Just a little update, ive been revisiting this in my spare minutes.
My jet engine is getting a complete overhaul...
"jet engine version 2"
-New/bigger/redesigned combustion chamber
-New redesigned flame tube
-New redesigned fuel injector
-Airflow swirl inducer/evaporator mounted in the combustion chamber behind the fuel injector for better air/fuel mixing and to improve atomization. This also improves combustion efficiency and insures a more complete burn
-redesigned control panel/electronics
-redesigned oil cooler/fan
-new electric start system
-dual spark plug ignition system (my previous design only had 1 spark plug), basically it just uses the spark plugs for starting, think of them like glow plugs on a diesel engine
-BIGGER Garrett turbo off of a 12v71 detroit or something...I got it on ebay for cheap...this one has non-leaky seals and perfect bearings too. The old turbo had leaky seals and the bearings were shot which is why I retired "Ben Jet engine version 1"
With all of those improvements I decided I had to really step it up a notch in terms of engine control...
So I designed/programmed/built my own ECM.
This ECM is not some mess of resistors, timers, relays, and other ghetto'd stuff like the early analog car ECM's from the 70's-80's.
It is a true fully-electronic digital ECM.
Its processor runs at blazing 8mhz, it has 128 bytes of RAM, and 4096 bytes of EEPROM. I wrote the entire operating system software from scratch. The current ECM OS is only about 1100 bytes so I have plenty of room left if I decide to add on more features or change stuff. My jet engine ECM is fully flashable, just like we can flash our dmax ECM's with EFILive.
Theres an "OBD" port on the board that I hook up to a USB port on my laptop and it takes about 5 seconds to reflash it.
Otherwise it is similar to a FADEC fly-by-wire system used on modern jet engines.
I can run it in "auto" mode, but I also have manual back up switches for the pilot injection, main injection, ignition, oil pump, and starter if I want to control everything completely manually. In addition to those manual-override switches, it also has:
-master power on/off
-auto-start button
-emergency shutdown button
-RUN/OFF toggle switch
The indicator lights on the new panel are:
-oil pump ON
-pilot injection ON
-main fuel injection ON
-ignition ON
-starter ON
-emergency shutdown light with a loud horn/buzzer
-MIL (yes, it has a check engine light!)
Gauges are:
-Turbine inlet temp (yes, its actually referred to as TIT)
-turbine outlet temp (TOT)
-combustor pressure (basically like 'boost')
-fuel pressure
-oil pressure
There are 3 "codes" it can throw:
-1 blink of the MIL/check engine light is low oil pressure (below 10psi anytime the engine is starting or running)
-2 blinks of the MIL is low combustor pressure (if its about to stall/flame out/whatever) (below 2psi when running)
-3 blinks of the MIL is high TIT (like the EGT gauge in our trucks, it sets a code if the temp gets above 1300*)
The AUTO START feature is probably my favorite. Generally, starting jet engines is a
very tricky/critical procedure that almost requires 3 hands and a second set of eyes to watch all of the gauges.
All that will be required to start my engine is to first turn the 'master power' switch ON. When you turn the switch on, the ECM powers up and turns on all of the indicator lights/alarm for 3 seconds (just like your truck does when you start it). After the 'bulb test' is complete it goes into standby mode. Now you can start the engine manually with the manual-switches, or do the "AUTO-START". To auto-start the engine, just flip the OFF/RUN toggle to "RUN", and press and hold the start button for 5 seconds.
Once its in 'auto start' mode, it turns on the oil pressure and waits until it builds 35psi. Once the oil pressure is above 35psi it then turns on the starter motor (leaf blower that forces air into the cold side of the turbo) to spool up the engine. After 5 seconds of spool-up it turns on the ignition (spark plugs), and then the pilot injection (propane, its easier to light with a cold engine). After it turns on the propane it waits for the fuel to start burning. If proper light-off is not achieved within 5 seconds of turning the pilot injection on it cancels the start process and shuts down for safety. Once it sees the EGT/TIT go above 400* it determines that the engine has lit properly and waits for the combustion pressure (boost) to get above 3psi or so. Once the ECM sees the engine building boost it turns on the main fuel injection (diesel!!!). After it sees the EGT further rise above 600* or so and boost pressure get above 4 or 5 PSI, it turns off the spark plugs (because the engine is now self sustaining) and transitions to normal idle/running mode.
