Drive units like this are great. For DIY'ers, salvage Tesla drive units usually provide more power for a much lower cost, but if I were embarking on a commercial design, I would definitely try to source a drive unit like this. You may also want co check out https://webshop.swindonpowertrain.com/inde...

This seems like nothing but a vague suggestion by somebody looking for opinion. I'm broadly in favor of such addition tests. However, realistically, in my opinion the only way to "test" an EV battery is going to be similar to a PAT test. Mostly a visual inspection, looking for worn / fraye...

Most of these boards come from companies who are not very good at sharing their designs, and as such the gerbers are not available. I had a quick look and found this, but it doesn't match up with the other boards, so I'm not sure if it's useful: https://github.com/relectric-car-team/pcb-tesla-cell-tap

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Regarding the TVS approach. could you give some more information on how you dimensioned the diodes and resistors? Don't overthink it. Just make sure the contactors never open unless the vehicle is idle. tripode=1 should be all you need. There are some extreme edge cases like blowing a low voltage f...

I was under the impression the output of a Prius Gen2 and Gen3 inverter was a SPWM and am now reading might not be as clean as I was thinking. I may be thinking that way due to reading via controlling using the openinverter. Either way, filtering would be required... though less based on the SPWM a...

ViktorT wrote: ↑Thu Jul 21, 2022 8:15 am Hi Catphish
Did you get it right with the oil?

As far as I know, yes. The drive unit has been running fine with it

So, after lots of tuning (and only minor code changes) I would like to release what will hopefully be the final version for now. This version enables regen! It's still not as polished as I'd like, but it seems to work. Attachments: stm32-sine.bin - Version 5.26.X tesla-sdu-performance-slipmin.json -...

The only parameter to update to directly reduce torque is throtmax. This is used as part of the throttle calculation at 100Hz. There are two problems here though: 1) Throtmax won't have any impact until it's less than the actual throttle value (potnom). This probably isn't a huge issue, traction is ...

Big success. I now have stable regen. I didn't achieve this by any particularly clever code, just by limiting various slew rates. regen-success.png Specifically: 1) I introduced separate gains for positive current correction vs negative current correction. This allows me to tune the negative gain t...

What's the benefit be of using FOC for induction motors versus just the plain Sine algorithm? I'll be running an induction motor (nothing fancy like a tesla, a forklift motor). Wondering if/how this might affect me. In theory, a correctly implemented FOC algorithm has three main benefits: 1) More e...

A while back, I experimented with some code to graph the in-phase (real) and out-of-phase (reactive) current. Looking again at that data I am convinced it is useful for a couple of reasons. Firstly, looking at the following 0-60 graph it can clearly be seen that as speed increases, the ratio between...

How about coupling the two motors together. One on MG1 the other on MG2 and run the pair as a dyno ;) This is seeming like it might be the best idea. Probably easiest to do with two identical sizes motors, will make mounting and coupling a lot simpler. I am putting this FOC on hold for now as it ki...

I lowered the fweakstrt to 0 a lower value of fweak will give you more current fweak and fweakstrt control the speed at which 100% voltage is applied. Set one of them to zero and you will get 100% voltage at zero speed. That's certainly a quick way to destroy your controller, sorry :( It's not clea...

I did some more regen testing today, this time using higher current targets and lower slip as proposed. This does lead to a substantial improvement in stability! Regen seems to work and remains stable. road-regen-almost.png However, one problem remains. When reducing regen (ie moving from regen to z...

In therory, fweak is the frequency at which the motor is rated to run at your full battery voltage. Here are some tings to consider: 1) Rated parameters of motors are more like suggestions than exact values, so don't worry about getting it exact. 2) That a lower value of fweak will give you more cur...

I've been donated another 1kW motor with a chain sprocket on it. This one might be more practical to attach a load to

I found myself thinking about regen again today, and I think I have an idea how to prevent the unpleasant current spikes. It's my suspicion that all along I've been trying to set the current too low. Looking at this chart, we can see that as we switch into regen and set slip negative, we get a risin...

Slightly envious of your test setup too ;) I really like this setup. Thanks to johu for providing the STM32 board! The Prius inverter and industrial motor were quite cheap (about £80 each). The battery and contactors were leftover from my car build. I'd still like to find a way to test with a load....

Are you referring to equation (11) here? If so that is just for the steady state, where dPsir/dt = 0. Under non-steady state conditions I think you need the other term too. Nope, referring to Phir in equation 9 - the one that's self-referential. I'm suggesting that if you replace Phir with... itsel...

Had a look at this but still can't work out how Lm could cancel :? Here are my calcs in case they are of any use? Thank you for going through this. On the very first line of your calculations, you have "-Psir/Tr". My argument was based on the assumption that Lm and Id are both factors of ...

Here's another short demo of the motor running on the bench after some tweaking of settings.

So, rather late last night I wrote a simpler FOC implementation. The full code is here: https://github.com/catphish/stm32-sine/blob/foc-sine-basic/src/pwmgeneration-sine.cpp First we fetch some settings. slipconst is a time constant. It's a combination of motor parameters and the PWM frequency. It d...

Anyway... proposed code. Not yet tested! https://github.com/catphish/stm32-sine/commit/c6ac4a6cb652415e0402ae42a34603a58137cceb#diff-b8914fe3a0942d8ed9dfd6f4996301481a1a4a1ec65b8467a5733807ac931d26 Going back over the code, I feel like this might work in steady state, but there's one aspect that co...

Need to write it out to be sure but if the rotorFlux calculation is written on a single line rather than two them Lm isn't common to both terms and so won't cancel when calculating slip. Or am I misunderstanding the question? I'm not sure how best to explain, but I'm thinking that Lm multiplies the...