is present even on overrun unless the engine stalls and rail pressure is lost.
Following installation the DFC is calibrated to the engine’s diesel injector signal and fuel rail pressure sensor using a handset and programming lead.
During calibration the DFC automatically detects if Piezo or inductive type injectors are employed and then synchronises to the signals accordingly.
Minimum and maximum diesel injector opening times, fuel rail pressure, engine speed and acceleration rate data is recorded during the automatic calibration drive cycle.
This stored information is used to create two maps, one for diesel control and one for LPG/CNG. The maps consist of three engine loads, high, medium and low, also five evenly spaced engine speed selections. These fifteen sites can then be adjusted by the installer allowing more precise tuning adjustments at any desired engine speed and load.
Using an optional emulator the microchip maybe removed from the DFC where a 32 x 32 map can be more precisely adjusted using the 1024 available sites.
When using a handset all 15 site windows begin with a value of 100 indicating a gas millisecond value proportionate to an amount of diesel being injected into the engine.
These ms outputs are based upon a calculation using diesel injector opening times and actual fuel rail pressure whilst also taking into account diesel injector latency.
A baseline output of 2ms at low engine speed and load is set by default and can be altered in the setup section. The gas ms output is set at 360 degrees after top dead centre (ATDC) so as to avoid gas being injected into the cylinders during exhaust valve opening times, (with consequential increase in emissions). This value is also adjustable anywhere between 0 degrees and 720 degrees ATDC.
The installer must now use his knowledge to choose the correct gas injector size and reducer pressure, making sure to start with smaller amounts of gas and then increasing accordingly.
An approximate substitution rate of 35% is normal but with higher increases being possible at medium engine speeds and loads during cruising.
The DFC’s baseline gas ms output and 15 window map values can also be adjusted by the installer as well as further adjustments being made using the LPG/CNG systems own software.
Adding gas to the standard diesel map will result in more power but without any emissions benefit, however selecting the 15 window diesel map and altering any of the values to a number less than 100, allows the quantity of diesel to be reduced from the vehicles standard fuel map.
The DFC can increase or decrease the amount of diesel injected by emulating the voltage from the fuel rail pressure sensor. Therefore blending the 2 fuels whilst reducing the amount of diesel injected, results in the engine continuing to produce its original standard power (BHP) and torque.
A wide band lambda sensor option enables accurate gas control, ensuring no smoke from the exhaust when accelerating and improved fuel economy. The DFC can also be wired to only switch on a diesel reduction map when running on both fuels and then return to standard diesel when the gas is switched off.
Mark Howarth, Chief Electronic Design Engineer – Mobilizer Limited was asked to:
"describe where this protects your product in being unique and difficult for anyone else to copy"
And this is his response -
Our product is able to calculate instantaneous engine speed and load by measuring diesel fuel pressure and injection opening times. The latter of which is very accurately (+/- 2 millionths of a second) and non-intrusively timed using a unique arrangement, comprising of an advanced hall-effect sensing device and a complex calibration software process developed by Mobilizer. This technology makes the product extremely universal and simple to install.
The calculated engine speed and load values are used as a baseline to generate gas injector output signals and to control diesel. A number of high resolution fuel maps (1024 cells, each with over 65,000 steps of adjustment) can then be used to accurately adjust both fuels independently of each other for all combinations of engine speed and load. A hand control allows for a quick setup of any map, using just 15 cells (which are automatically converted into a 'full' map using interpolation). All maps and parameters are stored on a separate memory chip which can easily be removed, reprogrammed or copied.
Diesel fuel pressure is intelligently controlled by software using advanced solid-state hardware circuitry that is able to mimic the vehicle's fuel rail pressure sensor to ensure that the signals the engine management receives are always plausible, preventing fault conditions from being detected. In the event of a power-loss the fuel rail pressure sensor is instantly reconnected to the engine management system and, in the event of an accident or loss of fuel rail pressure, gas output control signals immediately cease.
The control software is the result of years of research and development and is the copyright of Mobilizer Ltd. It consists of over 30,000 lines of source code which are compiled (into a relatively indecipherable binary code) before being stored on the main processor, along with a unique, source-identifiable serial number. The processor itself incorporates highly secure code-guard technology making processor cloning impossible.