Sean S,
Beta testing hasn't begun for MicroSquirt yet. Beta tests are generally very small, and I don't know if all the beta units have already been assigned or not. If you want to be considered, email Bruce directly (look up user 'Bruce Bowling', then click on the 'email' link).
Lance.
MicroSquirt ETA
Forum rules
Read the manual to see if your question is answered there before posting. If you have questions about MS1/Extra or MS2/Extra or other non-B&G code configuration or tuning, please post them at http://www.msextra.com The full forum rules are here: Forum Rules, be sure to read them all regularly.
Read the manual to see if your question is answered there before posting. If you have questions about MS1/Extra or MS2/Extra or other non-B&G code configuration or tuning, please post them at http://www.msextra.com The full forum rules are here: Forum Rules, be sure to read them all regularly.
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Bruce Bowling
- Site Admin
- Posts: 285
- Joined: Mon Feb 16, 2004 4:25 pm
- Location: Baltimore, MD
Lots of progress! MicroSquirt testing is underway on a vehicle as we speak. The setup is fuel only with opto-input, but it was tested on a significantly long drive with no reports of any errors or issues. This type of test is verifyng sections of the circuit such as the power supply, injector drivers, opto input, etc. Heat is the big enemy and the board is staying within a few degrees of ambient temps.aarc240 wrote:Not that we're impatient or anything, but how is progress going?
Most everything else is in place!
At this point, with a little more endurance testing, we can get a batch made up for a beta run. It has been a longer to launch orders than usual, but with this setup (being SMT) it is imperative that the hardware operate properly and that we discover and correct any issues before going into production. With that said, I can say that we are almost at the point where we can declare MicroSquirt ready for prime time!
- Bruce
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Bruce Bowling
- Site Admin
- Posts: 285
- Joined: Mon Feb 16, 2004 4:25 pm
- Location: Baltimore, MD
Update on MicroSquirt.....
A beta MicroSquirt has been undergoing in-vehicle testing the last 3 weeks in a daily driver driving about 110 miles a day, every day. Setup is fuel-only with opto tach input. So far it has been operating flawlessly. A switch to VR input is next, then ignition control.
We are also gearing up the Contract Manufacturer (CM) for assembling and testing the MicroSquirt. Lots of little details to take care of for this. For those curious, here is a rundown on what needs to occur to assemble a MicroSquirt:
First off, getting the board panel ready for the IR reflow and wave solder operation. To minimize assembly cost a "panel" of 12 MicroSquirt boards are assembled at a time. Here is an outline of the IR reflow (soldering) process: first the panel is placed in a frame holder. Next a stencil is placed over the board and solder paste is applied to the pads thru the stencil openings. Then a "pick-and-place" operation places the SMD parts on the panel. Next the panel is IR reflowed in an oven to flow the solder paste on the SMD leads.
Next step is the wave solder operation. The AMPSEAL and the 6-pin BDM header are placed on the panels (hand operation) and the panel is run thru a wave solder operation. This is like a wave of solder which the board rides over which solders the thru-hole components.
Next, the two VB921s are hand-assembled on the aluminum heatsink, and the assembly is placed on the boards(s) and hand-soldered. Note that before the wave solder process, a solder resist was applied on the VB921 thru-holes (hand operation) in order to prevent them from being filled in.
The panels are then separated into individual MicroSquirt boards.
After the boards are assembled they need to be tested. This will require the bootloader be burned into the processor via the BDM interface, then the actual EFI code will need to be bootloaded onto the board. Then the board need to be fully tested - each input and tach source, and each output. All this requires a full-up test jig and training for the individual operating it.
Next, the boards need to be conformal coated. This is a spray operation where the boards are hung up and sprayed on both sides. Then they need to dry...
Next, the boards need to be placed into the case and the end plates screwed on. In a parallel operation, the AMPSEAL terminals need to be crimped on the free wires and placed into the connector housing. Both of these are hand operations - there is a auto crimper machine for the actual crip, but the wires are inserted by hand into the pins. And the wires are placed into the connector housing by hand. The AMPSEAL is not the easiest thing to assemble.....
As can be seen, there are a number of hand operations in the process. The CM is attempting to minimize the occurrance of hand operations but in reality this will most likely be the final flow for assembly. Note that each hand operation slows down production and increases assembly cost.
I have had to make several changes to the PCB artwork in order to make up the panels. For instance the AMPSEAL takes up panel real-estate because it hangs off of the edge of the final board. So a blank area is put in on the panel to compensate for the AMPSEAL. A few more board tweaks may be needed as well.
I also need to get a bunch of the heatsinks made up at a machine shop. Its pretty easy, just a 1/4" by 3/4" bar stock cut 1 inch long and three holes tapped at 4-40.
- Bruce
A beta MicroSquirt has been undergoing in-vehicle testing the last 3 weeks in a daily driver driving about 110 miles a day, every day. Setup is fuel-only with opto tach input. So far it has been operating flawlessly. A switch to VR input is next, then ignition control.
We are also gearing up the Contract Manufacturer (CM) for assembling and testing the MicroSquirt. Lots of little details to take care of for this. For those curious, here is a rundown on what needs to occur to assemble a MicroSquirt:
First off, getting the board panel ready for the IR reflow and wave solder operation. To minimize assembly cost a "panel" of 12 MicroSquirt boards are assembled at a time. Here is an outline of the IR reflow (soldering) process: first the panel is placed in a frame holder. Next a stencil is placed over the board and solder paste is applied to the pads thru the stencil openings. Then a "pick-and-place" operation places the SMD parts on the panel. Next the panel is IR reflowed in an oven to flow the solder paste on the SMD leads.
