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Challenger7 Fly by Wire - V100
Challenger7 Fly by Wire - V100
Machine management
The Challenger7 ECU tuning pack is supplied with accompanying of the program Winjall. It is
subjected to the same rules of use and license.
The Winjall program requires a license of use. In its complete shape, this license is established by a
file license and a material dongle key
To make access to Challenger7 ECUs easier, this pack contains a licence made of one single file,
without a dongle.
This licence gives you access to the main tuning functions for Challenger7 ECUs.
However, to have access to the complete features, it is necessary to obtain with the Company Skynam
a complete license.
Though it is possible to make copies of the Winjall software distributed in this pack, you have to
comply with the regulations for use and the licence you have accepted when installing it on your
computer.
This documentation version has been specifically upgraded for the Tuneware Challenger7 versions
distributed from November 10th, 2018, notably:
- throttle / rpm: version 1.00
- pressure / rpm: version 1.00
These Tuneware versions only work with the Winjall V9.30 version or a later one, which also requires
a XP SP3, 7, 8, 10 or any later version of the Windows operating system of the Microsoft Corporation.
III) WARNING:
The CHALLENGER7 ECUs are meant for racing cars, boats or bikes and not for any other purpose.
Consequently, the softwares to be found in this pack are for racing use only and are not meant to
match the emissions standards required for standard or road cars.
Remember it mustn’t be used on open roads, as it does not comply with road regulations.
Indeed, the fly by wire cannot function without a measure of accelerator pedal position.
It is made by means of the function of configuration of inputs, described in detail in the file
'Configuration of inputs'.
Activate then the measure of accelerator pedal position: Skynam advises for the standard looms to use
the analog input 2.
Before configuring the auxiliary outputs, unplug the connector of the fly by wire so that it is not
commanded. You will plug it later.
You then have to configure an auxiliary output to manage the motorized throttle. On Challenger7, they
are the outputs 1 and 2 that know how to do it:
The Challenger7 owns two modes of command of the motorized throttle, the synchronous mode
(which is the standard one), and the asynchronous mode (which is the new one).
The frequency of command of the PWM should be positioned to 500 Hz, frequency at which they
work best, but can go according to electric motors up to 1000 Hz. We do not advise it, but consult the
documentation of the manufacturer.
The separated maps of PID (to be loaded with the function "Read data file") provided by Skynam do
own the part name 'ASynch'.
The frequency of command of the PWM should be positioned to 500 Hz, frequency at which they
work best, but can go according to electric motors up to 1000 Hz. We do not advise it, but consult the
documentation of the manufacturer.
The separated maps of PID (to be loaded with the function "Read data file") provided by Skynam do
not own the part name 'ASynch'.
As soon as these two initializations are made, the ECU positions itself in motorized throttle mode and
provides calibrations and tunings relative to it.
If it was plugged, the motorized throttle would try to position on the current target. As it is not
calibrated, it could over force and destroy itself or destroy its stops or burn its commands.
To avoid this, we use the cutoff of the command if the rpm is below a programmable threshold.
This tuning is on the page of the proportional map.
It is to note that even if the command is stopped, it will automatically be activated on the throttle
calibration
As soon as these two initializations are made, the ECU positions itself in motorized throttle mode and
provides calibrations and tunings relative to it.
The main calibration is the pedal + motorized throttle position calibration, that you will find in the
State menu of the ECU:
This operation will allow the ECU to calibrate automatically the potentiometer of position
measurement of the motorized throttle so as to normalize the position between 0 and 1000.
This calibration ensures that the ECU will find correctly its position in deceleration cutoff and its tick
over position.
You have a map 'Motorized throttle target' to indicate the position of the throttle according to the pedal
position and to the rpm, allowing to slow or to accelerate the position of the throttle with regard to the
pedal.
For a good bang-bang on turbo engines, it is simpler to have a piloted device that adds air intake at
throttle closure, and the motorized throttle is a very effective means.
