We all know that the weakness in the F1 electrohydraulic manual transmission (EMT) is the simple electromagnetic relay sitting in the middle between the TCU and the hydraulic system.
Electromagnetic relays use an electromagnet to mechanically operate a switch and contains several moving parts as well as a spring to release the switch. Such relays have several big weaknesses when they must power very high loads at regular frequencies like a hydraulic pump. The sparks created between the relay contacts, especially when the power is released, tend to meld the contact points. As a consequence, the current required by the pump can't be delivered any more which makes the relay contacts to spark even more. Unfortunately, it happens very often that the contact points will eventually melt together and will make the hydraulic pump run forever until the electric motor burns out due to the excessive heat. Since the relay is "hot-wired", this can happen at any time without any early warnings, even when your car is resting in your garage. Furthermore, with the pump running during such extended period of time, the hydraulic pressure will get so high that several internal components of the hydraulic system will be permanently destroyed requiring its complete replacement which is a very expensive part (10-20K USD). The electric motor alone is also usually an expensive part (1K - 2K USD).
Electromagnetic relays have another important weakness. The internal magnet coil generates a very high voltage peak each time the power is released. Considering that the relay is directly wired to the ECU or TCU, there is a high risk that the electronic components of the ECU will eventually be destroyed requiring its complete replacement (2K – 5K USD). Most of the relays use only a small internal resistor to limit these voltage peaks which is far from being an efficient transient suppression solution! Some fewer relays have an internal diode (flywheel) which makes the relay polarity sensitive and increases the relay contact release time making the contacts to spark even more.
When so many expensive parts are put at risk because of such simple relay, I started more than 1 year ago to design and to develop a smart 100% electronic solution which eliminates entirely such risks.
This new Plug&Play Smart eMT Relay ECU
is a direct replacement of the original robotized gearbox hydraulic pump relay like for the F1/E-Diff of Ferrari but also for many other car brands.
As a very Smart 100% MCU/CPU based electronic solution and thanks to the integrated early warning system
, it will greatly improve the reliability of our dear cars and will help to prevent very expensive hydraulic system failures.
When we say 100% electronic, it means that we eliminate entirely any mechanical moving parts, magnet coils or switch contacts. Our Smart eMT Relay ECU
is a real micro-processor based ECU, running our complex firmware
, which can instantly switch currents as high as 200A
without any heating, sparks, interference, transients or delays! Such solution will last forever as it is undestroyable. The Smart eMT Relay ECU
is a real Plug & Play solution and can be easily installed in only 5 minutes as it plugs directly into the relay socket.
In addition to safe and reliable high current switching, the Smart eMT Relay ECU
integrates also an early warning system
which will inform you when your hydraulic system start to require more time to build up the pressure than usual. By offering more visibility on how the hydraulic pump performs, fatal EMT failures can be prevented which can leave you stranded on the road. Hydraulic pressure loss is often caused by very small hydraulic leaks (worn gaskets or lose bleed nipples) or air bubbles but it can also hide some more serious upcoming issues.
The Smart eMT Relay ECU
will always attempt to protect the hydraulic system and will even shutdown the pump if it was running for too long time. For instance, if the pump can't build up the hydraulic pressure after 30 secs, the Smart eMT Relay ECU
will shut it down to prevent the pump to burn out and/or damage the hydraulic actuators. Part also of the early warning system
is that the Smart eMT Relay ECU
will constantly check the power consumption of the hydraulic pump. The current consumption of a failing pump will start to vary considerably indicating that the motor will completely fail over time.
Compared to an electromagnetic relay, pump cycle times are efficiently reduced thanks to the superfast response times of the Smart eMT Relay ECU.
We've seen improvements where the pump run time decreased from 6 secs to 2.5 secs per cycle
One of the other smart features we've integrated is the elimination of several TCU bugs
. Indeed, we discovered for example that the TCU has hysteresis issues when the hydraulic pressure starts to drop and gets between 2 thresholds. In this case, the TCU will try to power the hydraulic pump for ultra short periods of time between 100 and 250 milliseconds
which has a catastrophic
effect on the electromagnetic relay and the hydraulic pump. The Smart eMT Relay ECU will detect and automatically eliminate such requests coming from the TCU.
The Smart eMT Relay ECU integrates also many protections against reverse polarity, load dump, overvoltage, undervoltage, short-circuit, current limitation, thermal, ESD and transients. The power consumption is extremely low thanks to our advanced sleep mode (0.22mA), standby mode (8mA) and active mode (14 mA). Even in sleep mode, the Smart eMT Relay ECU will still continue to monitor the hydraulic system and will alert and prevent any abnormal behavior. For Ferrari F1 on F430 (also F430 manual for the E-Diff hydraulic system), 360, F355, 575M, 599, 599 GTO, 612, Enzo, FXX
Can also be installed for the EMT systems of Maserati
(E-Gear), Aston Martin
(ASM/SSM), Alfa Romeo
(Selespeed), Audi R8
(AMT) and Toyota
Pre-sale is now open with free shipping until the official launch of mid-September 2017 (Orders will start to be dispatched around mid September 2017)
Read more here: https://www.scuding.com/Shop/en/ecu-...relay-ecu.html