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Old 01-26-2005, 06:40 PM   #1
andys
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Default DCCD controller info

Someone may want to store this somewhere......

The EMCD controller is directly powered by +12V via two green wires sharing the current. These are on pins 7&8 on my V.III controller. Chassis common is on pins 15 and 16. (Although I understand pin configuration varies with version, all these V2,3,4,5,6,7 five speed EMCD controllers seem to work the same). The 12V then powers a switching power supply that supplies 5V to power the processor. When the processor is fired up it activates a pin which closes an external relay that supplies power to power the EMCD solenoid circuit, pins 2 and 3. The EMCD unit is always supplied with 12V @ pin 1 and the PWM controller switches the return wire to common to complete and modulate the solenoid energy. Holding the ebrake sensor wire, pin 19, to ground reduces the PWM duty cycle to about 5% and not zero as you may expect. The thumb wheel varies the duty cycle from 5% at the minimum indent, then 10%-90% then about 95% at the locked indent. The switching frequency is 100Hz and this corresponds to a switching period of 10ms or 10,000 us. The controller has 7 outputs for the dash LEDs and one for the power relay (which really isnít that necessary). These controls really donít do much except vary the lock with the thumb wheel and then release the diff then the ebrake is activated.

However, we are now designing a universal replacement unit that will have the same features as well as four active maps that use the throttle position, brake activation, RPM and engine speed sensors (plus more maybe). The units will have wiring harnesses that neatly plug inline with the OEM ECU connectors. The controllers will be available for USDM 2.5RS, WRX and STI models for use with both EMCD enabled 5 and 6 speed transmissions. The units will either be dash mount or DIN mount. Stay tuned for more infoÖ.
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Old 01-26-2005, 06:53 PM   #2
PHATsuby
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that is cool info, you used a scope to check all these then? I am curious if it is the same on all of the DCCD's even current.

So, you are saying that full lock up is basically just a 12v 100hz signal?

are you going to be scoping a current USDM sti as well?

nice work.

Ben
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Old 01-26-2005, 07:28 PM   #3
andys
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I'll scope the STI but I think it'll be the same as the RA tannys.

It appears that full lock (remember we don't know if this is a full 100% mechanical lock up) is straight up 12VDC across the coil. Pretty simple. No controller required. Just an on/off switch.

To acheive varying "lock-up" the 12VDC is switched on and off by the diff controller 100 times a second. 50% duty cycle means on for 5ms and off for 5ms. 25% duty cycle means on for 2.5 ms and off doe 7.5ms. And so on.
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Old 01-26-2005, 07:52 PM   #4
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what would you use to run 12v? since the alternator actually puts out over 14v, could i get something to keep it at 12v?

thanks
Ben
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Old 01-26-2005, 07:55 PM   #5
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Yeah, 12 - 14 whatever. It's whatever the voltage of the car is.
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Old 01-27-2005, 12:02 AM   #6
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Interesting stuff. I'm surprised the full lock = 12vdc. My measurement of the coil showed only a couple of ohms simple resistance. Thats a lot of current...
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Old 01-27-2005, 12:54 PM   #7
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Default dccd info

Yeah - to be honest I haven't attached the controller to the coil yet so I don't have any idea what the currents really are. I'll post this info soon when I measure it.

The coil wires are really small and only good for a couple of amps max before they get too hot themselves. This means the coil should be about 6ohms or greater to keep the currents down. It may change resistance when current starts flowing or the controller may sense some overcurrent conditoins and regulate the current - but I doubt it as the conroller has no on-board ability to sense the coil current. Like I said, 95% duty cycle is full-lock and this is close enough to 100% for it to perhaps not matter. But before anyone connects 12V directly you should wait until I take the measurements to see if it's ok. I can't see why it would make a difference but you never know what's in there. I've heard stories of 12VDC overheating the coil but I think that was with a broken driveshaft. I can't see 2Ax12V or 24W of heat input damaging anyting inside that tranny......but like I said, I haven't tested it yet.

-Andy
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Old 01-30-2005, 11:21 PM   #8
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Default dccd current

The EMCD coil resistance is about 2.5 ohms. The coil current vaires linearly from 0 to 4A when the switch is varied from no lock to max lock. The current is highly DC with very little ripple meaning that, as expected, the coil is highly inductive in nature. The PWM diff controller is more than just a 12V on and off supply. It enables the current to 'free-wheel' around the controller when the coil power is in the zero state thus creating a buck type or 'chopper' type switched mode power supply.

The centre diff must mechanically amplify this control input to acheive the lock it does. I know mine has some slight mechanical delay. It's still pretty cool tho. With only 2A EMCD current my car drove its self off the jack stands

Let me know who wants a controller.......

-Andy
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Old 01-31-2005, 12:16 AM   #9
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Quote:
Originally Posted by andys
However, we are now designing a universal replacement unit that will have the same features as well as four active maps that use the throttle position, brake activation, RPM and engine speed sensors (plus more maybe). The units will have wiring harnesses that neatly plug inline with the OEM ECU connectors. The controllers will be available for USDM 2.5RS, WRX and STI models for use with both EMCD enabled 5 and 6 speed transmissions. The units will either be dash mount or DIN mount. Stay tuned for more infoÖ.
Is this going to be open source kinda like the mega squirt or is this a closed source by the finished product kinda project. If so any guesses on the cost yet.