We use then the map of target to indicate the position of the throttle according to the pedal position
and to the rpm, allowing to manage the air quantity added at the time of bang-bang.
This map indicates that the bang-bang at 4000 rpm will open the throttle to 200, but that the normal
value on released foot for this rpm is 10.
Load the maps of piloting of the PID with that corresponding to the used throttle.
There are 3 maps of PID to load:
- Proportional RCO
- Differential RCO
- Integral RCO
For every map use the function 'Read file data, with comment insertion' which allows to directly
record in the comment of the map the name of the read file, for information (see details in Winjall
manual).
Browse then in the categories of actuators maps and choose the one who corresponds best to your
throttle.
The actuators maps own the manufacturer name and the manufacturer reference.
For maps specific to the Asynchronous mode, the map name owns 'ASynch' as part of the name, for
example the standard tuning is named ' Standard.Asynch'
If you do not find exactly the maps corresponding to your motorized throttle, and if none gives you
satisfaction (for example the throttle beats in the dynamic phases), you can correct existing maps or
build some completely new (see chapter below).
The ECU allows to cut-off the command of the motorized throttle if the engine rpm is below a
programmable threshold.
This tuning is on the page of the Proportional map.
The regulation used in the PID of management of the motorized throttle of Skynam is a parallel
architecture, that is the command sent to the throttle is the sum of 3 Proportional, Integral and
Differential actions.
PROPORTIONAL ACTION
It is the base of the PWM command of the throttle, indexed to the given target.
Note that in asynchronous mode, the PWM command is signed: if the value is positive, the pulses will
be produced on the positive output, opening the throttle. If it is negative, the pulses are produced on
the negative output, closing the throttle.
DIFFERENTIAL ACTION
It is the dynamic regulation of the positioning of the throttle: it allows the throttle to answer quickly a
modification of target.
This map is indexed vertically on the difference between the desired position (target) and the measured
position.
Horizontally, it is indexed on throttle speed in synchronous mode and on throttle position in
asynchronous mode.
INTEGRAL ACTION
It is the fine regulation of the positioning of the throttle: it allows the throttle to take place exactly on
the target: at every cycle of calculation, the correction of error of positioning is added to previous
correction until reaching the desired throttle position.
Three tunings must be done for the operation of the motorized throttle, corresponding to three maps.
These tunings should be done when engine is stopped To get the throttle running
- set the engine rpm threshold of throttle command to 0 (page of Proportional map).
- if the protection parameters have not yet been tuned, set to 'Standard' the two protection parameters,
maximum RCO and maximum exceeding time.
I) PRINCIPLE:
This map defines the base of the command to remain stable when the throttle is already
correctly positioned.
PRINCIPLE
The PID Proportional is based on the given target: the value in the map is so a direct result of the
desired throttle position.
But do not expect that this mapping is dynamically efficient.
It is rather that when the throttle is positioned on the target, it remains on it with a small response of
the Differential and Integral.
TUNING MODE
When you have tuned the Differential and Integral maps, come back to this map.
You will so fill the lines of this map.
1) Break points:
Generally, we need one line every 1/4 throttle (0, 250, 500, 750, 1000), and also one line near from the
place where the return springs cancel each other (there are generally two return springs in a fly by
wire, one to mechanically open and one to mechanically close, the rest position being the one where
the two springs cancel each other). To know this rest position, stop the running of the fly by wire by
setting the engine rpm threshold of throttle command to 0 (page Proportional map), the throttle
position obtained being the rest position, then launch again your sly by wire to keep on tuning.
It is also possible to work more fine on this base from the battery tension (column scale), but it is
generally not necessary.
2) Data:
Set the target on the value of a break-point, wait some seconds and note on the corresponding data the
RCO value read: these values will never be the same from one time to another and are only
approximate.
This mapping defines the instant correction of the basic command to get the desired position. It
is it which is mainly involved in the dynamic opening and closing. Its setting is also used to
manage overflows.
