| HDS 9 |
General description
An internal combustion engine controller is a device that provides engine control all strategies, fuel supply, forced spark ignition control, control of many engine operating parameters and implements self-diagnosis functions and safety of the engine and all auxiliary systems.
Our joint development of a new controller began with the Italian company Metatron in 2014. Before our participation, Metatron was producing a serial device the HDS7 model. The next model Metatron was to be called HDS8, but the beginning of our participation in the project and the formation of new expanded requirements for the functionality of the controller led to the formation of a new model - HDS9.
The ECU is designed for 24V battery systems, 12V battery system is available as option. The ECU is able to manage:
- Analog input signals (temperature, pressure, potentiometer, …)
- Two knock detection sensors
- One UEGO lambda sensor (BOSCH LSU4.9 or BOSCH LSU5.2)
- Two HEGO lambda sensors, one as alternative to the UEGO
- Digital input signals (switches to ground or battery+)
- Frequency and PWM input signals, including engine speed and phase
- ON/OFF low side, low power commands, such as lamps, relays, …
- ON/OFF low side, medium power commands, such as electro valve pressure reducer, …
- ON/OFF high side, medium power command
- Frequency and PWM low side, low power commands, such as engine speed and phase repletion, …
- Frequency and PWM low side, medium power commands, such as lambda heather, turbo,…
- Up to eight injector commands, driven through smart programmable solenoid controller ASICs
- Up to eight ignition commands (logical commands for active coils)
- Up to two H-bridges, typically for electronic throttle actuator and EGR actuator, driven through smart programmable solenoid controller ASICs
- Up to four CAN high speed communication lines, one of these supports CAN FD extension
The ECU is equipped with internal temperature and pressure sensors. Three separate power supply lines (5V) are available for sensor supply. The ECU is provided with the NXP multicore microprocessor MPC5777 and with the NXP power system basis chip (power SBC) 33908 (multi-output power supply integrated circuit dedicated to the automotive market). The multicore microprocessor and the power SBC include enhanced safety features, becoming a safety oriented system and reaching a high integrity safety level.
The ECU is equipped with embedded software fully developed by Metatron through a Model Based Approach according to the current state of the art widely diffused into the automotive field. The ECU is able to perform all the control functions needed to safely operate a spark ignited engine including:
- comburent air estimation
- fuel injection, as this ECU is intended for gas only fueled engines there are no dummy injectors
- spark ignition with integrated functions of advance timing calculation and actuation
- air-fuel ratio adjustment
- safety engine shutoff: the ECU cuts off the gas valve within 100ms in case of engine stalling, broken fuel supply pipe and when the engine is turned off.
On Board Diagnostics software functions have been developed in order to comply with European applicable standards in order to optimize the engine performances, reduce the pollutant emissions and continuously monitoring the system integrity and reliability.
ECU pins are short circuit protected to battery+, ground and to each other connections, with the exceptions below: ground pins are not protected against short circuit to supply voltage Battery+ and positive supply pins are not protected against short circuit to ground.
Mechanical Interfaces
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Installation position The ECU shall be mounted in vertical position (along vehicle Z axis), as indicated in document ME-SP-A-H900004 (HDS9 – Installation Note). Any other mounting position is not recommended and must be agreed with Metatron engineers. Dimensions and weight The ECU weight is about 1050g. Connector The connector used is an AMP-TYCO 154 pins, item type P/N. 284617. 
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Electrical Interfaces
Blocks Diagram of ECU Architecture  |
Inputs Description Analog inputs. There are 28 input conditioning circuits for external sensors:
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Digital inputs
There are 15 input conditioning circuits for external switches. Each input channel can be configured, via software, with pullup or pulldown resistor, according to switch connection to ground or to battery voltage. There are also two specific inputs dedicated to:
- Key switch, with pulldown resistor
- Auxiliary key switch, with pulldown resistor
- These two specific inputs, when active, will turn on the ECU.
Frequency inputs
Input conditioning circuits for:
- Engine speed VRS type sensor, hardware configurable also for hall effect sensor
- Engine phase VRS type sensor, hardware configurable also for hall effect sensor
- 5 Hall effect sensors
Outputs Description
ON/OFF Outputs
- 4 low side drivers: 0.5A RMS, 1A peak
- 4 low side drivers: 1.5A RMS, 3A peak
- 1 specific output for fuel pump command, configured as high side driver: 0.75A RMS, 1.3A peak
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1 specific output for starter command, it can be configured as :
▪ low side driver: 0.75A RMS, 1.3A peakor
▪︎ High side driver: 0.75A RMS, 1.3A peak
PWM/Frequency Outputs
- 2 low side drivers: 0.5A RMS, 1A peak
- 2 specific low side drivers dedicated engine speed and phase signals repetition: 0.5A RMS, 1A peak
- 1 low side driver: 1.5A RMS, 3A peak
- 5 low side driver: 2A RMS, 10A peak. One of these as alternative to the fuel pump high side command
- 1 low side driver for pre catalyst lambda heater (UEGO or HEGO type): 2A RMS, 10A peak
- 1 low side driver for post catalyst lambda heater (HEGO type): 1A RMS, 5A peak 3.3.3.3
Ignition command
Eight ignition commands are available, they are dedicate only to active coils and are able to provide up to 10mA (source current). For particular applications these outputs can be configured as low side driver: 0.025A RMS, 0.05A peak.
Injection command
Eight half bridge channels for injectors driving are available (ON/OFF or Peak&Hold type): 2.5A RMS, 8A peak channel in normal operation, for ant sticking operation, in cold condition and for a very short time (50ms), peak current could be increased up to 10A.
H Bridges command
There are two channels for H bridge actuators (i.e. electronic controlled throttle): 3.5A RMS, 7A peak.
Microprocessor
The ECU is equipped with the NXP microprocessor COBRA55 (MPC5777). The MPC5777C Power Architecture MCU is dedicated to industrial and automotive engine control applications that require advanced performances, timing systems, security, and functional safety capabilities. This microprocessor offers a high-performance multicore architecture with industry standard eTPU based timer system, a security module and the highest level of functional safety (ASIL-D) support. Microprocessor main characteristics are:
- 2 x Main cores + 1 x Checker core (lockstep)
- 1 x Single precision FPU
- 404 KB System SRAM (+ 192 KB data RAM included in the CPUs)
- 8 MB on-chip Flash Memory
- 8 × 64 KB + 2 × 16 KB Data Flash Memory (EEPROM)
- 1 × 64 QADC channels
- 4 x High Speed CAN
- 8 x DSPI (4 x SPI, 3 x MSC, 1 x SyncSCI)
- 3 x ETPU
Communication
HDS9 is provided with four Controller Area Network communication modules, according to BOSCH specification 2.0B, one of these (CAN1) supports CAN FD extension. One LIN transceiver compatible with LIN Protocol Specification 1.3, 2.0, 2.1, 2.2 and SAEJ2602-2 is available as option.
Accordance of standards
Compliancy with international standards
HDS9 ECU is compliant to the following satndards:
