graduation project research and experiment of eco mode device apply to ice vehicle innova model

Independence – Freedom– HappinessHo Chi Minh City, August 1, 2022ADVISOR’S EVALUATION SHEETMajor: Automotive Engineering.Project title: “Research and Experiment of ECO mode device apply

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING

GRADUATION PROJECT

RESEARCH AND EXPERIMENT OF ECO MODEDEVICE APPLY TO ICE VEHICLE (INNOVA MODEL)

Student ID: 18145029

Student ID: 18145007

Major: AUTOMOTIVE ENGINEERING Advisor: DUONG TUAN TUNG, Ph.D.

Ho Chi Minh City, August 2021

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATIONFACULTY FOR HIGH QUALITY TRAINING

GRADUATION PROJECT

RESEARCH AND EXPERIMENT OF ECO MODEDEVICE APPLY TO ICE VEHICLE (INNOVA MODEL)

Student ID: 18145029

Student ID: 18145007

Major: AUTOMOTIVE ENGINEERING Advisor: DUONG TUAN TUNG, Ph.D.

Ho Chi Minh City, August 2021 THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

Ho Chi Minh City, August 1, 2022

GRADUATION PROJECT ASSIGNMENT

Date of assignment: Date of submission:

1 Project title: “Research and Experiment of ECO mode device apply to ICE vehicle (Innova model)”

2 Initial materials provided by the advisor:

Innova 2009 vehicle & 1NZ-FE service manual & Textbook 3 Content of the project:

Papers related to ECO mode device for Innova vehicle model, tools, software, experiments with the device and measure equipments.

4 Final product: Thesis report including the caculation, simulation and experimental results.

CHAIR OF THE PROGRAMADVISOR

Independence – Freedom– Happiness

Ho Chi Minh City, August 1, 2022

ADVISOR’S EVALUATION SHEET

Major: Automotive Engineering.

Project title: “Research and Experiment of ECO mode device apply to ICE vehicle (Innova 6 Mark……… (in words: )

Ho Chi Minh City, August 14, 2022.

ADVISOR

Independence – Freedom– Happiness

Ho Chi Minh City, August 1, 2022

PRE-DEFENSE EVALUATION SHEET

Major: Automotive Engineering.

Project title: “Research and Experiment of ECO mode device apply to ICE vehicle (Innova model)” 6 Mark……… (in words: )

Ho Chi Minh City, August 1, 2022.

REVIEWER

Independence – Freedom– Happiness

Ho Chi Minh City, August 1, 2022

EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER

Major: Automotive Engineering.

Project title: Research and experiment of ECO Mode device on ICE apply to ICE vehicle (Innova 5 Mark……… (in words: )

Ho Chi Minh City, August 1, 2022

We hereby declare that this is our own research project, the thesis is done at Ho Chi Minh City University of Technology and Education under the guidance of PhD Duong Tuan Tung The data and results presented in the thesis are completely honest and not has been published by anyone in any other work I also hereby declare that all references for the implementation of the thesis has been explicitly cited.

To complete the graduate project on time and achieve the results only the effort of the person who made the topic, but also the assistance and advice of the Faculty of Vehicle and Energy Engineering and Faculty of High-Quality Training and the motivation and experience of classmates, the project team completed the graduation project on time.

Our group would like to sincerely thank to:

- The guidance and enthusiastic help of Mr Duong Tuan Tung for instructing, providing necessary documents and supporting to check and correct inaccurate information.

- Our team would like to thank the Ho Chi Minh City University of Technology and Education lecturers, Faculty of Vehicle and Energy Engineering, and Faculty of High-Quality Training for their dedication to instruction, imparting experience and knowledge in the learning and training process so that we could have today success In the process of implementing this project, although we have tried our best, there will be inevitable shortcomings We hope to receive the comments and criticism of lecturers and students.

Once again, thank you lecturers and students!

