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Paul Tonkin
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Auckland
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Friday, March 27, 2015 - 06:13 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Greeting fellow adjustable suspension enthusiasts. In this thread I will be documenting my design and build of a custom aftermarket uzz31 suspension height controller. At the point of starting this post, I have a prototype up and running, but will document the process up to the current point in time, then continue as development progresses.

I had been finding it quite difficult to get my hands on an off the shelf aftermarket height controller, the one I did get cost $200 and didn’t work.

Being an electronics engineer, I figure let’s build one. Totally aware that there is a wealth of shared (and unshared) knowledge out there, so please feel free to comment or contribute.

The next post will cover some assumptions made on the operation of the height controller system.
Paul Tonkin
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Auckland
Soarer V8 Ltd

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Friday, March 27, 2015 - 06:18 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Step 1) how do the sensors and suspension ECU work?

A few years back I read a post that described the sensors, but have not been able to find it since. What it (may have) said was that they have a 0 to 5V output, depending on the position of the sensor / suspension height. Anyone that knows of it and can link it up here would be appreciated. To continue, a few assumptions where made.

Assumption 1 – from each sensor, 0 volts output is as low as the car can go, 5V as high.

Assumption 2 – the height controller computer reads each sensor, and adds or removes air to the bags to bring them to an equilibrium at a 2.5V threshold.

Assumption 3 – the low / high switch changes the threshold at which the height ECU creates an equilibrium.

Assumption 4 – off the shelf aftermarket height controllers must interrupt the line from the sensors to the ECU, and manipulate it in a positive or negative direction depending on the controller setting.

The next post will be exploring the possible solutions.
Paul Tonkin
Tinkerer
Auckland
Soarer V8 Ltd

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Friday, March 27, 2015 - 06:35 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Step 2) assess possible solutions.

Possible solution 1) modify the standard ECU to have a variable / adjustable threshold, as theorised in Assumption 2.

The Suspension controller was removed and opened, in the hope there would be some possibility of determining where the assumed threshold would reside. Although potentially a clean and lean solution, this was parked. Too hard.

What was noted that the suspension PCB has identifiers written beside most of the pins of the 3 connectors. Interesting and useful for later solutions. Those pins, as well as they could be read, are listed in the image.


Upload


The result of solution 2 assessment is next.
Jan van Berendonk
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Friday, March 27, 2015 - 07:28 pm, by:  Jan van Berendonk (Janjen) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

What does the high low switch alter in the ECU?
If it switches through different resistor could you not setup a control circuit at that point?
May be a dumb question, if so accept my apology.
Jan
Paul Tonkin
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Saturday, March 28, 2015 - 04:25 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Hi Jan,

Its a good question, thanks for your input. I did have a look around the ECU PCB, but didn't find where or how the height adjustment circuit was implemented. I probably gave up on this option before fully understanding it, because i was quite keen to try a couple of other solutions. Possible things it could be - as you suggest a different resistor - switched into a comparator circuit creating a different threshold, or it could be done if firmware if the sensor feeds right into a micro-controller analog-to-digital input. I'm interested to continue pursuing this option after finishing my current solution!

Paul
Paul Tonkin
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Auckland
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Saturday, March 28, 2015 - 05:28 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Possible solution 2) create an analogue signal interrupter to accept the voltage from each wheel sensor, and manipulate it in a positive or negative direction.

For this solution I utilised the harness from my not-working off the shelf height adjuster, and made two learnings.
1) The controller I have (and more importantly the harness) are for a Celsior, not a Soarer. The main difference is the power supply pins are in a different place.
2) While mucking around with this harness I managed my first screw-up. Applied voltage to an in-appropriate place and damaged the ECU. The TEMS control no longer works. The standard height control still works, so ill ignore this for now.

For this solution I created a 4 channel voltage adjusting circuit using an op-amp, some resistors, and potentiometers. This was simulated first using LTSPICE, as shown below.

Upload


The intention of the circuit is:
1) Divide the sensor voltage by 2 (or more). For this example 2.5V from the sensor becomes 1.25V.
2) Provide an adjustable gain of 1 to 4 on the sensor voltage, using the potentiometers as the control.
3) The output of the circuit is then fed back into the ECU, which reads a 2.5V sensor as anywhere between 1.25V to 5V, depending on the gain set by the pots.

Success. Well partial. The car can swing from very low (wheels tucked under the guards as shown) to very high. The problem is that it was very hard to set a height in between. An op-amp circuit of the above type has a liner response, but the control was feeling far from it.

