Idea for glow plug controller/Wilson switch alternative

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amaurer said:
I realize I might be coming off argumentative, but really I just love design problem, so forgive me. :cheers:


That said, the cost of the drivers and four SS relays is going to FAR outstrip the cost of one relay and then four resistors, which would also give you the ability to find which plug is dead.
Click to expand...
No problem. I don't think you're being argumentative. I appreciate the feedback. I'm no genius and I've been away from this stuff for 10+ years so I'm a bit rusty.

Did you get a chance to take a look at the PDF for that glow plug driver chip? It's worth a quick glance. It's pretty slick.
 
I'm not sure that I'll ever get around to selling these things. There's a ton of patented glow plug controller circuits out there. I'm not willing to get into a patent dispute. I doubt it would happen but even the remote possibility of infringing on some patent with my pet project is enough risk to make me not want to sell them.

I may tinker with the design though just because I think it will be a fun project.
 
I've been working on the design a little bit in my spare time. I've been studying the VW TDI glow system since it was my original inspiration for this project. I think I'll use the VW glow plug relay. It will drive the Superglow 6v Cruiser glow plugs perfectly. It has two current paths built into it. One for a full 12 v and a second that automatically varies resistance for the afterglow period. The relay is only $33.95 at various part suppliers which is pretty reasonable. I'm going to order one and test it out.
 
I don't get this... why make a system more complicated then it needs to be... these are simple diesels... In my mind they should have come with factory momentary, glow switches, instead of an atari ciruit board... sure they last a good long while, but what's to go wrong with a momentary switch? and how much is it to replace if it does for some reason fail!

In the world of mechnical diesels... the electronics should be simple...I just find it so nice to have the glow plugs at the push of a button!
 
Because I want an automatic, temperature compensated afterglow feature. I hate starting my tired, old, non-Superglow 3B in the cold. I live in northern Maine.

In my truck the glow plugs get nice and hot, the engine starts and within 10 seconds it's running rough and I have to start over. If it's real cold, like zero degrees F, I might have to do this three or four times before the truck starts to run halfway decent. It's a drag. I just like the way the VW TDIs work. I have the time and the inclination to do the design work. It's not for everyone, I realize that.

BTW, in my design I have the option of a manual momentary switch override for those times where it might be needed.
 
while I applaud the notion of engineering/tinkering a great solution... I'm also a big fan of keeping things simple

without ruffling any feathers- is there a reason that you couldn't/shouldn't do a manual glow then also just hold down the switch to afterglow for 10 seconds if it runs rough?

Having said that-- a $35 doodad from VW sounds like a fairly cheap n easy solution as well.

Just wondering if a completely manual solution has any downside besides the added effort (and having to teach somebody else how to use it if they start your car, or making it a hassle if you want to load groceries while the truck warms up a little...)
 
No feathers getting ruffled on my end. I appreciate the feedback.

My wife drives our BJ42. She also drives our VW TDI. She's used to the manual glow period on the key switch in the Cruiser. I'm sure I could "train" her to do a manual afterglow with a momentary switch. The thing that concerns me is having the full voltage going to the glow plugs during this period. I guess I could use the key as a normal pre-glow and have a dash mounted momentary switch for after-glow that controls a relay supplying a lower voltage to the plugs.

Now that I'm typing this it seems like that would be a really simple solution with the VW relay. I could drop the Toyota glow plug relay and replace it with the VW TDI relay. The key switch glow function would route through the 12v path on the VW relay. The dash mounted switch would control the lower voltage side of the relay. Splitting them in this manner would make it difficult (but not impossible) for the operator to simultaneously glow both sides of the circuit.

I purchased a couple of amaurer's momentary switches so it would be an easy thing to setup. I doubt it would take more than an hour or two.

I still want to do the design work though just because I miss tinkering with stuff like that. I hated it as a job but it's been 10+ years since I've designed any hardware and I kinda miss it a little. I'm sure I'll be over it when the snow melts in early May.
 
I went for the KISS method and wired a momentary switch to replace the superglow system on my HJ60. It supplies 24V (actually more like 21V during prestart) to the glowplugs. I installed 20.5V glow plugs meant for a 3B engine to handle the constant 24V. I often hold the switch 3-5 sec for afterglow to smooth the idle.

My verdict? It's a bummer that you have to hold the switch, cause an automatic switch is wayyyy nicer to do other stuff during warm up (such as buckle the kids in!!). BUT the $20 switch is all it cost me, so that helps me feel better about it. And I remind the kids about the value of saving money!!!

