Tech Hidden In Plain Sight: Cruise Control

July 8, 2021 by Al Williams 29 Comments

The advent of the microcontroller changed just about everything. Modern gadgets often have a screen-based interface that may hide dozens or hundreds of functions that would have been impractical and confusing to do with separate buttons and controls. It also colors our thinking of what is possible. Imagine if cars didn’t have cruise control and someone asked you if it were possible. Of course. Monitor the speed and control the gas using a PID algorithm. Piece of cake, right? Except cruise control has been around since at least 1948. So how did pre-microcontroller cruise control work? Sure, in your modern car it might work just like you think. But how have we had seventy-plus years of driving automation?

A Little History

A flyball governor from a US Navy training film.

Controlling the speed of an engine is actually not a very new idea. In the early 1900s, flyball governors originally designed for steam engines could maintain a set speed. The idea was that faster rotation caused the balls would spread out, closing the fuel or air valve while slower speeds would let the balls get closer together and send more fuel or air into the engine.

The inventor of the modern cruise control was Ralph Teetor, a prolific inventor who lost his sight as a child. Legend has it that he was a passenger in a car with his lawyer driving and grew annoyed that the car would slow down when the driver was talking and speed up when he was listening. That was invented in 1948 and improved upon over the next few years.

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Electric Land Speed Racing Can Be Lightning Fast

July 8, 2021 by Lewin Day 4 Comments

Land speed racing is a pursuit of ultimate speed above all else. Most cars typically run on huge, flat salt pans, and racers run flat out for miles in a straight line, attempting to push their machines to the limit. Like most motorsports, the history of land speed racing has traditionally been centred around internal combustion, but electric racers have long been out there chasing land speed records as well.

The Need For Speed

At the most famous land speed trials, such as Bonneville’s Speed Week, speed runs take place over miles and miles of open salt, with timing traps along the way to determine competitor’s speeds. These tracks are long enough that acceleration is of little concern, which is of great benefit to electric runners. Additionally, only one or two runs is required to set a record. This means that heavy batteries aren’t always needed, as the distance a competitor must travel is short, and even if the batteries are heavy, it doesn’t excessively affect top speed.

With an eye to that, land speed competitors in electric classes are typically classified into weight classes. This is due to the fact that bigger, heavier battery packs can deliver more current, and thus potentially have a performance advantage over lighter vehicles. Thus, typical classes run by most salt flats competitions involve the E1 class, which allows for vehicles under 1100 lbs, the E2 class, for vehicles up to 2200 lbs, and the E3 class, which is for anything 2200 lbs and above. The FIA also publish their own set of classes, again separated by weight, though to a much more granular degree.

Procedures for setting records vary depending on the venue and the record in question. Local records at salt venues like El Mirage can typically be broken with a single run faster than the standing record, while Bonneville Speed Week competitors must set a higher average speed across two runs on two consecutive days. FIA records differ again, and are perhaps the most stringent, requiring competitors to set a faster average across two runs in opposite directions, set within an hour of each other, to attempt to minimise the effect of wind on the result. Things can sometimes get confusing, as many FIA records, for example, are set at the Bonneville salt flats, but not actually in Speed Week competition or by Speed Week rules. Continue reading “Electric Land Speed Racing Can Be Lightning Fast” →

Hacking Old Honda ECUs

July 3, 2021 by Chris Lott 21 Comments

Automotive security specialist by day [P1kachu] hacks his own cars as a hobby in his free time. He recently began to delve into the Engine Control Units (ECUs) of the two old Hondas that he uses to get around in Japan. Both the 1996 Integra and the 1993 Civic have similar engines but different ECU hardware. Making things more interesting; each one has a tuned EPROM, the Civic’s being of completely unknown origin.

[P1kachu] took his Civic to a shop to have some burned-out transistors replaced in the ECU, and a chance conversation with the proprietor [Tuner-san] sends him on a journey into the world of old EPROMs. [Tuner-san] pulled out an old PROM duplicator stashed away under the counter which he originally used as a kid to copy PROM chips from console games like the Famicom. These days he uses it to maintain a backup collection of old ECU chips from cars he has worked on. This tweaked [P1kachu]’s curiosity, and he wondered if he could obtain the contents of the Civic’s mysterious PROM. After a false start trying to use the serial port on the back of the PROM copier, he brute-forces it. A few minutes of Googling reveals the ASCII pinout of the 27C256 EPROM, and he whips out an Arduino Mega and wires it up to the chip and is off and running.

Advantest R4945A EPROM Duplicator c.1980s

He’s currently digging into the firmware, using IDA and a custom disassembler he wrote for the Mitsubishi M7700 family of MCUs. He started a GitHub repository for this effort, and eventually hopes to identify what has been tweaked on this mysterious ECU chip compared to factory stock. He also wants to perform a little tuning himself. We look forward to more updates as [P1kachu] posts the results of his reverse engineering efforts. We also recommend that you be like [P1kachu] and carry an Arduino, a breadboard, and some hookup wire with you at all times — you never know when they might come in handy. Be sure to checkout our articles about his old Subaru hacks from in 2018 if these kinds of projects interest you.

A Robot To Top Up Your Tesla

July 2, 2021 by Danie Conradie 37 Comments

The convenience of just plugging in your car in the evening and not going into a gas station is great as long as you remember to do the plugging. You really don’t want to get caught with an empty battery while you’re in a rush. [Pat Larson]’s Tesla plugging robot might be a handy insurance policy if you count forgetfulness among your weaknesses.

