DIY EGT and more Gauge

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Road Block
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Fri Apr 22, 2016 9:12 am

Dam really nice setup :thumbup: , I have just fitted a analog gauge for my egt and an other for the gearbox temp , i have been thinking about fitting the diff temps as well but needing to find space for more goodies , Thank-you this thread has been very interesting :subscribed:

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Mon Apr 25, 2016 8:36 pm

Hi Johan. Who would have thought about the polarisation of the screen. I couldn't help but have a chuckle. I don't wear sunglasses. :)

I have been learning non-stop about the arduino, sensors and coding and I am slowly getting there. I designed and built my own themoswitch to activate the glowplugs on my Isuzu and to display the water temp and and an led to indicate when the circuit is working in the cabin. I then "ported" it to an ATtiny 85. I also did the coding myself. Like I said, slowly getting there. I had to build my own shield for an Uno to be able to burn the bootloader (actually to set the fuses) and program the ATtiny. It works really well.

For this project I need to still get most of the sensors though.

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JohanW
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Tue Apr 26, 2016 9:56 am

Haha, ja Marnus I also laughed a bit at myself and the situation. Going to use the screen in portrait mode. It did make mounting it a bit more difficult.

I'm glad you are also diving into the arduino world. Its amazing how powerful these little controllers are. Something that would have taken months of development and testing 10 years back by a team of people you can now whack together in a evening.

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Tue Apr 26, 2016 11:21 am

It is truly AMAZING. Now that I am getting a better understanding of how the concepts work I have this stream of ideas that I want to do. From SMS notification on alarm states of my car and home to additional continuity monitoring on my electric fence and tons of home automation ideas!!!

It is interesting in your sketches how much code is required to display the information vs the actual reading of the monitors and calculating of the values.

I am still trying to figure out how you calculate the temp from the Hella senders using the Steinhart-hart formula. I've just been too busy with other projects and work to do the proper research. Will get there eventually.

Well-done yet again on this project!

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Frontier 320
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Sat Aug 06, 2016 11:33 pm

Any update?

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Witvos
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Thu Aug 11, 2016 8:55 pm

I would like to know as well. Going through JHB in 2 weeks so might have to pick up some electronics

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JohanW
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Sun Aug 14, 2016 6:32 pm

Well guys, i'm not going to go ahead and print boards for the V2 of this monitor. My KZ was sold with the original prototype and is still going well. The big problem and also the nice thing about the v2 was the big 3.2 inch TFT. But since it was polarised in the wrong direction an needed 36 lines to connect it was a deal breaker.

YOU DON"T NEED A PRINTED BOARD TO BUILD SOMETHING!

Phew, got that out. I will scan the hand drawn schematics I made for version 2 during the course of the week. Its really not that hard to make solder traces/bridges on a prototype board. Both v1 and v2 did in excess of 50k km without a single fault. Do a proper soldering job and they will last.

Its really not that hard to build these type of things. There are a TON of examples on the net. Nearly all of the info required to build this monitor, v1 and v2 is provided on this thread. I will reply with help as much as possible if someone is busy with a build. If you are looking for a cheaper solution that what madman offers and you are UNWILLING TO PUT IN SOME TIME BUILDING IT then this is not the right thread for you. I'm not a supplier nor do I have any ambition to commercialise a unit. I'm purely adding value to a pool of amazing information on this forum by sharing my journey.

To build v1 and v2 has cost me about R10k plus just in orders from micro robotics. BUT I have a couple of bins full of electronics parts and a invaluable amount of knowledge and understanding gained by building these units. I can now comfortably say that I can build a automated weather station providing live updates. A geyser-wise type system remotely controlled from a website. Its also given me a insight into how these vehicles electrical systems work and that I will probably be able to fix them in the sticks.

On the KZTE colt injector pump thread I showed how its possible to completely get rid of the electronics since its a commonly held idea that if the electronics go, or just a tiny bit of it misbehaves you are screwed. I no longer hold that idea. From building these monitors I have come to realise that toyota have built in quite a lot of diagnostic ability into these vehicles. They have unfortunately kept a lot of it secret or hidden. But it doesn't have to be.

