TheHappyHacker
Registered User
Hi everyone, I'm starting this thread to help anyone who wants to build a glowplug controller from scratch. Personally I couldn't justify spending money on the 7.3 controller, when you can get similar results with a $10 arduino and a bit of wire. Currently I have a push button to run what plugs are left, but I'll be updating this thread as I build the system and get it installed.
The goal is to make this process as easy as possible. So that anyone who knows how to copy/paste, and use wire crimps, can follow along without issue. In this post I'll be going over the basics of the project, such as:
-*** is an arduino?
-what will it do, and how does it work?
-what parts and tools are required?
-How does this go in my truck?
-and how can we take this further?
Arduino, What is it and why should I care?
An Arduino is a small, programmable circuit board that lets you control electronic components like lights, motors, and sensors. You can code it to respond to inputs (like pressing a button) and create outputs (like flashing an LED), making it great for DIY projects and learning electronics. There are other threads on this forum with members using Arduino's in various ways, but they typically don't go into detail in a way that another average home mechanic could understand. However, if more people started to use these in their projects, we could see a ton of innovation in a very short amount of time. They can control almost anything you want, your imagination is the limit.
This is perfect for us because we can use it to run the glow-plugs, and even have it change the cycle length depending on the temperature. We can even include a "fail-safe" and have it cut the cycle if the glow-plugs get up to temp before the cycle is finished (like when you have 1 or 2 failed plugs in the system) thus preventing overheating and blowing up more glow-plugs.
Okay, So how does it work?
The way I'm going to set this up will be to use the Arduino as a basic logic controller. Once it gets power from the key, it will read the ambient outside temperature, as well as the temperature of the engine to determine how long to cycle the glow-plugs for. We can also connect it to the factory glow-plug light or buzzer, and have it work just like the stock system would. We will also probe into the power wire for the glow-plugs themselves, so we can read how much resistance there is. This will be how we detect a failed plug, and prevent ourselves from over running the remaining glow-plugs.
What parts and tools will i need?
Parts List: (estimated)
-Arduino (I'm ordering an ELEGOO UNO project starter kit {some parts may come in handy})
-Temp sensor (like the DS18B20)
-Current sensor module (like the ACS712 or INA219)
-22-24 awg wire for the Arduino
-12 awg wire for our custom glow-plug harness
-4 awg wire to feed the glow-plug harness 12v and handle current draw.
-Heat shrink tubes
-Electrical tape
-Barrel-connector type glow-plugs and dielectric grease (optional epoxy if you follow the upcoming epoxy waterproofing guide)
-Braided wire sleeves (to keep the harness neat and tidy)(optional)
-Mini Display screen (I'm installing this in the dash to show a timer, temps, and if there's a plug failure)(optional)
-LED bulb (if not using the factory glow-plug light/buzzer)
-Push button for manual over-ride (bypass the controller and run plugs manually in case of failure)
Tools List: (estimated)
-Basic PPE
-Any laptop/desktop computer
-Wire cutters
-Soldering iron (optional, can use crimp connectors but not recommended)
-Small torch/lighter
-Hot-Glue gun (for attaching Arduino to the inside of the gauge bezel by the g-p light)
-Multi-meter (to test the circuit and find any faults prior to install)
-Any wrenches/screwdrivers needed to remove the old g-p system (were only keeping the light and relay)
In the coming days/weeks I'll be updating this thread with Pictures of the build process and step-by-step instructions going over installation and troubleshooting. Tonight I'll be uploading a few simple diagrams depicting how the system will be laid out and wired in, as well as a few snippets of sample code for the Arduino. I can not stress this next point enough. You don't need to be a programmer or computer wiz to follow along! Once i place the order, and the Arduino arrives from Amazon, I'll test and upload my code so you can all copy/paste your way to success. I just hope this encourages a few of you to delve a bit deeper, and begin implementing these tools and techniques in your own projects. In the mean time, while I'm waiting for snail mail, I'll be scratching down some rough code and testing things. If you have any questions feel free to ask away. There's no such thing as a dumb question in this thread. If someone is wanting to understand more about the project or how they can apply this to another idea, I'll answer to the best of my ability. Also I'm definitely open to suggestions for extra functionality we can include.
