05/21/23
Automotive Grade Operator Initiated, Temperature Based I/O Control System
Author: Robert J Calhoun
Basic System Description:
This control system is a self contained Automotive grade circuit controller. This control system is
initiated by vehicle operator and its operation is determined specifically by a single temperature
sender. The temperature input at time of operator initialization will determine a time based output to
a relay that will further operate a high amp circuit. In this use case that circuit will be to control the
initialization of glow plugs for optimized cold starting ability of a diesel engine.
Basic System Operation:
When the vehicle operator initializes the start sequence the ignition circuit is energized providing an
input to the Control System. Once the Control System senses this initial input signal it will then poll
the Temperature Sensor and acquire a voltage signal based on NTC Thermistor sensor that is
installed in the coolant system of the engine. The controller will then use the voltage input to
determine time in seconds to send an output signal to a relay that will then operate a secondary
control circuit, in this use case, a series of Glow Plugs for cold start operation of a diesel engine.
Basic System Input Signals:
Ignition Switch:
The ignition switch provides the power source to the control unit and detects whether the ignition
switch is turned on or off. The Control System initializes the control sequence as soon as this signal
is input.
Engine Starter Signal:
The engine start signal is input to the Control System to detect when the engine is cranking. The
Control System carries out the preheating control during the cranking phase of operation.
Engine Coolant Temperature Sensor:
The Control System determines the engine warm up state based on the voltage input received from
the coolant sensor. Based on this input the Control System decides whether the preheating and/or
afterglow control are required or not.
Alternator “L” Terminal or RPM Sensor: (TBD)
The alternator L terminal detects that engine starting has completed by increasing the alternator L
terminal voltage signal to high. || The RPM Sensor detects engine start by polling the engine speed
from sensor input. If either/or input is detected the Control System will carry out afterglow control.
Control Unit Operations:
1. Preheating Control before Starting
2. Preheating Control during Starting
3. Afterglow Control
4. Glow Lamp Control
Automotive Grade Operator Initiated, Temperature Based I/O Control System
Basic System Outputs:
Glow Plug Relay:
The glow plug relay is the device that applies battery voltage and amperage to the glow plug circuit.
When this relay is given a signal from the Control System it triggers the coil that switches the relay
circuit and power is applied to the glow plugs. The Control System carries out the preheating and
afterglow by controlling this relay.
Glow Lamp:
The Glow Lamp is located at the dashboard that is observable to the vehicle operator. This lamp
gives indication to the operator of when the glow plug relay is energized and the glow plug circuit is
in operation. In addition, if there are any faults detected within the Control System circuit a warning
flash will be sent to the lamp to inform the operator that a fault was detected. The flash frequency
will allow the operator to ascertain the type of fault detected by the Control System.
Glow Control:
Operational Item Temp <= 60*C Temp > 60*C
Glow Indicator Lamp Present Absent
Preheat Control Present Absent
Preheat Engine Cranking Present Present
Afterglow Present Absent
Cold Start Preheating Control:
When coolant temperature is less than or equal to 60*C (~140*F) the relay is energized and the
glow plug circuit allows the glow plugs to increase temperature to assist in engine starting. The
period of current flowing into the glow plug circuit via the control relay is determined by the
Control System.
Preheating Control Engine Cranking:
The glow plug circuit is energized during engine cranking to keep glow plug temperature high. This
allows for good cold start performance.
After Glow:
The glow plug relay continues to be energized after engine start for a specified time to aid in engine
performance, reduce engine smoke and vibration after starting. If the engine temperature increases
to ~60*C or higher during this afterglow period then the glow plug relay is de-energized.
This is the end of this document. This document can be edited as required. Please reference
document date to make sure it is the most recent version.
Rev. 001