/me would love to see it as free software (Free as in freedom, not as in free beer)

Cheers,
Chris
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Old 01-31-2005, 12:33 AM   #10
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im really thankfull that andys and phatsuby are doing this for us
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Old 01-31-2005, 03:31 AM   #11
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Default dccd controller

Hmm well you might not be so thankfull when you see the price. And they won't be open source per se - although I don't mind sharing the details of how the EMCD works - at least from a control input perspective. With this info and with a background in power electronics you can probably build something that does the trick. Since there is a certain amount of effort required to get the units designed and manufactured etc. etc. the production of these units will end up being a commercial excerise. Unfortuneately, it is very difficult to build a good one with out knowing what you are doing and even if you do know what you are doing it's time consuming and expensive. That being said they'll be MUCH cheaper than anything else you can buy to do the job.
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Old 01-31-2005, 10:00 AM   #12
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Quote:
Originally Posted by andys
Hmm well you might not be so thankfull when you see the price. And they won't be open source per se - although I don't mind sharing the details of how the EMCD works - at least from a control input perspective. With this info and with a background in power electronics you can probably build something that does the trick. Since there is a certain amount of effort required to get the units designed and manufactured etc. etc. the production of these units will end up being a commercial excerise. Unfortuneately, it is very difficult to build a good one with out knowing what you are doing and even if you do know what you are doing it's time consuming and expensive. That being said they'll be MUCH cheaper than anything else you can buy to do the job.
Fair enough, I'm a programmer (by trade) and my roomate is a ee (by hobby) and the idea of being able to tinker with auto mode code seems cool, in fact cool enough I would probally actually go get a transmission with a DCCD

Cheers,
Chris

ps thanks for the work none the less
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Old 01-31-2005, 12:46 PM   #13
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Quote:
Originally Posted by andys
The EMCD coil resistance is about 2.5 ohms. The coil current vaires linearly from 0 to 4A when the switch is varied from no lock to max lock. The current is highly DC with very little ripple meaning that, as expected, the coil is highly inductive in nature. The PWM diff controller is more than just a 12V on and off supply. It enables the current to 'free-wheel' around the controller when the coil power is in the zero state thus creating a buck type or 'chopper' type switched mode power supply.

The centre diff must mechanically amplify this control input to acheive the lock it does. I know mine has some slight mechanical delay. It's still pretty cool tho. With only 2A EMCD current my car drove its self off the jack stands

Let me know who wants a controller.......

-Andy
I'm in !!!!

Do you have an idea of the price !?

Thanks for your effort!!!

Martin
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Old 01-31-2005, 12:57 PM   #14
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Well, if i actually get my hands on my own controller i plan on either taking these measurements from that or my friends STi, but i have said that for a while and have been delayed a lot by school.

so once i get all the frequencies and such confirmed(since my last thread and list of measurements is questionable) i will list them up, then it would be up to someone else to reproduce those, i had planned to just make an off switch for 50/50 in the winter really, or at most, manual mode since i have the thumbwheel switch.

Unless i get my own controller to play around with the dccd measurements will prob not come until after school.

Ben
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Old 01-31-2005, 04:44 PM   #15
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Well, I've got one made. But one thing after another has kept me from testing it. Mostly, I need a scope and I don't have one. I'm a bit nervous about connecting to my diff till I have an idea of what signal I'm actually generating.

Right now, I'm hip deep in my specC driveline swap, so I don't think i'll actually test for another couple of months. When I do, I'll post my work and let anyone do what they want with it (except make money). Hopefully someone will improve on my basic controller.
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Old 01-31-2005, 05:27 PM   #16
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You should tell me what you did and I can tell you if it'll work or not. It's important that the circuit can freewheel.
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Old 02-01-2005, 12:37 AM   #17
PHATsuby
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what do you mean by "freewheel" doesnt sound very technical

Ben
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Old 02-01-2005, 02:48 AM   #18
andys
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Default dccd controller

freewheeling refers to letting the inductive coil current zip around the controller curcuit board while you are holding zero volts across the coil. If you don't pay attention to this your controller will blow immediately. Fer sure. No question about it.

You'll also need to pay attention to snubbing the FET switch against the inductance of the power leads as well as putting a high current gate drive circuit on the FET switch to crank it on and off quickly. The FET switches are more delicate than can imagine. The fact that it is all only happening at 100Hz instead of 100KHz is on your side tho... there's a reason these things cost moula. Then there's all the active mapping....and the noise immunity issues etc. etc.
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Old 02-01-2005, 01:16 PM   #19
ImprezaRSfan!
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all i want for christmas is a 50/50 switch
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Old 02-01-2005, 07:56 PM   #20
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Quote:
Originally Posted by ImprezaRSfan!
all i want for christmas is a 50/50 switch

LOL!!!! IT's a good "start" .....
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Old 02-02-2005, 08:17 PM   #21
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I'd be interested in one. Email me with a price and I'll probably buy one if its reasonably priced.

I have been looking at the Rallispec kit already for $700USD.

cmmpro@hotmail.com
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Old 02-02-2005, 08:35 PM   #22
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....
....

Last edited by Spiider; 02-21-2005 at 05:25 PM.
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Old 02-03-2005, 01:36 AM   #23
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My controller is designed around the SG2525A chip. Its expressly designed for control of motors.
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Old 02-03-2005, 04:37 PM   #24
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Quote:
Originally Posted by Spiider
Hey what do you think of this with the IRF530 for the higher current gate drive, and the UF4001 for the inductance problem?

555 PWM circuit
Yes, this would pretty much do it. You still may run into a couple of small problems but not many. It would also probably work with the TIP31 and then you don't have to worry about the gate drive.
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Old 02-03-2005, 04:44 PM   #25
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Quote:
Originally Posted by fragment
My controller is designed around the SG2525A chip. Its expressly designed for control of motors.
This is cool too but maybe a bit overkill. You may also have problems getting it to work as low as 100Hz. You can get thw 555s at radio shack.

-andy
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