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Tech Talk – 3.0 TFSI ECU Tuning

3.0 TFSI ECU Tuning

The most important thing taken away from this journey into 3.0TFSI ECU Tuning and the SIMOS8.x ECU was that Different =/= Worse.

First and foremost, Driver Motorsport has always been experts with the Bosch ECU. The Bosch ECU is where we make our living. We’ve done hundreds of different ECU software versions and multiple generations of the Bosch ECU across many platforms. We’re at the cutting edge of Bosch ECU Technology and producing ECU Calibrations for the newest Audi / VW vehicles.

However, Up until 5 months ago my knowledge of the modern Continental SIMOS ECU was zilch. Considering I’m responsible for Driver Motorsport‘s ECU Calibrations I knew this was a bridge I was going to have to cross to keep up with the times in VW / Audi ECU tuning. I’ve known that the EA888 Gen 3 was going to be using the SIMOS ECU since 2012 and it’s been in the back of my mind ever since.

I began development on our 3.0 TFSI ECU Tuning offerings 5 months ago. Bar none, the 3.0 TFSI ECU Tuning development was the most fun I’ve had in 2014. Getting into a new engine management system and a higher output engine found in a modern S-Line Audi definitely makes work more enjoyable.

 

3.0 TFSI ECU Tuning

 

TECH DETAILS – 

Engine Calibration:

For obvious reasons, the 3.0 TFSI is much different than any of the other engines found in modern Audi vehicles. From a calibration standpoint, it meant a vastly different approach.

There’s a belief that getting power out of this engine is simple. All of the 3.0 TFSI ECU Tuning solutions will make the same power by simply keeping the RFP (Bypass Valve) from bleeding off boost pressure. In a sense, this is true. I could’ve finished development in a day. As far as increasing power you can receive 90% of what the engine has to give in a few hours.

Since this process took >1 day, that route isn’t the way I went. Outside of the RFP not bleeding off boost pressure, the calibration as a whole can be optimized greatly. You cannot calibrate a way to create more airflow out of the the supercharger. The supercharger’s airflow is capped to a fixed amount per revolution but the volumetric efficiency of the engine is a bit more dynamic. Through phasing of various set points such as lambda, VVT and ignition advance a proper balance was created and the result was large increases in midrange torque. The dyno graph of our 3.0 TFSI ECU Tuning Upgrade will not follow the same shape produced by competitors as a result.

Outside of creating horsepower, majority of development time was spent on improving things that will not show up on a dyno sheet. As far as acceleration enhancements go, I’ve included Left Foot Braking to our production file. There were changes made to the ECU’s torque model. These changes allow the transitions to a positive load request to be more responsive to the driver’s request. Throttle Tip-In timing delay was reduced for a faster Tip-In.

The most important changes made were to the ECU’s logic to dynamic conditions. There are re-calibrations to the ECU’s responses to altitude, IAT, EGT and fuel quality. The ECU will limit permissible airflow based off of IAT. Ignition advance is added or subtracted to base ignition timing based off of IAT. Our boost pressure setpoint is set accurately to what the supercharger can realistically produce to allow the ECU to control it’s response to the vehicle’s changing environment. There is optimized lambda enrichment dependent on EGT. The list goes on…

Reverse Engineering SIMOS8.x -

The SIMOS ECU concerns, were largely unfounded. In fact SIMOS and Bosch are more alike than they are different. When developing the 3.0 TFSI ECU Tuning solution, the biggest hurdle was not related to the ECU type.

The structure of these 2 different ECUs follow the same principles. As an example, all modern ECUs have to relate airflow to torque. Bosch does this through a Load% to a percentage of torque(0-100%). SIMOS does this same task by taking a MAF measured in kg/h and converting it to a measurement of torque in Nm. Ignition timing is still based off of VVT and intake manifold runner flap position. Both ECUs are working with a torque model with principles that are similar. In a sense, it’s merely learning new nomenclature and different takes from 2 separate manufacturers on the same topics.

The future outlook for Driver Motorsport and the next step to modern SIMOS ECU Management is promising. I think that this 3.0 TFSI ECU Tuning Upgrade will reflect that. We’re already working with SIMOS12/18 on the EA888 Gen 3. We have quite a few surprises in store on that front.. That’d be for another blog post :-)

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In summary..

I believe if you’re selling a $1,000 ECU flash for a $50,000 car it goes without saying that it needs to be more advanced than a simple increase in horsepower. I think we accomplished that with the 3.0 TFSI ECU Tuning Upgrade. The expected release of this software is first quarter of 2015.

Bronson Dixon / CEO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Driver Motorsport’s New Online Home!

Volkswagen / Audi Tuning Specialist

Volkswagen / Audi Tuning Specialist

Our new website is here and brings forth the next chapter for Driver Motorsport, LLC.

Welcome to Driver Motorsport‘s new Blog. This is where new product releases will be announced, and where we will offer an inside look into Driver Motorsport and our growth as Volkswagen & Audi Tuning Specialist. As an enthusiast, I’ve always enjoyed looking at various blogs from other aftermarket automotive brands such as perrinperformance.com or dinancars.com. I firmly believe it is the best way to connect with our customer base, and to bring in fresh and entertaining content. We’ll use this blog to speak about technical topics, relevant news to our industry (Volkswagen / Audi Developments) and to release new products. One of us will be able to respond to comments or field questions, most likely it will be my brother or myself. Now, onto the details of the website…

In our first year of business we’ve grown immensely, we’ve more than doubled in our Volkswagen / Audi Tuning offerings, and have developed an international distribution network. Over time it become more and more apparent we outgrew what our old website had to offer. With the development of this website, our primary goal was to improve the customer experience and follow through with various suggestions we’ve been given (see – Tech Support). It is also bringing many new dimensions to our online home, such as -

Blog – The personal favorite is the Driver Motorsport Blog.

Technical Support Page – We set out to improve our customer experience by developing a Technical Support Page that will host installation documents, software for the newer Programmer and gives the customer the ability to send us an email directly off of this page. We plan to add our Vag-Com logging suggestions to this page as well.

Distributor Locator – The Distributor Page has an updated list of our distributors and now includes our international distributor network. We have included an online map, making it easy to search for local support for Driver Motorsport‘s products.

Media – This is still under construction. We’re currently organizing all videos/photos to put into appropriate sections and use as an archive to look back at us attending events and releasing new content going forward.

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Driver Motorsport‘s Product Releases -

With the new website also comes many new and exciting software releases. We recently purchased a 2013 B8.5 A4 that we have used to developed Stage 1 & 2 Software as well as K04 software that is currently in development. Our TTRS Software is something newly released, as well as our planned development into offering a Loba Motorsport Lo500 Calibration. We’re also releasing software for the ROW market as well, which includes 1.8TSI and 1.4TSI software. We’re now one of the few in the world to offer Volkswagen / Audi tuning for the 1.4TSI engine found in Audi / Volkswagen vehicles Model Year 2013+.

- Bronson Dixon / CEO

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