All of the variables displayed by the monitor with exception to the EGT, oil pressure and intercooler temp on the KZ, are already being monitored by the ECU. Why can't we just display the values being fed to the ECU? In version 3 probably only in 4. I'm hoping to be able to just plug in a OBD2 dongle and display these values via a TFT or OLED screen mounted somewhere. Unfortunately the vehicles supplied to South Africa don't need to be OBD2 compliant. So toyota still ships them with their proprietary M-OBD protocol which doesn't have a lot of info out on the net. So it's difficult to decode and understand. I'm planning on doing some message interception and decoding and writing up a proper api to do the heavy lifting work. I have acquired a MINI-VCI J2534 cable with the proprietary Toyota software and will be doing so investigating.

In the mean time, there is nothing stopping anyone from using the info and code provided on this thread from building a monitor that does the basics. Most people just want EGT.

If you want just to be able to display EGT:

Buy a Ardunio Nano current price about ~R150
https://www.robotics.org.za/index.php?r ... uct_id=804" onclick="window.open(this.href);return false;
Buy a board that can read your thermocouple ~R310
https://www.robotics.org.za/index.php?r ... uct_id=272" onclick="window.open(this.href);return false;
Buy a protoboard ~R30
https://www.robotics.org.za/index.php?r ... duct_id=94" onclick="window.open(this.href);return false;
Buy a small display ~R215
https://www.robotics.org.za/index.php?r ... ct_id=1512" onclick="window.open(this.href);return false;
Buy a small voltage regulator ~R85
https://www.robotics.org.za/index.php?r ... uct_id=950" onclick="window.open(this.href);return false;
Buy a few resistors R70
https://www.robotics.org.za/index.php?r ... ct_id=1522" onclick="window.open(this.href);return false;
Thermocouple probe ~R570
http://www.madman.co.za/index.php/produ ... probe-60mm" onclick="window.open(this.href);return false;

Find some wire and time and build. This has room for extra bits and upgrades.

You will need a soldering iron. A decent one makes your life easier.
https://www.robotics.org.za/index.php?r ... ct_id=1219" onclick="window.open(this.href);return false;

I list a lot of micro robotics links simply because I get most of my stuff from them and their prices are fair and I'm not going to trawl the internet to find a other links to things needed. It would be nice if they see this thread and give me a discount on my next order. :mocking: But that is not the aim of this post.

Now go forth and build!

Ons leef in 'n tyd met ongekende toegang tot inligting. As jy nie hierdie toegang tot jou voordeel benut nie kan jy net jouself blameer. ;-)
Last edited by JohanW on Sun Aug 14, 2016 6:42 pm, edited 2 times in total.

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JohanW
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Sun Aug 14, 2016 6:39 pm

If you want a really cheap pre-built solution just for EGT then buy the following:

Display and working bits: ~R175
https://www.robotics.org.za/index.php?r ... ct_id=1416" onclick="window.open(this.href);return false;
EGT Probe: ~R570
http://www.madman.co.za/index.php/produ ... probe-60mm" onclick="window.open(this.href);return false;

Fit, connect and go.

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ChrisF
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Mon Aug 15, 2016 6:28 am

Johan DANKIE vir die inligting wat jy met ons deel.

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Witvos
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Mon Aug 15, 2016 7:53 am

Dankie Johan, Laat ek bietjie shopping gaan doen.

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Frontier 320
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Mon Aug 15, 2016 8:30 am

Thanks Johan for the help. You gave us hope. Yours worked well and was very cool.

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Frontier 320
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Mon Aug 15, 2016 8:34 am

Guys I'll try see if I can get a vdo egt pyro at good prices. I've got way to much projects on the go and everything is on hold due to a fractured hand. So I won't be able to make up an egt up soon.

I'll get back to everyone as soon as I can for those that might want.

