Automotive Engine Service Equipment - Custom controller for easier operation

Challenge: Provide an easier to use control panel for the service technician to improve system cleaning and ensure no catastrophic failures. The ease of use is important because the new machine will flush oil and sludge from an engine while the engine is running. It must dispense a proprietary, powerful, yet safe detergent into the crankcase and through the entire lubrication system of the engine that will remove the burned, caked on oil created by heat. At the end of the service, a regulated supply of on-board air will evacuate any remaining oil or sludge from the lines and oil pan and clean the oil pump screen.

Analysis: In addition to the above design, the unit was required to be portable, powered from the vehicle's 12 VDC power. Since operator experience varies greatly, the user interface must be very informative yet easy to read. The system must precisely dispense the detergent and air automatically during a timed cycle. And it had to fit in a limited volume because the majority of space must be dedicated to the pumps and reservoirs of the self-contained system.

Results: Working closely with the product development team, Intellicon engineers developed a semi-custom 8-bit micro-controller-based solution that integrated many more features then the user had specified. Intellicon also developed a new valve assembly that increase the precision of the detergent dispensing (does not waste detergent) and an electronic timer to more accurately control the dispensing and evacuation cycles, ensuring no detergent is left in the vehicle's oil lines.

Other improvements that resulted included better warnings to the service technician. Competitive units have a single warning buzzer to indicate cycle changes and potential problems, such as low oil pressure, that could result in the engine seizing, a catastrophic and costly failure. The Intellicon design varies the tones of the warning buzzer, alerting the service technician more quickly to the status of the process.

The controller also provided better diagnostics and protection for the machine. Intellicon's power supply design and auto mechanic experiences allowed for a simple polarity and over-voltage protection and warning to be incorporated on the board, protecting the unit while informing the operator.

Better and more built in self-diagnostics not only help service the machines, but keep them running longer. The unit also has a run-time counter that can only be reset by the manufacturers technicians, ensuring that on leased machines the customer uses only the manufacturer's detergent products.

Advantages of the Intellicon designed controller and valve assembly go beyond the ease of use. Intellicon engineers, who are experience in both electrical and mechanical assembly, also look at ways to reduce manufacturing costs of the machine. Taking advantage of their microcontroller board design, they incorporated all the previously separated warning and process indicator LEDs onto the controller board. This eliminated the time to wire and mount each LED while providing an out of the way space to mount the controller.  

In addition, the new dispensing valves became an entire assembly, making it much easier to build and service the equipment. Intellicon's assemblies reduced the manufacture's production time leading to a better product that cost less.

The Proof: A better end product is always our goal. Intellicon designed a custom controller and valve control assembly to lower the cost and improve the performance of the Motorvac Engine Oil Flush System.

Email: info@intelliconelectronics.com

Tel: 714.751.9257