PRINCIPLE
The Differential map is based on two inputs:
- the error between the given target and the actual position,
- the throttle position.
The position error is calculated by 'Position minus target'. This means that if the position is higher, the
error is positive, and inversely.
It is understandable that greater is the error, more the force applied to the throttle to correct its position
must be important, and therefore the correction value must be high in absolute value. The direction of
the correction will be opposite to that of the error: If the error is positive (position too high relative to
the target), the correction will be negative (to close the throttle), and vice versa.
Skynam has used in more the throttle position as a 2nd input of the map (different from the
synchronous mode).
This tuning keeps into account the return force of the spring, and its compression depends on the
throttle position.
TUNING MODE
We advise you to start from the map "Standard.ASynch" that you can load with the function "Read
data file" of the popup menu of the map header, and to modify it to improve the working of your
throttle, to speed it up or slow it down if it changes it its position by jerks or makes beatings.
If you cannot find a correct tuning, get inspired from the tuning mode proposed on the synchronous
mode to make the map from scratch.
If the throttle makes small fast beatings when you open it continuously on all the range of the pedal or
by making target increments of +10 (key [SHIFT] [+]) on the target map, increase the scale value -2
until the beatings disappear:
In the same way while you close the throttle, modify the scale values +2, +15 and/or +50
This map defines the final and long term correction of the base command to get the desired
position.
PRINCIPLE
The Integral map is based on two inputs:
- the error between the given target and the actual position,
- the throttle position.
The greater is the error, more the force applied to the throttle to correct its position must be important,
and therefore more the correction value must be high in absolute value. The direction of the correction
Skynam has used in more the throttle position as a 2nd input of the map, but it is in general not
necessary to use this variable, and a one column map works very well.
TUNING MODE
We advise you to start from the map "Standard.ASynch" that you can load with the function "Read
data file" of the popup menu of the map header, and to modify it to improve the working of your
throttle, to speed up or slow down the finalization of the position to come on the target.
If you cannot find a correct tuning, get inspired from the tuning mode proposed on the synchronous
mode to make the map from scratch.
The map is generally rather symmetric between the positive and negative errors. For example:
If the Integral increment is too high, you will get throttle beatings, without reaching a stabilization.
If it is too weak, you will have to wait too long before the throttle reaches the target in stabilized
operation.
Once you have filled this Integral map, it is possible that you have to modify some values in the
Differential map at the level of the small error lines.
The 'Standard' value is obtained when we set the value 0. The ECU then uses its internal setting
preprogrammed.
Page 15 on 21 Motorized throttle Challenger7
You can also modify this value to fix by yourself the target speed at which the Integral is canceled.
Using the synchronous mode is not advised. Prefer the Asynchronous mode.
Three tunings must be done for the operation of the motorized throttle, corresponding to three maps.
These tunings should be done when engine is stopped To get the throttle running
- set the engine rpm threshold of throttle command to 0 (page of Proportional map).
- if the protection parameters have not yet been tuned, set to 'Standard' the two protection parameters,
maximum RCO and maximum exceeding time.
I) PRINCIPLE:
This map defines the base of the command to remain stable when the throttle is already
correctly positioned.
PRINCIPLE
The PID Proportional is based on the given target: the value in the map is so a direct result of the
desired throttle position.
But do not expect that this mapping is dynamically efficient.
It is rather that when the throttle is positioned on the target, it remains on it with a small response of
the Differential and Integral.
TUNING MODE
When you have tuned the Differential and Integral maps, come back to this map.
You will so fill the lines of this map.
1) Break points:
Generally, we need one line every 1/4 throttle (0, 250, 500, 750, 1000), and also one line near from the
place where the return springs cancel each other (there are generally two return springs in a fly by
wire, one to mechanically open and one to mechanically close, the rest position being the one where
the two springs cancel each other). To know this rest position, stop the running of the fly by wire by
setting the engine rpm threshold of throttle command to 0 (page Proportional map), the throttle
position obtained being the rest position, then launch again your sly by wire to keep on tuning.