Looks something like this I hope. But just in °C and it will be cool if it had the light or a buzzer.
uploadfromtaptalk1471242873683.jpg
uploadfromtaptalk1471242873683.jpg (27.51 KiB) Viewed 2226 times
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KZTE Nut
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Tue Aug 16, 2016 8:45 am

Dankie Johan for all the info shared so freely. It is a pity that you bought that D4D :) Enjoy !

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Tue Aug 16, 2016 2:36 pm

Frontier 320 wrote:Guys I'll try see if I can get a vdo egt pyro at good prices. I've got way to much projects on the go and everything is on hold due to a fractured hand. So I won't be able to make up an egt up soon.

I'll get back to everyone as soon as I can for those that might want.

Looks something like this I hope. But just in °C and it will be cool if it had the light or a buzzer.

images (4).jpg

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PLEASE get one with a SHORT buzzer at startup .... :beg: :frustrated:

The one in my Hilux makes one racket each and every time you start it, and it lasts for a few seconds :slap: :thumbdown:

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Frontier 320
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Tue Aug 16, 2016 2:37 pm

ChrisF wrote:
Frontier 320 wrote:Guys I'll try see if I can get a vdo egt pyro at good prices. I've got way to much projects on the go and everything is on hold due to a fractured hand. So I won't be able to make up an egt up soon.

I'll get back to everyone as soon as I can for those that might want.

Looks something like this I hope. But just in °C and it will be cool if it had the light or a buzzer.

images (4).jpg

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PLEASE get one with a SHORT buzzer at startup .... :beg: :frustrated:

The one in my Hilux makes one racket each and every time you start it, and it lasts for a few seconds :slap: Image

What have you got fitted Chris ?

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ChrisF
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Tue Aug 16, 2016 4:54 pm

DSCN1202 (Small).JPG

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Witvos
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Tue Aug 16, 2016 5:26 pm

Chris hoe het jy hom gekoppel? Ook met die EGT temp probe??

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JohanW
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Tue Aug 16, 2016 5:50 pm

Ai kêrels al hierdie goed wat julle voor vra kan so maklik self gedoen word. Buzzers, liggies, timeouts ens.

@ChrisF, jy het reeds die probe. Bou nou 'n netjiese monitor. Sien dit as 'n stap nader aan 'n volledige geoutomatiseerde swembad beheer stelsel...

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JohanW
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Tue Aug 16, 2016 6:13 pm

Frontier 320 wrote:Guys I'll try see if I can get a vdo egt pyro at good prices.
WHY?
VDO make good sensors. Their thermistors are some of the most accurate on the market. But you pay for them. Never seen a VDO thermocouple before, but I'm sure you get them.

This brings up a really important point. ACCURACY.
How accurate do you really need to be? Is it really worth paying 3-4 times as much to be 1 deg C more accurate?
In my first post I explained how I APPROXIMATED the temperature readings with the stein-hart equations. So your super expensive and accurate sensor is still only going to give you a temperature reading of X degC ~2degC (+-) compared to a average one with a accuracy of ~3deg C (+-)

My requirement for this monitor was to know if I'm starting to push the limits of the vehicles design or when things start to go wrong. I want my EGTs under 700 degC and want to know when my water temp goes over a 100 degC.
If its 97 or 100 or 103 or 105 its a fair amount above its normal temp of 80-90.

http://electronics.stackexchange.com/qu ... rmocouples" onclick="window.open(this.href);return false;
http://www.controleng.com/search/search ... 6fe91.html" onclick="window.open(this.href);return false;

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ChrisF
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Tue Aug 16, 2016 6:14 pm

JohanW wrote:Ai kêrels al hierdie goed wat julle voor vra kan so maklik self gedoen word. Buzzers, liggies, timeouts ens.

@ChrisF, jy het reeds die probe. Bou nou 'n netjiese monitor. Sien dit as 'n stap nader aan 'n volledige geoutomatiseerde swembad beheer stelsel...
MotorCade het die intercooler en EGT vir my ingesit.