Upload


Back to Excel for some calcs and the problem becomes apparent. (Sorry if this gets confusing. And I’ll admit now i probably like Excel way more than any grown man should). If the only task was to adjust the sensor voltage for the ECU, it would not be a problem. What actually happens (because it is a closed loop control) is the ECU gets its new voltage, controls the suspension to bring it back into equilibrium causing the sensor voltage to also change, effecting the set point. I think. Anyway graph 1 is the opamp response, graph 2 is what I think actually happens to the height.

Upload


The summary and main learning from this is – the height controller can’t MULTIPLY the sensor voltage with a gain to provide adjustment, it needs to ADD an offset.
This leads into my third, and current solution. I’m actually kind of excited about this.
Mike Beck
Goo Roo
New Zealand
UZZ32 No.32 & JZZ31 3.0GT

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Monday, March 30, 2015 - 07:54 am, by:  Mike Beck (Gold_40gt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Nice work Paul!

Do you work around Highbrook / East Tamaki by any chance?

I'm pretty sure we've both seen each other in our Soarers a few times. I'm usually in my red 3.0GT, occasionally the green 32.
Paul Tonkin
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Auckland
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Monday, March 30, 2015 - 07:00 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Thanks Mike!

Indeed I do - work at Fisher & Paykel Healthcare. Where are you - ever near Kerwyn ave? Seem to remember seen a Red GT around those ways a while back. Mate I'd love to check out ya 32 if there was ever the opportunity. Always wanted to have a look at one but wouldn't have clue where to start.

Paul
Paul Tonkin
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Monday, March 30, 2015 - 07:05 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Solution 3 – A Microcontroller.

This is the solution I am currently working on. It is more complex, but in return provides far better control and visibility of what is happening.

Basically the 4 sensor outputs are fed directly into a microcontroller, where they are adjusted and fed back out to the height controller ECU.
The microcontroller platform chosen is Arduino. I have worked with a few different ones in the past, but have heard this system is cheap and easy to get up and running. So far it has not disappointed – there is so much existing demo code, the effort is more focused on high level functionality rather than debugging low level code.

This is it – there are others even cheaper that would work identically, as long as they utilise a ATmega328 or better. Plug it straight into a computer, use the free software to download examples, and have it running in about 15 minutes.
http://www.dx.com/p/diy-funduino-uno-r3-development-board-microcontroller-w-usb-cable-240588

From here some requirements where established. This will be used as acceptance criteria to determine when the project is finished.
1. A single Potentiometer shall be used to control both front and back height equally.
2. The minimum and maximum settings on the Pot shall allow full travel of the suspension range, but not exceeded it, to prevent damage.
3. There shall be indication of the actual height presented to the driver.
4. There shall be indication of when the car is raising, or lowering.
5. There shall be a method to connect a computer for tuning and viewing all parameters.
6. There shall be the ability to simulate the car sensors, so development can happen out of the car.
7. The final solution shall be reliable, integrate cleanly into the car, and have the ability to be replicated.

Next is where I will describe in more detail how all the hardware is configured.
Paul Tonkin
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Auckland
Soarer V8 Ltd

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Monday, March 30, 2015 - 07:31 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I forgot to mention one point on the main reason for choosing the microcontroller solution.

Digitally processing an analogue signal (ie height sensors) provides some massive advantages over an analogue method, in some scenarios. An analogue method example is solution 2.

The reasons why it has advantages in this implementation is:

1) How the sensors and ECU actually work is still not fully known. A digital system can measure and display system response with ease, so it can be used as a tool to 'learn the system'.

2) Circuit adjustment can be finicky and time consuming in an analogue system. Currently to adjust a gain or a range with the microcontroller solution takes around 30 seconds. Configurations and setups can be saved, so going back is always a simple option.

If a solution required maximum signal integrity and resolution, then an analogue solution may be preferable. (not the case for this task).

Hardware configuration. Next.
Mike Beck
Goo Roo
New Zealand
UZZ32 No.32 & JZZ31 3.0GT

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Tuesday, March 31, 2015 - 07:25 am, by:  Mike Beck (Gold_40gt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Paul Tonkin wrote on Monday, March 30, 2015 - 07:00 pm:

Thanks Mike!

Indeed I do - work at Fisher & Paykel Healthcare. Where are you - ever near Kerwyn ave? Seem to remember seen a Red GT around those ways a while back. Mate I'd love to check out ya 32 if there was ever the opportunity. Always wanted to have a look at one but wouldn't have clue where to start.