Only problem is, it worked awesome for 6 months, great starts even in -20C temps, but I have now burnt out the glow plugs. I can't see why they couldn't handle the full voltage, since they must be designed to do that in a 3B. Am I right? I'm getting another set, and this time I'll keep my glow times to 5-10 sec rather than the 15 sec I used to do. I hope they last better.

What kind of resistor could I put in the heavy guage 24V cable to reduce the Voltage by 1 or 2 Volts?
 
Hi guys,

I also wired in a momentary switch into my 2L-T to bypass the superglow system. The problem is that the plugs in that engine are rated at 7V and I've been feeding them 12V (or thereabouts) and been having the same problems as veggieguy, burnout after a couple months. Also wondering if anyone has any input as to a resistor?

They sell 12 to 6 V "reducer's" for old cars that use 6V but they are only good to 1.5 A and my plugs draw ~30 at temp. Perhaps a voltage regulator? It is possible to get 11V plugs but they need to come from overseas and I've burned those out too!
 
RufusTheDufus said:
I've been working on the design a little bit in my spare time. I've been studying the VW TDI glow system since it was my original inspiration for this project. I think I'll use the VW glow plug relay. It will drive the Superglow 6v Cruiser glow plugs perfectly. It has two current paths built into it. One for a full 12 v and a second that automatically varies resistance for the afterglow period. The relay is only $33.95 at various part suppliers which is pretty reasonable. I'm going to order one and test it out.
Click to expand...

Definitely less money than the Redarc units you can order from OZ. But they do have units that work in a 24v system.
Redarc timers
 
Rufus you sound like me... starts off as a more or less simple piece of code/application and develops into a gargantuan telephone book sized file.
Sounds good I like it! :D

edit: by the way I'm not a fan of quirky computers in cars either (especially my BJ40) but.... if you can bypass it and go manual with then its all fine.
 
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veggieguy said:
I went for the KISS method and wired a momentary switch to replace the superglow system on my HJ60. It supplies 24V (actually more like 21V during prestart) to the glowplugs. I installed 20.5V glow plugs meant for a 3B engine to handle the constant 24V. I often hold the switch 3-5 sec for afterglow to smooth the idle.

My verdict? It's a bummer that you have to hold the switch, cause an automatic switch is wayyyy nicer to do other stuff during warm up (such as buckle the kids in!!). BUT the $20 switch is all it cost me, so that helps me feel better about it. And I remind the kids about the value of saving money!!!

Only problem is, it worked awesome for 6 months, great starts even in -20C temps, but I have now burnt out the glow plugs. I can't see why they couldn't handle the full voltage, since they must be designed to do that in a 3B. Am I right? I'm getting another set, and this time I'll keep my glow times to 5-10 sec rather than the 15 sec I used to do. I hope they last better.

What kind of resistor could I put in the heavy guage 24V cable to reduce the Voltage by 1 or 2 Volts?
Click to expand...

Ohm's Law Calculators

It's not all too bad though, if you mount it on your dash you can warm one hand and defrost your windshield all at the same time whilst pressing the switch with the other :hillbilly:
 
I kinda gave up on the project. When I saw the number of patents that have been issued related to glow plug controllers I realized there's no practical commercial application for the gizmo. I've been consumed day trading since the first week of March and haven't had any mental energy to put into the glow plug controller project.
 
sheesh, i get a head ache just reading this thread...
a manual glow is a simple install, nice thing is if it is cold out and at initial start up your engine starts to run rough then hit the glow again for a few seconds.
so simple, so cheap...
if you want complex then stick with the factory system.

although a fuseable link would be a nice addition to the system to be on the safe side but then when you smell something buring then let go of the momentary switch...
 
Hey Rufus

If you want some enticement to finish your project I'd be happy to order one!

I need a new timer system for the 1KZ-T I'm putting in an old truck. It's four cylinders, 12 volts... And I would love to have a system that does both pre and afterglow.
Maybe I should just buy a VW relay though?
 
I gave up on the project. Been too busy with other stuff.

I took one of the VW relays apart. They are pretty slick but won't do the job on their own. They have some kind of current sensing mechanism that provides feedback to the ECU to check for bad glow plugs. If I remember correctly there are two inputs from the ECU that each control two glow plugs connected to the relay. I think it might be a suitable replacement if the stock Toyota glow plug controller ever craps out but I'd have to check again to be sure.
 
That level of knowledge is more than is required in this instance.
 
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I was thinking about designing similar thing but little different. my idea was to have thermo sensor or a resister sealed next to glow plug. heat it and measure the max temp or resisetace difference and give it 1-2 sec extra then run it thru a relay and start the engine automatically.
 
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