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DEPARTMENT OF MECHANICAL ENGINEERING

A report submitted by M.Rajesh – Assistant Professor / Mech and Mr. V.Kondusamy – AP /

Mech, Department of Mechanical Engineering for undergoing industrial training & syllabus
framing at REYN LAB, Chennai.

DAY: 1 – 05.03.2023

 Mr. Sajeeth Kumar, CEO of Reyn Lab, gave a thorough presentation about the
company.
 We were also informed about the safety procedures that must be followed within the
organization.

During practical instruction on ECU tuning and remaps, we learned about the following:

ECU Tuning and Remaps - Engine management systems for OEM and motorsports
use. We found helpful information about the ECU tuning and remap procedure under
the topic. More on how it was helpful for high-performance engine building and
motorsports applications. We also learned that courses in automotive mechatronics,
control systems, and calibration are useful for the process of ECU tuning. A student
can acquire sufficient knowledge about automotive mechatronics, control theory,
OEM gasoline and diesel ECU reprogramming, and ECU tuning through ongoing
instruction.

ECU (ENGINE CONTROL UNIT)

Today's vehicles, including all cars and vans, are equipped with an engine control
unit, or ECU. This engine control unit, which has a tiny processor that gathers data
from numerous sensors spread throughout the engine, is practically the "brain" of the
vehicle. In addition to many other parameters, it analyzes data on the engine
temperature, accelerator pedal angle, and oxygen content in the burned exhaust
gases. It can then add the appropriate amount of fuel at the ideal moment to provide
a good balance of fuel economy, performance, and emission control when reversing,
passing, pottering down the road, or speeding down the motorway using the data
from these sensors.

ECU REMAPPING

ECU remapping involves taking the standard compromised map from the ECU's
processing chip and modifying a number of map parameters, including fuel pressure,
boost pressure (for turbocharged applications), ignition advance, and throttle pedal
control, among others, to unleash the engine's full potential. Giving the engine the
performance it should have always had—before all the compromises were made to
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the original programming—makes it a perfectly safe procedure. Each engine has a

specific map that can be adjusted to optimize the engine's characteristics, resulting in
increased power and often lower fuel consumption.

BENEFITS OF ECU REMAPPING

Enhancing the engine's power and torque figures through ECU remapping also
results in a wider power band and more precise throttle response. Due to the
increased linearity of the power delivery, the engine will become more flexible and
the vehicle will feel much more lively to drive. Reducing fuel consumption is the other
primary advantage of remapping.

ECU REMAPPING BENEFITS FOR TURBOCHARGED DIESEL AND PETROL

ENGINES

 Increased horsepower
 Increased torque
 Better throttle response
 Smoother power delivery
 Improved fuel economy
 Safer overtaking

ECU REMAPPING BENEFITS FOR NON-TURBOCHARGED PETROL ENGINES

Even though normally aspirated gasoline engines are difficult to tune, they can
nevertheless gain 10–15% more power and torque by carefully reprogramming a
number of engine parameters within the map. Better power and torque output can be
achieved by fine-tuning parameters like the fuel and ignition curves. Further
improvements can be obtained on certain engines by fine-tuning the camshaft timing
within the map. Automotive Diagnostics - Diagnostics and repair for automotive
electrical, electronic and software systems. Under the topic we got the information
such as the core principles underlying gasoline, diesel, hybrid, and electric vehicles.
Also informed about the essential principles and mechanics of the cutting-edge cars
and motorcycles.

 Effectively troubleshooting the vehicle's electrical, electronic, and a software

module is also very helpful. For the most part, mechanical problems can be
solved with simple visual inspections of the component parts, but electrical or
electronic problems require more in-depth knowledge to diagnose.

Different steps of automotive diagnostics

 Step 1: Verification and confirmation

This is the automotive diagnostic step that will allow the specialist to check for
a problem. In fact, this can be compared to a visit to the medical doctor. The
mechanic will take the time to do a thorough analysis of your vehicle and will
ask you about the different problems or noises you have noticed.
 Step 2: Define the problem

Once the preliminary analysis is completed, the mechanic will then be able to
define the origin of the problem, no matter where it is located. Be aware that a
problem can occur on both a main circuit and a sub-circuit.
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 Step 3: Isolation of areas

At this step, the auto diagnostic specialist will isolate the problem in a circuit
or in an electronic or electrical sub-circuit.
 Step 4: Repair
This is the step where your auto diagnostic specialist starts repairing the
circuit or sub-circuit causing the problem.
 Step 5: Final check
Verification is the final step. Indeed, this is the time when your car diagnostic
professional verifies that the repair has actually eliminated the detected
problem and that your vehicle is working properly.

To gain a precise understanding of the automotive technology installed in the cars, we

returned to the workshop.

 We received practical instruction on how to affix parts to a small electric vehicle's

chassis.
 We made notes of the steps involved, and we spoke with the on-site engineers and
technicians about any questions we had about the procedures.
 We now have a clear understanding of the kind of course that needs to be provided
to our students thanks to this workshop session.
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On DAY: 2 – 07.03.2023

We had a conversation about course content preparation for the Fundamental of

Automotive Technology with Mr. Maniarasu, Technical Lead of the company.

We were provided with a comprehensive explanation and hands-on experience

regarding the operation of the ignition system, chassis system, Hybrid electric vehicle
and ABS with EBD, Traction Control.

After consulting with the company's engineers, the following curriculum was decided
upon to serve as the foundation for the Fundamental of Automotive Technology
course.

 Types of Ignition systems

 Different types of Chassis
 Transmission Systems
 ABS with EBD, Traction Control
 Alternate fuels for Automobiles
 Hybrid electric vehicle
 ADAS, Collision Avoidance system, Adaptive Cruise Control
 The course materials were then given to Mr. Sajeeth Kumar, and his
recommendations were included.

 The prepared materials will be showcased at the CDC and BOS meeting for
feedback and finalization.

We express our gratitude to the Management and the Department of Mechanical

Engineering for giving us the chance to receive training at REYN LAB in Chennai.

With Regards

HoD/MECH