The goal is to make this process as easy as possible. So that anyone who knows how to copy/paste, and use wire crimps, can follow along without issue. In this post I'll be going over the basics of the project, such as:
-*** is an arduino?
-what will it do, and how does it work?
-what parts and tools are required?
-How does this go in my truck?
-and how can we take this further?
Arduino, What is it and why should I care?
An Arduino is a small, programmable circuit board that lets you control electronic components like lights, motors, and sensors. You can code it to respond to inputs (like pressing a button) and create outputs (like flashing an LED), making it great for DIY projects and learning electronics. There are other threads on this forum with members using Arduino's in various ways, but they typically don't go into detail in a way that another average home mechanic could understand. However, if more people started to use these in their projects, we could see a ton of innovation in a very short amount of time. They can control almost anything you want, your imagination is the limit.
This is perfect for us because we can use it to run the glow-plugs, and even have it change the cycle length depending on the temperature. We can even include a "fail-safe" and have it cut the cycle if the glow-plugs get up to temp before the cycle is finished (like when you have 1 or 2 failed plugs in the system) thus preventing overheating and blowing up more glow-plugs.
Okay, So how does it work?
The way I'm going to set this up will be to use the Arduino as a basic logic controller. Once it gets power from the key, it will read the ambient outside temperature, as well as the temperature of the engine to determine how long to cycle the glow-plugs for. We can also connect it to the factory glow-plug light or buzzer, and have it work just like the stock system would. We will also probe into the power wire for the glow-plugs themselves, so we can read how much resistance there is. This will be how we detect a failed plug, and prevent ourselves from over running the remaining glow-plugs.
What parts and tools will i need?
Parts List: (estimated)
-Arduino (I'm ordering an ELEGOO UNO project starter kit {some parts may come in handy})
-Temp sensor (like the DS18B20)
-Current sensor module (like the ACS712 or INA219)
-22-24 awg wire for the Arduino
-12 awg wire for our custom glow-plug harness
-4 awg wire to feed the glow-plug harness 12v and handle current draw.
-Heat shrink tubes
-Electrical tape
-Barrel-connector type glow-plugs and dielectric grease (optional epoxy if you follow the upcoming epoxy waterproofing guide)
-Braided wire sleeves (to keep the harness neat and tidy)(optional)
-Mini Display screen (I'm installing this in the dash to show a timer, temps, and if there's a plug failure)(optional)
-LED bulb (if not using the factory glow-plug light/buzzer)
-Push button for manual over-ride (bypass the controller and run plugs manually in case of failure)
Tools List: (estimated)
-Basic PPE
-Any laptop/desktop computer
-Wire cutters
-Soldering iron (optional, can use crimp connectors but not recommended)
-Small torch/lighter
-Hot-Glue gun (for attaching Arduino to the inside of the gauge bezel by the g-p light)
-Multi-meter (to test the circuit and find any faults prior to install)
-Any wrenches/screwdrivers needed to remove the old g-p system (were only keeping the light and relay)
In the coming days/weeks I'll be updating this thread with Pictures of the build process and step-by-step instructions going over installation and troubleshooting. Tonight I'll be uploading a few simple diagrams depicting how the system will be laid out and wired in, as well as a few snippets of sample code for the Arduino. I can not stress this next point enough. You don't need to be a programmer or computer wiz to follow along! Once i place the order, and the Arduino arrives from Amazon, I'll test and upload my code so you can all copy/paste your way to success. I just hope this encourages a few of you to delve a bit deeper, and begin implementing these tools and techniques in your own projects. In the mean time, while I'm waiting for snail mail, I'll be scratching down some rough code and testing things. If you have any questions feel free to ask away. There's no such thing as a dumb question in this thread. If someone is wanting to understand more about the project or how they can apply this to another idea, I'll answer to the best of my ability. Also I'm definitely open to suggestions for extra functionality we can include.