Audi A2 with Prius Gen2

[geduxaz]

Hi. Starting the trial and error marathon
Audi A2 1.6fsi as a recipient. 550Eur.
OpenInverter VCU 180Eur.
Prius gen2 gearbox 100Eur.
Prius gen2 inverter 65Eur.
Chev Volt Gen2 80 cells 900Eur.
Prius shafts 50Eur.
Oil for gearbox 15Eur.
Total 1860Eur.


Gearbox was tested on the bench.
Batteries, will be sourced later. Anything from scrap.
Goal to test myself and do it very cheap.

[RetroZero]

Looks very familiar .
Gen 2 transaxle is great, but bulky and heavy for small fwd. You will need 2 adapter boards if the aim is Mg1 and Mg2. If you want to go real cheap, yaris inverter and Damiens dual motor board, but you then need to modify motor cabling to inverter. Choices, choices.

[johu]

Cool, looks like we'll be doing the exact same thing: viewtopic.php?f=11&t=650

[geduxaz]

I read you wrote "Prius transmission would be beneficial for registering, because no EMC testing is required. But I think it is too tall to fit,"
I measured it and I didn't find any issues to fit it. I plan to center Prius transmission, weld Prius driveshafts to A2 driveshafts.
Was planning to start making mounting brackets this weekend, but my workshop is in now restricted area because of immigrants from Belarus (declared state of emergency)

Cool, looks like we'll be doing the exact same thing: viewtopic.php?f=11&t=650

[geduxaz]

I would like to use only MG2, remove MG1 from transaxle to reduce weight.

Looks very familiar .
Gen 2 transaxle is great, but bulky and heavy for small fwd. You will need 2 adapter boards if the aim is Mg1 and Mg2. If you want to go real cheap, yaris inverter and Damiens dual motor board, but you then need to modify motor cabling to inverter. Choices, choices.

[RetroZero]

Been thinking the same. Even better, make a blank off plate and remove Mg1 completely. More space for batteries etc. All that said, dual motor is a good option too, for larger vehicles. I'm scratching my head for rwd that could welcome a transaxle. Combi comes to mind

[geduxaz]

After long time made small steps forward.
Decided to put VCU into original ECU housing and use audi ecu connectors.
Car moves. Now need to fine tune SyncOffset and put Volt Gen2 battery pack.

[geduxaz]

Audi throttle pinout:
First sensor 1 (24 on ecu) is +5V, 5 (19 on ecu) is Gnd, 6 (33 on ecu) is signal;
Second sensor 2 (43) is +5V, 3 (18 on ecu) is Gnd, 4 (15 on ecu) is signal;

[geduxaz]

Shaft were made from Audi external and Prius internal shafts. Welded together with additional pipe pressed on them together.

[geduxaz]

[Jack Bauer]

Excellent. Are you using both mg1 and mg2?

[geduxaz]

Excellent. Are you using both mg1 and mg2?

Only MG2. If all goes well I plan to remove MG1 and reduce weight.

[geduxaz]

Some info to remember

[RetroZero]

Congratulations . How did you resolve the forward reverse problem?

[geduxaz]

Congratulations . How did you resolve the forward reverse problem?

This was test on backwards direction could easily spin wheels on some snow till it melted snow and heated tyres . Lots of power. But i am not happy. Need to make forward go forward.

Also in video rear had like 300+ Kg of lead batteries. Now it is lithium- more light.

[EV_Builder]

This was test on backwards direction could easily spin wheels on some snow till it melted snow and heated tyres . Lots of power. But i am not happy. Need to make forward go forward.

Also in video rear had like 300+ Kg of lead batteries. Now it is lithium- more light.

What do you mean the car moves forward in the video?

[geduxaz]

It is selected as rewerse in vcu but motor spins forward

[johu]

So it's just the label that bug you? Because otherwise there is no difference between fwd and rev

[geduxaz]

Really? There were some comments that this should not be used as this.
Is all the regens etc also working the same on reverse?

[EV_Builder]

There is a setting johu knows so you can swap the firing of the phases I think that will do the trick. I agree that fwd in software should be forward of the car.

[geduxaz]

Guys, there is too much miscommunication. If Johu (master of this system) now wrote that moving forward on reverse is OK, then i will continue this way.
If there was any setting that would swap phases for direction, i believe Johu would already wrote it. It is not the same as pinsawp for correct current measurement.

What i will try to do- i will try to play with resolver to get angle rising not falling.

[johu]

Really? There were some comments that this should not be used as this.
Is all the regens etc also working the same on reverse?

To my knowledge all tesla SDU people have to do that, same story there. Regen works the same in reverse.

[geduxaz]

Roger. Thats it. I will not try anymore to swap direction.

Tomorrow will make test rides and will continue on canbus messages to audi to make everything work.

SyncOfs is something 10000-11000. Now set at 10300.
Second offset is around 43000 but wheels have almost no power. All good when wheels in air, but no movement on the ground.
So i could say there is only one correct offset..

[Gregski]

luv it, followink

[geduxaz]

some test on the snow. Summer tires with no traction.
Also could make burnouts on the concrete.

Removed fuel tank, exhaust, fuel lines. In general nothing is left from the petrol system.

My wife gonna kill me. Its too cold and i think i am going to get ill