The robot consists of a standard Tesla charging plug attached to a 2-axis robotic arm mounted on [Pat]’s garage wall. Everything is controlled by a Python script running on Raspberry Pi 4. After taking a picture with a camera module, it uses a Tensor Flow Lite machine learning model to determine the position of a reflector on the charging port cover. The platform moves back and forth to align with the charging port, after which it opens the charging port using the Tesla API. It then extends the arm towards the charging port, using ultrasonic proximity sensors for distance control, and again uses the camera module and Tensor Flow to look for the illuminated Tesla logo adjacent to the charging port. The charge plug is flipped out using a large servo, and after some final position adjustment, it takes the plunge. While robot won’t be winning any interior design contests, it does the job well, and adds a bit of convenience and peace of mind.

Other Tesla hacks we’ve seen include building a working Model S for $6500, turning an old Honda into a speed demon using Tesla parts, and a Casio F-91W that can unlock your Tesla.

Dumping 90’s Honda ECU Programming With Arduino

July 2, 2021 by Danie Conradie 19 Comments

[P1kachu] owns a pair of early 1990’s Honda’s with custom tuning on their stock ECUs, and after having to get the ECU repaired on his ’93 civic, he found himself going down the rabbit hole of Honda ECU EPROM chips.

During the repair process, the tuning shop owner, or [Tuner-san] as [P1ikachu] refers to him, made a backup of the custom tuning to another EPROM chip. This was done with an old Advantest R4945A EPROM programmer, which [Tuner-san] supposedly also used to clone Famicom cartridges back in the day. After realizing that [Tuner-san] could only clone the contents, but not view or modify it, he started looking at ways to do that.

EPROMS are programmed using higher voltage (12.5 V – 25 V) but to read them 5 V is used. The memory address is selected by setting each of the 15 address pins high or low, and then reading the status of the 8 data pins to extract one byte of data. Rinse and repeat for each of the 256 memory addresses on the Microchip 27C256 EPROM. One of the previous owners of [Pikachu]’s Civic made some unknown tuning changes, so he is in the process of looking at the dumped data to see what was changed. Once he has completed figuring out the programming table of the EPROM, he plans to do some testing with [Tuner-san] to possible smooth out the rev limited.

An interesting aspect of EPROMs is that they are erased using UV light, which sets all the memory bits to 1. During programming, selected bits can be set to 0, but it’s not possible to set them back to 1 without erasing the entire chip again.

Messing around with the computers in cars is not only for tuning, but can also expose some rather serious security flaws, especially in modern vehicles.

Retrofitting Fast Charging To A Nissan Leaf EV

June 28, 2021 by Lewin Day 21 Comments

Electric cars have been around for a while now, and thus they’re starting to get chopped up and modded just like any other car. [Daniel Öster] is one such person doing the work, and recently posted his efforts to retrofit fast charging to an base-model Nissan Leaf that didn’t ship with the feature.

[Daniel] uses special high-voltage insulated tools when working on EVs for safety.

It’s an involved swap, requiring the substitution of several parts and surgery on the wiring loom. Cost of components was just 700 euros but the swap required 20 hours of labor. The vehicle in question is an early model Leaf that was already fitted with an upgraded 40 kWh battery, and the owner desired an upgrade to CHAdeMO fast charging to better use the larger pack.

The swap required the power distribution unit to be replaced, and the CHAdeMO port to be installed in the front of the car. The vehicle control module (VCM) also had to be opened in order to run a wire to a relay to activate the fast charging subsystem. Finally, wires had to be spliced to get everything to play nicely between the car and the fast charger.

[Daniel] had the benefit of quality forum resources and a Nissan Leaf that already had CHAdeMO to reference, which helped a lot. At the end of the day, the fast charger worked first time, much to [Daniel]’s relief. We’ve featured his work before, too. Video after the break.

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Miata Sci-Fi Digital Dash

June 27, 2021 by Matthew Carlson 26 Comments

One of the hardest, but sometimes best, things you can do for a project is to walk away. [Jroobi] had spent hundreds of hours crafting the digital dash for his MX5 Miata (video, embedded below) and after spending far too long chasing down I2C bugs, he made the difficult decision to step away for a while. However, as of May 2021, [Jroobi] returned to the project and found a power supply was under-specified and was causing brownouts that resulted in crashes.

All in all, it’s an incredible work of engineering. Everything from the massive codebase that describes all the different states to the tasteful graphic design is masterfully done. The Star-Trek-inspired theme and attention to detail really show in the different modes on the tachometer. The dynamic soft RPM limit based on engine temperature is particularly ingenious.

Under the hood of this custom dash are two Ardunios running the show. The center media console offers more controls with a generous touch screen while the instrument cluster shows most of the data. They talk over I2C to each other and communicate with other parts in the car, such as the RGB cabin lighting and the TEIN electronic suspension dampeners. Fuel and temperature levels come in as voltage levels which can be read via an ADC. The gear position is calculated based on RPMs and speed given the wheel size and the transmission in the vehicle.

It is a phenomenal labor of love and if you’re inspired to further upgrade your Miata you might want to see how to put carbs on the engine or RGB light rings in the instruments. Continue reading “Miata Sci-Fi Digital Dash” →