If at any time during the auto-start process the EGT goes above 1300*, oil pressure drops below 10psi, or the combustor PSI/boost goes below 2psi, it will turn on the check-engine light but it will still continue the start process.
IF during the auto-start sequence the boost pressure suddenly drops to zero psi, the oil pressure drops to zero psi, or the EGT continues to rise above 1400* and the engine starts to run away (called a hot start, jet engines can run away just like diesel engines), it immediately sounds the "emergency" alarm and automatically shuts down the engine.
Now that the engine is running properly you can use the throttle and speed the engine up/down/whatever.
When the engine is in normal running mode the ECM is monitoring EGT, boost, and oil pressure. If the oil pressure gets below 10psi, boost gets below 2psi, or the EGT goes above 1300*, it turns on the check engine light. If the 'driver' ignores the warning and the EGT gets above 1400*, oil pressure goes to zero, or the boost goes to zero, the ECM sounds the alarm and automatically emergency-shuts down the engine. You can also do an emergency shutdown by pressing the 'emergency shutdown' button, duh.
The normal shut-down process (which is different from the emergency shutdown) is also automatic. Flip the RUN/OFF toggle to OFF. The ECM then shuts off the fuel, turns on the "COOL DOWN" indicator light, and waits 5 seconds for the engine to spool down. After 5 seconds it turns ON the starter motor/blower to run cool air through the engine (kinda like letting your truck idle before shutting it off). It does that for 15 seconds. After 15 seconds passes it turns off the starter blower and waits another 3 seconds for the turbo to spool down. After 3 seconds it finally shuts off the oil pump and goes back to "standby" mode.
The emergency shutdown procedure basically just shuts everything down immediately. It simultaneously turns off the fuel and turns on the starter blower (to clear the combustion chamber so nothing explodes). Then 1 second later turns off the oil pump and starter blower. Its obviously not "good" for the engine to do an emergency shutdown because the oil pump is turned off right away, but if you blow an oil line, you cant do a "normal shutdown" procedure, because then the ECM would keep the oil pump running/spewing oil everywhere...
That is how everything works 'on the bench' and in my program/software/ECM simulator. I still have to finish up wiring the ECM to the jet engine and finish building the combustion chamber.
NOW...PHASE TWO of the jet engine rebuild, or "Jet engine version 3". This is way down the road...
Once I get "jet engine version 2" running properly and the auto-start system and ECM fine tuned, im going to convert it to electronic throttle control/fly-by-wire. Ill basically just hook up the throttle lever to a potentiometer that will send a signal to the ECM, and then the ECM will drive a little servo thats attached to the fuel valve.
When I eventually do convert the engine to electronic throttle control, Ill look into programing the ECM to monitor temps and stuff so when you push the throttle control to '100% power', the ECM will adjust the fueling a little bit to keep it from overspeeding or getting too hot. It will probably be a VERY VERY VERY basic feedback-loop system though. As far as I have figured right now, I think ill only be able to make it adjust the throttle in like 4 small steps "further open" or 4 steps "further closed", so it might surge a little bit, but who knows...
Also, the OBD port is bi-directional too so I
theoretically might even be able to do some [very] basic data-logging like Turbine Inlet Temperature, Turbine Outlet Temperature, combustor pressure, throttle %, fuel pressure, and oil pressure with my laptop??? Maybe not though, I have no idea. I probably wont bother with that though...doesnt serve any purpose here on this scale other than the 'gee-whiz' factor.
Ill put up pictures of the new jet engine 'hard parts' in a little bit but here is a
small portion of the ECM software/operating system programming.
Ben