Ho Chi Minh City, August 2022 Group member

Nguyen Dang Khoi – Nguyen Thanh Danh

1.Purpose of thesis selection: 1

2.Research object and scope: 2

3.Research content 3

4.Research method 3

5.Scientific significance of the research thesis: 3

6.Structure of the thesis: 3

Chapter 1 : INTRODUCTION 5

1.1.Problem statement 5

1.2.Review of related studies 6

1.2.1.Factors affecting fuel use – Auxiliary system 7

1.2.2.Engine control methods of manufactures 8

1.2.3.Research on driving modes 16

1.3.Research ECO mode – fuel saving mode 18

1.3.1.What is ECO mode? 18

1.3.2.What does ECO mode do? 18

1.3.3.Other names for ECO mode 19

1.3.4.When should ECO mode be used? 20

1.3.5.Some disadvantages of ECO mode 20

1.3.6.Conclusion 21

Chapter2: LITERATURE REVIEW 22

2.1.Theory of electronic throttle control: 22

2.1.1.Basic build: 22

2.1.2.Electronic throttle control algorithm 23

2.1.3.Optimization of the electronic throttle control process: 28

2.2.Research on the second generation Toyota Innova 29

2.2.1.Research the popularity of car models on the market 29

2.2.2.Engine control system 31

2.2.3.Introduction to the 1NZ-FE engine and control system 32

Chapter 3: BUILDING MODEL, DESIGN AND MANUFACTURING EQUIPMENT 42

3.1.Research on driving mode control device 42

3.1.1.Methods of changing vehicle power 42

3.1.2.Tweak the ECU 42

3.1.3.Research and manufacture ECO driving mode controller 45

3.2.Simulate the structure of the device on Proteus software 47

3.3.Simulate media on Matlab Simscape 50

4.1.1.ECO BOX device 68

4.1.2.Fuel consumption meter model 9531A 70

4.1.3.Techstream Program 72

4.2.Experiment procedure 75

4.2.1.Installation for first-time run 75

4.2.2.Idle test 75

4.2.3.Road test 76

4.3.Experimental test drive and driving cycle data: 78

CONCLUSION AND RECOMMENDATIONS 87

1.Conclusion: 87

2.Recommendations 87

REFERENCES 88

List of figures

Figure 1 1 Some mechanisms that align the accelerator pedal position with the sensor are

highlighted in red 6

Figure 1 2 Basic car comfort system 7

Figure 1 3 Mini cooper 2008 – the first BMW model equipped with the Start-stop system 8 Figure 1 4 Hondad 3 phases VTEC 11

Figure 1 5 BMW Vanos system 12

Figure 1 6 Toyota VVTL-I system 14

Figure 1 7 Rover's VVC system 15

Figure 1 8 Some comparision on different drive modes acceleration proccess 17

Figure 2 1 Structure of an electronic throttle control system 22

Figure 2 2 Block diagram of throttle control system 24

Figure 2 3 Throttle parameter values 27

Figure 2 4 The relationship between Torque and air mass 28

Figure 2 5 External image of the engine and RPM-P-T graph Error! Bookmark notdefined. Figure 2 6 Location of details on the 1NZ-FE engine 35

Figure 3 1 Example of the process of building a program to fine tune ECU 43

Figure 3 2 A JB4 brand multifunctional Piggyback set 44

Figure 3 3 Independent ECU Speeduino and Arduino open source application 44

Figure 3 4 Schematic diagram of the motor speed control system 45

Figure 3 5 Device operating location 46

Figure 3 6 Simulation estimates the relationship between accelerator pedal position and voltage level 46

Figure 3 7 LM741 47

Figure 3 8 Simulate ECO mode control device 48

Figure 3 9 Signal control structure 49

Figure 3 10 Throttle control signal W/WO ECO BOX 50

Figure 3 11 Matlab Simscape 51

Figure 3 12 S-PS converter unit 51

Figure 3 13 PS-Simulink converter 52

Figure 3 14 Engine block 52

Figure 3 15 Mechanical Rotational Reference 54

Figure 3 16 Torque Converter 54

Figure 3 17 Vehicle Body 55

Figure 3 18 Block diagram of the simulation 56

Figure 3 19 2021 Generation Toyota Innova 57

Figure 3 20 Driving Cycle signal 59

Figure 3 21 Vehicle simulation model (General) 60

Figure 3 22 Simscape Results 61

Figure 3 23 Block diagram of Model’s operation 62

Figure 3 24.Vehicle speed graph (m/s) 63

Figure 3 25 Power graph 64

Figure 3 26 Fuel consumption graph 65

Figure 3 27 Engine speed graph 66

Figure 3 28 Torque graph 67

Figure 4 1 ECO BOX device 68

Figure 4 2 Installation of ECO BOX 69

Figure 4 3 FC Meter 9531A 70

Figure 4 4 Main components of FC- 9531A 71

Figure 4 5 Installation position of FC sensor 72

Figure 4 6 Interface of Toyota Techstream program 72

Figure 4 7 VCI cable to connect the laptop with Techstream program to OBD2 port 73

Figure 4 8 Flow diagram of Installation for first-time run 75

Figure 4 9 Flow diagram of Idle test 75

Figure 4 10 Flow diagram of Road test 76

Figure 4 11 Driving cycle map 78

Figure 4 12 Normal mode driving cycle data 79

Figure 4 13 ECO mode driving cycle data 80

Figure 4 14 Sport mode driving cycle data 81

Figure 4 15 Injection volume Normal mode 82

Figure 4 16 Injection volume Eco mode 82

Figure 4 17 Injection volume Sport mode 83

Figure 4 18 Engine speed Normal mode 83

Figure 4 19 Engine speed Eco mode 84

Figure 4 20 Engine speed Sport mode 84

Figure 4 21 Vehicle speed Normal Mode 85

Figure 4 22 Vehicle speed Eco mode 85

Figure 4 23 Vehicle speed Sport mode 86

List of table

driving cycle data.

In recent years, the automobile market in Vietnam has made great progress in many aspects such as production , sales , service, etc Thanks to the government's supportive policies in many directions, the automobile industry in Vietnam has gradually become saturated with other countries in Asia The number of cars per capita in Vietnam is also gradually increasing year by year But most of those new cars are located in the low-end and popular segments, the reason for that is the rapid development of the online passenger transportation system - typically Grab and service cars (Taxi) The characteristics of these cars are moderate prices, easy to use but it lacks advanced comfort functions Meanwhile, users' demand for driving experience in multiple modes is increasing In addition, the driving modes Sport, Racing or ECO are rarely equipped on these models.

Therefore, in order to improve the above disadvantages, the author decided to research and manufacture a device to select the driving mode applied for GRAB and TOYOTA INNOVA vehicles And one of the main objectives of the research direction is to evaluate the efficiency of the vehicle when installing the mode selector with the vehicle without the mode selector in order to study the feasibility and economics of the device In this thesis, the author will give an overview of engine control through modes, present the theoretical basis of electronic throttle control, use Matlab/ Simulink Simscape software to build the device and actual testing of the device From those results will give an overview of the effectiveness

of the device on the vehicle's operation compared to other traditional vehicles.

11 Purpose of thesis selection:

Today, the problem of environmental pollution is a problem that is mentioned a lot in global conferences And in the IEA report [1] on the world's CO2 emissions, in 2020 the

industrial production and transportation In recent years, along with the socio-economic development, the number of private means of transport in our country has also increased rapidly According to the Vietnam registry as of July 2021, there are more than 14 million motorbikes and 4.2 million cars of all kinds In which, vehicles using internal combustion engines account for 90% of the total number of existing vehicles With a large number of vehicles, the amount of fuel used every year is also large and at the same time it also creates a large amount of CO2 emissions to the environment.

Thanks to the development of technology and techniques, the structure of the automobile is more modern and comfortable, most of which are equipped with intelligent systems to bring safety, stability, fuel economy and other safety features car customer experience The typical fuel-saving system research methods can include the fuel-saving modes of companies such as Toyota, Ford, Honda The start-stop system on BMW, the variable valve control system and the system GDI direct injection and including the ECO intelligent driving mode control system with the ability to create driving modes suitable to the movement conditions of the car to be effective in terms of torque and power and also control the fuel consumption of the vehicle According to designs from car manufacturers around the world, fuel-saving driving mode can reduce fuel consumption by up to 5%, which shows great economic benefits from this feature But in reality today, the control system for intelligent driving modes ECO has not been much equipped in most of the low-segment cars of Taxi companies.

Although there have been many studies published such as research on factors affecting fuel consumption and CO2 emissions of passenger cars [2], the study of Fontarnas [3] ablout the fuel consumption in Europe, research on reducing emissions in passenger transport [4] to contribute to improving environmental pollution and maximizing the benefits

of natural resources However, if put into practice, the research can only affect the hardware and the fuel

optimization systems are not always available on every car model Finding effective ways to increase fuel economy and optimize system control on existing vehicles becomes extremely necessary.

Therefore, if conducting research and installing this system on Toyota Innova lines, it will be able to contribute to improving vehicle performance, user's driving experience, reducing fuel consumption, thereby reducing fuel consumption reduce costs for both users and taxi service providers and contribute to environmental protection On that basis, the author chose to research and manufacture a device to select the driving mode application for Toyota Innova The study was conducted to study the electronic throttle control system, contributing to reducing fuel consumption and improving the user's experience when driving To realize the above goals This is a device that is directly attached to the accelerator pedal and ECU, through the ECU controlling the input signal from the accelerator pedal to control the desired output signal on the electronic throttle set.

2 Research object and scope:Research subjects:

The object of the research is the ECO mode control device for the 2nd generation Toyota model (from 2007 to 2014, 1NZ-FE engine) The device will be installed directly on the vehicle The research was carried out at the chassis and bodywork research room, Ho Chi Minh City University of Technology and Education.

Matlab software Simulink Simscape will be used to model the motor control system Studying blocks serves the purpose of studying the engine and operation of the blocks mentioned above.

Research scope:

Learn about ECO modes on vehicles from various manufacturers Learn about ways to save fuel with minimal hardware impact Develop a plan to design and control a set of fuel-saving devices, control vehicles according to pre-set running modes Studying the effect of the device on the technical and economic performance and emission of the engine Research methods to determine fuel consumption without using

specialized equipment Research, develop and upgrade the ECO fuel-saving mode controller.

3 Research content:

- Research and simulate the Innova engine and build the engine model on Matlab Simscape ® ® .

- Research and design equipment on Proteus simulation environment.- Research on 1NZ-FE motor speed control method.

- Experimenting with operability and evaluating the efficiency of the control device to

evaluate the engine's ability to optimize fuel use and emissions.

- Research and build RPM/Torque/ fuel ratio diagram.4 Research method:

The thesis uses theoretical research methods, modeling combined with experimental research to evaluate the operability, efficiency and scientificity of the research result In addition, to build the knowledge base on thesis in a scientific and effective way, the method of document review is also applied.

5 Scientific significance of the research thesis:

This is the first scientific study built on the device Currently on the market, there are devices that help increase power through increasing the amount of air entering the combustion chamber, these devices can increase engine power in a short time but damage the engine and increase fuel consumption is very significant Therefore, the device is not intended to increase capacity Instead, if successfully researched, the device can be used to create more fuel-saving modes that are easy to use for vehicles that do not have the ECO system available or the ECO system does not have high efficiency Help save fuel, increase engine life and can also improve efficiency.

Researching methods to optimize engine power through throttle controller optimization.

Proposing to widely apply and commercialize the ECO mode control device.

6 Structure of the thesis:

The structure of the thesis is divided into the following sections:

• Preamble.

• Main Content section Consists of: - Chapter 1: Overview

- Chapter 2: Theoretical basic;

- Chapter 3: Building model, design and manufacturing equipment; - Chapter 4: Experiment with Eco box device.

• Conclusion and recommendation.

1.1 Problem statement.

Chapter 1 : INTRODUCTION

Much of the process of controlling a vehicle is controlling its speed The vehicle's speed comes from the engine's traction and is routed through the transmissions to the rotating mechanism of the wheels On each gasoline car, the driver will use the accelerator pedal to control the amount of fuel entering the engine and the throttle system will control the amount of air entering to create a mixture of air and air into the cylinder Accordingly, accelerator pedal control also allows the driver to control engine torque to accelerate the vehicle and maintain the desired speed, as well as reduce or eliminate torque to slow down and stop the vehicle Previously, the throttle was controlled directly by the driver via the accelerator pedal based on a mechanical connection (e.g Bowden cable) and if the vehicle was equipped with an automatic throttle then another cable was added connected to the throttle valve and the cruise control actuator One way or another, the throttle position must be determined to control the proper amount of fuel injection.

In 1988, the first electronic throttle control (ETC) system was introduced [5], which eliminated the mechanical connection between the accelerator pedal and the throttle body by replacing it with an electronic control system complete This system includes the pedal sensor, throttle sensor and actuator as well as the necessary control unit ETC is a technology that allows advanced features including cruise control and vehicle stability control to be made easier and is widely used in cars today Since the operation of the ETC system is related to the safety of the driver, the quality control requirements on the accelerator pedal sensor are relatively strict [6].

Figure 1 1 Some mechanisms that align the accelerator pedal position with the sensor are highlighted in red.

The general trend of car manufacturers today is towards driving comfort, increasing driving feeling, increasing safety for the whole system Those requirements are expressed through technical features such as: high linearity, low latency, small deviation and equivalent sensitivity with long life Along with the development of other industries, the automobile manufacturing industry has undergone many periods of replacing and renewing the method of controlling engine speed with different types of sensors.

1.2 Review of related studies.

In this section, the author presents researches on fuel-saving methods and applications to improve internal combustion engines of some car manufacturers such as BMW, TOYOTA, HONDA on Variable Valve Timing, Smart Cam in high-end car models and research on driving modes in car manufacturers Besides, there is an overview study of two driving modes, ECO.

1.2.1 Factors affecting fuel use – Auxiliary system.

Auxiliary systems refer to elements and accessories that improve driving safety and comfort such as air cleaning systems, lighting systems [7], wipers, doors power windows, heating and air conditioning systems [8], parking assist, collision warning [9] These devices are not normally operated continuously, however this work did not consider the usage factors in detail due to lack of information Auxiliary use requires an increased electrical or mechanical supply, thereby increasing the power demand of the engine and fuel consumption The latter rates are estimated in order of 9% for the use of the air conditioning, up to 4.5% for the steering assist system and up to 6.5% for the other ancillary items According to the literature, optimization and advanced technologies can provide fuel consumption benefits of up to 2% Purely mechanical auxiliary systems are losing their place compared to electrical systems serving the same purpose.

Figure 1 2 Basic car comfort system.

A variety of energy needs for additional electrical and mechanical loads have been evaluated by simulation This resulted in an average increase of 14.9% for NEDC (New European Driving Cycle) and 9.6% for WLTP (Worldwide Harmonised Light Vehicle Test Procedure) for global light vehicles), are considered relatively high values for the intended