One‑Pager Overview

Truck ASIC — FPGA‑Based 4L60E Transmission Controller

Objective → Result snapshots of the design: inputs, logic, safety, hardware, validation, and go‑to‑market fit.

Prepared
Aug 11, 2025
Core Goal Inputs State Machine Safety Hardware Testing Comms Product Fit

Core Goal

ObjectiveDeliver a safe, reliable, and repairable controller for classic swaps and retrofits. ResultFPGA‑centric architecture with LUT‑driven shift logic and modular, serviceable I/O.

MVP Inputs

ObjectiveMinimize complexity while enabling functional shifting in prototypes. ResultPrimary sensors: MAP via SPI/I2C and VSS (≈40 pulses/shaft rev). RPM input path identified for over‑rev protection.

State Machine & Tables

ObjectiveCreate deterministic, tunable gear selection. Result256×256 gear map (0.5 mph bins × 0–100 load) with upshift/downshift/lockup/override LUTs; automated .hex build from .npy.

Safety Systems

ObjectivePrevent destructive or unsafe shifts under abnormal conditions. ResultIndependent‑clock watchdog; RPM‑based downshift lockout; VSS delta/unplug detection; zero‑speed shift inhibit; manual paperclip reset.

Hardware Interface & Protection

ObjectiveSurvive automotive electrical abuse and be field‑repairable. ResultTVS on power/VSS/tach; protected digital bus for MAP; replaceable I/O submodules; harness‑friendly pinout.

Testing & Validation

ObjectiveProve logic robustly before road testing. ResultDual Pico2‑ICE (driver/DUT) with synthetic sweeps and bench host; >2M automated test points exercised to date. (51 complete scans)

Data & Debug Tooling

ObjectiveSurface logic mismatches quickly and visually. ResultJSONL logs parsed to 256×256 inspectors and mismatch heatmaps; Python pipeline for .npy→.hex generation.

Comms Robustness

ObjectiveEliminate serial and framing‑related faults. ResultHost‑side buffering and firmware input sanitation in place; framed protocol with checksum/CRC designed and staged for integration.

Product Strategy

ObjectiveShip something people can trust—and fix. ResultRepairable architecture; web portal for feature requests; focus on C10 retrofit niche; roadmap to CAN‑out and Sport Mode.

Roadmap — Next Up

  • Integrate RPM input on bench & road; finalize over‑rev guards.
  • Finalize CRC/framing and command parser hardening.
  • Add explicit SHIFT_IN_PROGRESS state & lockout logic.
  • Tune torque‑converter lockup strategy.
  • Harness adapter & in‑vehicle shakedown.
  • Phase 2: CAN output; configurable Sport Mode.

Status & Impact

2,043,537+ auto test points 256×256 map tooling ready Watchdog & guards prototyped Error heatmaps operational CRC protocol: design staged Repairable I/O approach