Paul




Ha, not a bad guess! Ah very nice, what do you do for them?

I'm on Arwen place just off Kerwyn, do CAD drawings of products for Fenix Autoparts.

I'd be happy to catch up sometime and show you, I always like to see other tidy Soarers too, yours looks to be in good nick the few times I've seen it! Feel free to flick me a message/email on here.

One thing I like about seeing a tidy original Soarer is how good they look riding on the road, such a unique shape that exudes refinement. Of course one can't always appreciate such because they are so rare!
Paul Tonkin
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Auckland
Soarer V8 Ltd

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Tuesday, March 31, 2015 - 07:17 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Not bad guess at all! I'm working in electronics design for a new product. Good times.

Appreciate the offer thanks, will be in touch. Mines ok, its the second 31 i have owned. This one was sitting unused in a garage in Napier for years. It does have a few of the usual ailments which probably should take precedence over playing with the suspension..

I feel the same way - not only rare but massively under appreciated / recognized by many for what they are.
Paul Tonkin
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Wednesday, April 01, 2015 - 06:46 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Hardware configuration

This post describes the basic hardware configuration. The architecture diagram shows how each item in the system interacts with each other, not exactly where and how each item connect. A future post may contain specific pin-out details.

The Arduino in the middle has an un-shown PCB plugged into it that contains the output filter components, and all the connectors to interface it to the car.

The filter converts the pulse width modulated output from the microcontroller to an analogue voltage, which is appropriate for the ECU.

Either the wheel sensors, or the simulator POT can be connected to allow out of car development.

The laptop is used to program the Microcontroller, and display information on the status of the sensors and control.

The LCD is not currently fitted.


Upload


The next post will describe the microcontroller firmware configuration and architecture.
Roland Elliott
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New South Wales
uzz32 1uz-fe

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Wednesday, April 01, 2015 - 11:19 pm, by:  Roland Elliott (Aussie2013) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Looking good Paul, very time consuming but worth the effort. I have a 32, also being an electronics engineer I have considered doing some axis sensor upgrades on mine, along with infinately adjustable height, what makes the 32 more complex is the 4 wheel steer, active suspension,road speed, yaw, aft etc sensors and braking ecu's are all linked together hence big job to mess with.
Mike Beck
Goo Roo
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Thursday, April 02, 2015 - 08:23 am, by:  Mike Beck (Gold_40gt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Looking good Paul. I gather you must be quite Arduino savvy given your profession?


Roland Elliott wrote on Wednesday, April 01, 2015 - 11:19 pm:

are all linked together hence big job to mess with.




Yeah Roland, I've thought about ideas for tinkering with the a-sus control.

But I remind myself its a complex system I can ill afford to damage in anyway.

I think the biggest issue would be effecting the factory performance with any modifications to the electrics... who knows how temperamental the computers are with the the way the sensors work etc.
Roland Elliott
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Thursday, April 02, 2015 - 11:55 pm, by:  Roland Elliott (Aussie2013) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Mike I think it would be a better to redesign and upgrade the sensors to current mico source ones like the ones available from DX , as far as the ECU 's are concerned its a big challenge, the guys that put the system together in the first place in Japan had far more resources than me, ( and money) .
Mike Beck
Goo Roo
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Friday, April 03, 2015 - 09:25 am, by:  Mike Beck (Gold_40gt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Roland Elliott wrote on Thursday, April 02, 2015 - 11:55 pm:

Mike I think it would be a better to redesign and upgrade the sensors to current mico source ones like the ones available from DX , as far as the ECU 's are concerned its a big challenge, the guys that put the system together in the first place in Japan had far more resources than me, ( and money) .




Agreed. There is no doubt the system could be improved upon.

But at the same time... does it really need any improvements? I think the fact of how well it goes and that its all late 80s engineering at its best means it's better left as is.

Meanwhile what Paul is doing with his air bag Soarer it's quite feasible, it's a more simple system and adding extra functionality brings more out of it. At least UZZ31s are more plentiful if anything does go wrong with a bit of tinkering. There are reportedly 12,500 UZZ31s made, 14 for every 1 active!
Michael Brogefjord
TryHard
NSW
V8

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Friday, April 03, 2015 - 11:15 pm, by:  Michael Brogefjord (Michaelb) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Hi Paul

Look good! I'm Very interested in hearing more about this!

