Project Overview
The EKÜ Phase II Project was a comprehensive engineering and R&D initiative focused on the development of an Electronic Control Unit (ECU) designed to perform critical control and management functions for turbojet engines.
The project aimed to develop an integrated control architecture capable of monitoring engine operating conditions, executing real-time control functions, ensuring reliable communication with critical subsystems, and implementing protective mechanisms under abnormal operating conditions.
Initiated in April 2019, the project covered a broad range of engineering disciplines, including critical hardware design, embedded software development, control algorithm design, system modeling, simulation, testing, validation, and technical documentation.
The project was successfully completed in July 2020 following the completion of its hardware, software, integration, and verification activities.
Project Development Timeline
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April – September 2019
1. Critical Hardware Design and Electronic Architecture
The initial phase focused on establishing the electronic architecture of the ECU and defining the critical hardware components required for reliable system operation.
Major engineering activities included:
- Selection of the STM32 microcontroller as the central processing unit of the ECU.
- Critical design of digital peripherals, including clock, RAM, and optical isolation interfaces.
- Development of current-controlled pyrotechnic igniter circuits.
- Design of a hardware-based pyrotechnic simulator to enable controlled testing of the igniter circuits.
- Development of thermocouple analog interface circuits for measuring temperatures at the turbojet engine inlet and turbine sections.
- Design of signal isolation and protection circuits to ensure accurate temperature measurements.
- Development of a robust RS-422 communication interface designed to withstand environmental disturbances and electromagnetic interference.
In September 2019, PCB component placement and thermal analyses were completed. Gerber production files were generated, and the first ECU hardware prototype was manufactured.
Following initial verification testing and calibration, the prototype was made ready for embedded software development.
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September – December 2019
2. Embedded Software and Real-Time Control Infrastructure
Following the completion of the hardware prototype, embedded software development activities commenced.
The initial software implementation included the integration of a Real-Time Operating System (RTOS) and the development of device drivers for the ECU's peripheral components.
To support the development and validation of control algorithms, a high-fidelity turbojet engine model was developed. This model was designed for use in both Model-in-the-Loop (MIL) and Hardware-in-the-Loop (HIL) simulation environments and was successfully integrated into the Speedgoat HIL simulation platform.
System Identification studies were also conducted using test data obtained from generic engine models available in the technical literature. These studies enabled the development of simplified linear engine models suitable for real-time execution within the ECU.
By December 2019, the parameterized Set-Point controller architecture had been established to regulate engine speed between idle and maximum operating conditions. Optimal controller parameters were determined, and both transient and steady-state performance characteristics were demonstrated using the HIL simulator.
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January – March 2020
3. Engine Control, Protection and Fault Management
During this phase, the control software was expanded beyond basic engine speed regulation to include comprehensive engine protection and fault management functions.
Dedicated protection algorithms were developed for the turbojet engine and its subsystems and integrated under a centralized Switching Logic architecture. The main protection functions included:
- Combustion chamber flameout detection due to insufficient fuel flow.
- Combustion chamber flameout detection associated with excessive fuel flow.
- Maximum turbojet shaft speed protection.
- Minimum turbojet shaft speed protection.
- Excessive turbojet shaft acceleration protection.
- Turbine outlet over-temperature protection.
In February 2020, advanced fault codes were implemented, and their testing and verification activities were carried out using the HIL simulation platform.
In addition, Degraded Mode management capabilities were developed to enable the system to operate under predefined restricted operating conditions in response to detected faults.
In March 2020, the engine start-up control software, responsible for transitioning the turbojet engine from ignition to idle operating conditions, was completed and successfully tested in the HIL environment.
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April – May 2020
4. Flight Envelope Testing and Environmental Verification
The initial development and validation of the Set-Point and protective control algorithms had been based on a reference operating condition of 0.9 Mach at sea level.
In April 2020, the developed controller structures were evaluated across additional flight envelope conditions. The resulting performance data were comparatively analyzed and documented.
In May 2020, preliminary environmental tests were conducted on the ECU hardware and software components, and the test results were documented.
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June – July 2020
5. Technical Documentation and Project Completion
The final project phase focused on preparing comprehensive technical documentation covering the developed hardware and embedded software systems. The documentation package included:
- Hardware design and manufacturing documentation.
- Embedded software and control algorithm documentation.
- Testing and verification reports.
- User and operation manuals.
- Maintenance and repair documentation.
With the successful completion of the documentation activities in July 2020, the EKÜ Phase II Project was formally completed.
Engineering Capabilities and Project Achievements
EKÜ Phase II represents a multidisciplinary engineering project combining electronic hardware development with real-time embedded software engineering and model-based system validation. The project demonstrated engineering capabilities in the following areas:
- Critical electronic hardware design and prototyping
- STM32-based embedded system architecture
- RTOS integration and device driver development
- Analog signal processing, sensor interfaces, and isolation circuit design
- RS-422 communication infrastructure
- Real-time control algorithm development
- Engine modeling and System Identification
- Model-in-the-Loop (MIL) and Hardware-in-the-Loop (HIL) simulation
- Fault detection, protection logic, and Degraded Mode management
- System-level testing, verification, and technical documentation
Conclusion
Initiated in April 2019, the EKÜ Phase II Project was successfully completed in July 2020, covering the entire engineering development cycle from critical hardware and software design to prototyping, simulation, verification, and technical documentation.
The project represents an important R&D experience in the development of complex electronic control systems through an integrated engineering approach.
EKÜ Phase II demonstrates the application of multidisciplinary engineering expertise in electronic system design, real-time embedded software, advanced control algorithms, and model-based verification within a comprehensive product development process.