Next step is the wave solder operation. The AMPSEAL and the 6-pin BDM header are placed on the panels (hand operation) and the panel is run thru a wave solder operation. This is like a wave of solder which the board rides over which solders the thru-hole components.
Next, the two VB921s are hand-assembled on the aluminum heatsink, and the assembly is placed on the boards(s) and hand-soldered. Note that before the wave solder process, a solder resist was applied on the VB921 thru-holes (hand operation) in order to prevent them from being filled in.
The panels are then separated into individual MicroSquirt boards.
After the boards are assembled they need to be tested. This will require the bootloader be burned into the processor via the BDM interface, then the actual EFI code will need to be bootloaded onto the board. Then the board need to be fully tested - each input and tach source, and each output. All this requires a full-up test jig and training for the individual operating it.
Next, the boards need to be conformal coated. This is a spray operation where the boards are hung up and sprayed on both sides. Then they need to dry...
Next, the boards need to be placed into the case and the end plates screwed on. In a parallel operation, the AMPSEAL terminals need to be crimped on the free wires and placed into the connector housing. Both of these are hand operations - there is a auto crimper machine for the actual crip, but the wires are inserted by hand into the pins. And the wires are placed into the connector housing by hand. The AMPSEAL is not the easiest thing to assemble.....
As can be seen, there are a number of hand operations in the process. The CM is attempting to minimize the occurrance of hand operations but in reality this will most likely be the final flow for assembly. Note that each hand operation slows down production and increases assembly cost.
I have had to make several changes to the PCB artwork in order to make up the panels. For instance the AMPSEAL takes up panel real-estate because it hangs off of the edge of the final board. So a blank area is put in on the panel to compensate for the AMPSEAL. A few more board tweaks may be needed as well.
I also need to get a bunch of the heatsinks made up at a machine shop. Its pretty easy, just a 1/4" by 3/4" bar stock cut 1 inch long and three holes tapped at 4-40.
- Bruce
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jsmcortina
- MegaSquirt Guru
- Posts: 332
- Joined: Mon May 03, 2004 12:34 am
- Location: Birmingham, UK
- Contact:
Thanks for the update, I'm sure many will be very happy to hear how wel things are moving along.
For those of us (me) not involved in production electronics it is very easy to forget just how much work is required to turn a prototype into a bulk supply item.
cheers
James
For those of us (me) not involved in production electronics it is very easy to forget just how much work is required to turn a prototype into a bulk supply item.
cheers
James
My Success story http://www.msruns.com/viewtopic.php?t=8008
MS1/Extra at: http://www.msextra.com/manuals/MS_Extra ... _Index.htm
MS2/Extra at: http://www.msextra.com/ms2extra (runs on MS2 and Microsquirt)
MS1/Extra at: http://www.msextra.com/manuals/MS_Extra ... _Index.htm
MS2/Extra at: http://www.msextra.com/ms2extra (runs on MS2 and Microsquirt)
Bruce/all:
While waiting for MicroSquirt does it make sense that I could make a "pigtail" (with Ampseal connectors to DB-37) to use the MegaSquirt for dyno testing and development. Then when the MicroSquirt releases, plug it into my wiring harness?
I hope that makes sense. I assume a little fiddling to disable the onboard MAP sensor on the MegaSquirt. My application is a single cylinder 4-stroke motor (one injector) with very little room for the MegaSquirt. For testing on the dyno, it wouldn't be a problem. For actual race use, it needs the MicroSquirt. I hope to fire the ignition too. Any reason this couldn't work? I've read through both manuals and I think I could do it. I don't want to spend the time and money if there is a technical reason to not do it, though.
Any advice on where to pick up the Ampseal connectors at the best price? Thanks!
Chris
While waiting for MicroSquirt does it make sense that I could make a "pigtail" (with Ampseal connectors to DB-37) to use the MegaSquirt for dyno testing and development. Then when the MicroSquirt releases, plug it into my wiring harness?
I hope that makes sense. I assume a little fiddling to disable the onboard MAP sensor on the MegaSquirt. My application is a single cylinder 4-stroke motor (one injector) with very little room for the MegaSquirt. For testing on the dyno, it wouldn't be a problem. For actual race use, it needs the MicroSquirt. I hope to fire the ignition too. Any reason this couldn't work? I've read through both manuals and I think I could do it. I don't want to spend the time and money if there is a technical reason to not do it, though.
Any advice on where to pick up the Ampseal connectors at the best price? Thanks!
Chris
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Bruce Bowling
- Site Admin
- Posts: 285
- Joined: Mon Feb 16, 2004 4:25 pm
- Location: Baltimore, MD
I do have a prototype board which converts the ampseal to a DB-37 pinout. It also has headers for all of the other signals and a MAP sensor, plus a DB9 plug. I made it up to simplify my testing and to help create a test jig for the CM. But we can make this conversion board available if people want.chrisbr wrote:Bruce/all:
While waiting for MicroSquirt does it make sense that I could make a "pigtail" (with Ampseal connectors to DB-37) to use the MegaSquirt for dyno testing and development. Then when the MicroSquirt releases, plug it into my wiring harness?
Chris
- Bruce