It is also possible to work more fine on this base from the battery tension (column scale), but it is
generally not necessary.
2) Data:
With the pedal position or by modifying the target map on the value used by the ECU, set the target on
the value of a break-point, wait some seconds and note on the corresponding data the RCO value read:
these values will never be the same from one time to another and are only approximate.
This mapping defines the instant correction of the basic command to get the desired position. It
is it which is mainly involved in the dynamic opening and closing. Its setting is also used to
manage overflows.
PRINCIPLE
The Differential map is based on two inputs:
- the error between the given target and the actual position,
- the throttle speed.
The position error is calculated by 'Position minus target'. This means that if the position is higher, the
error is positive, and inversely.
It is understandable that greater is the error, more the force applied to the throttle to correct its position
must be important, and therefore the correction value must be high in absolute value. The direction of
the correction will be opposite to that of the error: If the error is positive (position too high relative to
the target), the correction will be negative (to close the throttle), and vice versa.
Skynam has used in more the throttle speed as a 2nd input of the map (different from the asynchronous
mode).
Indeed, if the position is already too low and the throttle is closing (negative velocity), a correction
can be larger than if it is too low but that the throttle is opening (goes to the target). Similarly for the
other direction.
This allows to further increase the force with which the motor is opened or closed in the highly
dynamic phases.
TUNING MODE
You get now the Differential map acting alone to correct the throttle command.
You will fill the lines of the map.
1) Break points:
Generally, we need two lines framing the error 0 (-10 and +10 or -5 et +5), and some lines at more and
more high errors (-500, -200, …, +200, +500).
For the columns, three are generally enough, one for throttle closing rapidly, on for stable throttle and
one for throttle opening rapidly (-250, 0, 250). You can also simplify this map by making only one
column.
2) Data:
At the beginning, don't try to differentiate the throttle speeds for the strong errors: for the error lines -
500, -200, +200 et + 500, set the same correction value for all the line, correcting more and more for
higher errors.
A good start is to correct 0.2 for line 200 and 0.4 for lines 500 (the correction sign being the inverse of
the error sign). For example:
At this point, the throttle should follow very correctly the target.
If you experiment beatings (position instabilities), that means the corrections are too much strong.
Try to see which parts of the map are to be modified.
At the contrary, you can still improve the reaction by modifying the columns in the lines. For example:
Of course, without the Integral correction, you cannot get a very fine positioning, and an error of 10 is
normal in stabilized target.
This map defines the final and long term correction of the base command to get the desired
position.
The greater is the error, more the force applied to the throttle to correct its position must be important,
and therefore more the correction value must be high in absolute value. The direction of the correction
will be opposite to that of the error: If the error is positive (too high position relative to the target), the
correction will be negative (to close the throttle), and vice versa.
Skynam has used in more the throttle speed as a 2nd input of the map, but it is in general not necessary
to use this variable, and a one column map works very well.
TUNING MODE
You will add the Integral correction to the Differential map to correct the throttle command.
You will so fill the lines of the Integral map.
1) Break points:
Generally, we need two lines framing the error 0 (-10 and +10 or -5 et +5), and some lines at more and
more high errors (-500, -250, -50 …, +50, +250, +500).
2) Data:
The map is generally rather symmetric between the positive and negative errors. For example:
If the Integral increment is too high, you will get throttle beatings, without reaching a stabilization.
If it is too weak, you will have to wait too long before the throttle reaches the target in stabilized
operation.
Once you have filled this Integral map, it is possible that you have to modify some values in the
Differential map at the level of the small error lines.
To finalize your tuning, go back to correct the base map of the PID.
The 'Standard' value is obtained when we set the value 0. The ECU then uses its internal setting
preprogrammed.
You can also modify this value to fix by yourself the target speed at which the Integral is canceled.