I have a UZZ32 and there are no aftermarket height controllers available for them. My understanding is however that the uzz31 principles would be applicable, as long as the correct pin locations (which differ) are accounted for.

Btw there are various guides on the net confirming the pin names and test values - I assume you have seen these?
Michael Brogefjord
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Friday, April 03, 2015 - 11:26 pm, by:  Michael Brogefjord (Michaelb) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

My primary use for this would probably be to adjust the height when parking to make eg oil changes easier, but it would also come in handy for identifying the root cause for the "nervous twitching" that many uzz32s seem to be affected by.

Ie is the random minor height adjustments that occur (unnecessarily) while eg waiting at the lights due to the suspension controller sending bad outputs, or is the controller getting confused by fluctuating input values?

Also I have an allegedly working, but not tested by me, uzz31 after market height controller that I bought for the harness in anticipation of one day doing something like what you've started. If the controller would help in your development, let me know.
Mike Beck
Goo Roo
New Zealand
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Saturday, April 04, 2015 - 08:59 am, by:  Mike Beck (Gold_40gt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Michael Brogefjord wrote on Friday, April 03, 2015 - 11:26 pm:

My primary use for this would probably be to adjust the height when parking to make eg oil changes easier, but it would also come in handy for identifying the root cause for the "nervous twitching" that many uzz32s seem to be affected by.

Ie is the random minor height adjustments that occur (unnecessarily) while eg waiting at the lights due to the suspension controller sending bad outputs, or is the controller getting confused by fluctuating input values?




I just put my 32 into the test sequence and stop it on full high to do oil changes - easy!

Some say the nervous twitch is possibly due to squared off valve body seals, leaking slightly and / or the wheel height control rod sensors sending out noise to the A-sus computer. Seems it's just an age related issue.
Paul Tonkin
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Saturday, April 04, 2015 - 06:08 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Roland Elliott wrote on Wednesday, April 01, 2015 - 11:19 pm:

very time consuming but worth the effort.




Hi Roland, Yes quite time consuming but also a lot of fun. I don't have much time to spend on it, so its a slow moving project! Have to admit with a 32 I would be a bit more apprehensive about modifying it, but it would be well worth it if successful.

If you do start modifying it, would be great to hear how and what you are doing.
Paul Tonkin
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Auckland
Soarer V8 Ltd

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Saturday, April 04, 2015 - 06:13 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Mike Beck wrote on Thursday, April 02, 2015 - 08:23 am:

Arduino savvy given your profession?




Hi Mike. I'm not too bad with the Arduino, it is the first time i have used one, but it does make this sort of thing very easy. A basic understand of 'C' coding helps, but I have seen people with no training use these successfully.
Paul Tonkin
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Saturday, April 04, 2015 - 06:22 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Michael Brogefjord wrote on Friday, April 03, 2015 - 11:15 pm:

there are various guides on the net confirming the pin names and test values




Hi Michael, I did see a description a while back which discussed the sensor (which i can no longer find), but have not seen much else. Any link to any info on these would be appreciated.

This type of system could be quite useful for diagnosis, especially when the micro is coupled to a computer. I have an PC application nearly finished which displays a lot of info. This will be posted up here soon.

I am interested in the controller - what type is it? Currently everything i'm doing is trial and error, so a reference would be useful. What sort of arrangement would you suggest?
Paul Tonkin
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Saturday, April 04, 2015 - 07:10 pm, by:  Paul Tonkin (Kiwicarver) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Microcontroller Firmware / program flow

The following flow chart describes how the Arduino firmware is currently configured. It’s changing most days so when a final version is ready I'll re-post it.

Things to note here are:
• The green tinted boxes are where the devices is currently being tuned. The reason why described in the box to the right.
• The blue arrows show the flow of the program, it runs in a loop
• A lot of these items don’t have to be in this order
• There is not yet a function to tell if the suspension pump of solenoid valves are operating
• There is not yet a function to send data to the LCD


Upload


The next post will describe the PC application. This has been very valuable for configuring the firmware.
Michael Brogefjord
TryHard
NSW
V8

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Saturday, April 04, 2015 - 07:45 pm, by:  Michael Brogefjord (Michaelb) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

References that may help:

http://members.westnet.com.au/rbaird/SuspensionCodes.pdf
http://planetsoarer.com/UZZ32/activecomputer.pdf
http://www.alscarchive.com/cgi-bin/discus/discus.cgi?pg=prev&topic=3&page=50270

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