Probe en die meter



... swembad beheer ... uhm ja ... het laas week die timer versuip en toe die rook laat ontsnap. :siffler: skynbaar is die elektriese boks nie behoorlik "splash proof" nie ... :siffler: :surrender:
Last edited by ChrisF on Tue Aug 16, 2016 6:20 pm, edited 1 time in total.

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JohanW
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Tue Aug 16, 2016 6:19 pm

ChrisF wrote: ... swembad beheer ... uhm ja ... het laas week die timer versuip en toe die rook laat ontsnap. :siffler: skynbaar is die elektriese boks nie behoorlik "splash prrof" nie ... :siffler: :surrender:
Wel nou het jy mos motiveering om 'n nuwe een te bou bietjie verder weg van die aksie... uhm water af :D:

En dink net hoe mooi gaan 'n dubbel battery stelsel lyk as jy al die voltages en stroom op een skermpie kan vertoon. :siffler:

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Witvos
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Tue Aug 16, 2016 7:59 pm

Hahaha Johan, jy laat als baie aanloklik klink. So game on. Ek gaan dit bou. Why. Want ek like daai blerrie skermpie!!

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ChrisF
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Wed Aug 17, 2016 6:20 am

Johan ek is nou erg "tempted" om met die goed te speel - wil my PV stelsels monitor ...

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Fri Aug 19, 2016 5:36 pm

Chris
Check out this Raspberry Pi powered PV and energy monitoring system - that is if you have a grid-tie inverter.
https://shop.openenergymonitor.com/solar-pv-monitor/" onclick="window.open(this.href);return false;
With the rand/pound improvement it looks pretty good.

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ChrisF
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Sat Aug 20, 2016 7:22 am

KZTE Nut wrote:Chris
Check out this Raspberry Pi powered PV and energy monitoring system - that is if you have a grid-tie inverter.
https://shop.openenergymonitor.com/solar-pv-monitor/" onclick="window.open(this.href);return false;
With the rand/pound improvement it looks pretty good.
Thanks Mervyn

Trying to keep my system legal. And thanks to the Western Cape rulers we have some pretty skewed rules regarding PV systems.

Anything that ties to the grid must be approved by local council. Grid-tied with limiter, ie you wont be putting power into the grid is applied for and approved - but then you cant use the grid to store energy for night time use. If you want to put energy into the grid during the day and then use at night the application process becomes much more involved, with monthly costs involved - thus you end up spending R 250 000 to save R 175 per month ... sorry but that makes no financial sense ....

The other option is to have a "stand-alone" system, ie a system that does NOT connect to your DB board in any way. Eaxamples of these include:
- PV geyser installation (handy when your house roof is not ideal for a solar hot water installation). Payback period is in the order of 3 to 5 years (mine will be payed back in 3)
- 12V lighting circuit, with an inverter for emergency power in a power failure. Energy efficient 220V light options means that a 12V system probably will never reach a payback point, but the freedom of staying on makes this well worth it, and it was a relatively cheap installation.
- PV poolpump installation. NICE :thumbup: :cooldude: Payback is probably in the order of 5 to 7 years. The benefits of continual water flow, and thus solar heating, while the sun shines makes this well worth the cost.


Monitoring this lot becomes "interesting" !!

12V lights - easy enough to use the 4x4Direct power monitor for this :thumbup:
PV geyser installation - this setup runs at 75 to 110V ... not a lot of off-the-shelf monitoring equipment for this range ....
PV pool pump installation - works in the range of 150 to 185V, with an open circuit voltage of 220V DC - again not easy to find DC measuring equipment in this range.

yes, it does exist in catalogues ... try getting it at places like AC/DC ... :crazy: one sure way to see the sales-executives outside their comfort zone :mocking:

For now I use my multimeter and DC clip-on amm-meter to check the system. Good enough to know what is happening, but sadly not practical for long term monitoring.



But then, I cant justify spending thousands per system to monitor it ... nice project, for another day ...

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