Communicating with the Lexus GS450h Inverter/Converter

Topics concerning the Toyota and Lexus inverter drop in boards
xp677
Posts: 407
Joined: Sat Jul 27, 2019 10:53 am
Location: UK

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by xp677 »

sfk wrote: Sat Oct 19, 2019 5:25 pm Could someone with GS450h inverter please give me rough dimensions and weight? I need this info for freight estimates.

Thanks
Overall height (oil pan to top of bellhousing) is 39cm. Bell housing is full height, i.e. 39cm diameter, when the transmission is sitting on its oil pan (as it is on my bench), the bellhousing still just about touches the bench.

Widest point is 40cm, includes a bump for a starter motor which I don't believe the GS450h even has. Likely leftover to mate with the 2GR engine.

Overall length including tailshaft, output flange, and pilot shaft, is 82cm.

Transmission is tapered quite heavily, the width and height is closer to 25cm after the bellhousing, but hard to gauge due to various outcropping parts (motor cables, oil pump, PRNDL selector, etc)

Weight feels like in excess of 100kg, I'd say closer to 120-150kg.
User avatar
sfk
Posts: 288
Joined: Mon Jan 14, 2019 8:29 pm
Location: Wellington, NZ

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by sfk »

That's very useful thanks!

I was asking about the inverter though. You have that I assume?
-< Mazda Eunos JC Cosmo rotary -> EV conversion w/ Lexus GS450H gear >-
User avatar
arturk
Posts: 146
Joined: Wed Oct 02, 2019 3:58 am
Location: United States, MD

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by arturk »

Inverter specs

Weight: 40 lbs
Dimensions: 14" x 9-1/2" x 8-1/2"
1998 Jaguar XJR, GS450h drivetrain, 48kWh/96s BMW battery
User avatar
sfk
Posts: 288
Joined: Mon Jan 14, 2019 8:29 pm
Location: Wellington, NZ

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by sfk »

Excellent 👍
-< Mazda Eunos JC Cosmo rotary -> EV conversion w/ Lexus GS450H gear >-
ajh
Posts: 1
Joined: Mon Oct 21, 2019 5:25 am

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by ajh »

sfk wrote: Mon Oct 14, 2019 5:43 pm I have found plenty in Japan but just got a shipping quote of NZ$2500 so that's probably not a realistic option.
Hi SFK, I've been reading your posts as I'm looking at doing a similar conversation as you.
I too have been keeping an eye on GS450h's from Japan and have had rough quotes of only $200ish to get them to Australia using Import Monsters postage calculator, can't imagine it being that much more getting one to NZ, might be worth getting some other quotes.
User avatar
sfk
Posts: 288
Joined: Mon Jan 14, 2019 8:29 pm
Location: Wellington, NZ

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by sfk »

Yeah thanks. I actually heard about Import Monster and made enquiries with them. They basically sell space in a shipping container but only import into Aus. They told me they don't do the same for NZ because we don't import containers here anymore?!?!

Not entirely sure what they meant by that as there are container ships in every major port here. In any case, they can't help, and couldn't suggest an alternative sadly.

I'm still looking for freight options and have found another possibility. I'll add the details to my tiny build thread.
-< Mazda Eunos JC Cosmo rotary -> EV conversion w/ Lexus GS450H gear >-
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

I'm going to need a hacksaw
EVPanda
Posts: 11
Joined: Fri Apr 26, 2019 6:22 pm
Location: United States

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by EVPanda »

I'm so excited to see this work!! Great job!
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

Pleased to announce first successful tests of the controller. Video on the way:)
Attachments
2019-10-27 11.30.50.jpg
2019-10-27 11.30.46.jpg
2019-10-27 11.30.34.jpg
2019-10-27 11.30.27.jpg
2019-10-26 15.44.48.jpg
I'm going to need a hacksaw
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

and the video :
I'm going to need a hacksaw
xp677
Posts: 407
Joined: Sat Jul 27, 2019 10:53 am
Location: UK

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by xp677 »

Excellent work! At this rate, you'll have it running in a car long before I get mine off the bench ;)

I have some basic code for the oil pump controller, it's just 12V PWM, the duty cycle range is interesting, I had it written down but I'm not sure where, not too hard to find again with a frequency generator.

Still on my list is the converter, my aim is to have it running "backwards", i.e. converting the DC bus voltage (which is now directly connected to the battery) to something sensible to connect the charger and DCDC converter, etc. Simplest way looks to be to drive the IGBT gate drivers directly from an Arduino Nano or similar, which fits inside the inverter casing. I just need to "play" more to discover which pin is which.
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

My plan is to try running at 400 to 450v at first and see how it performs. Makes life easier with chargers etc.
I'm going to need a hacksaw
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

Got the pump controller fitted and now running from the main controller via pwm at 1khz. Pump speed is straight proportional to pwm duty. Needs a pullup resistor of 1k to 12v. Seems to take around 25amps at 50% speed. Last piece of the puzzle is to lock the input shaft then can start testing in the car.
Attachments
2019-11-07 15.36.14.jpg
2019-11-07 15.36.07.jpg
I'm going to need a hacksaw
User avatar
sfk
Posts: 288
Joined: Mon Jan 14, 2019 8:29 pm
Location: Wellington, NZ

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by sfk »

So close to victory
-< Mazda Eunos JC Cosmo rotary -> EV conversion w/ Lexus GS450H gear >-
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »



Posting this in the 7 series build thread also and will move over there for the car based bits keep this thread clean for controller development.
I'm going to need a hacksaw
Dilbert
Posts: 402
Joined: Mon Aug 12, 2019 7:21 pm
Location: Dublin, Ireland

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Dilbert »

Great work! I wonder would it be possible to use dual or quad rs485 drivers for the inverter interface. Was there a particular reason for the Sam Microcontroller?
xp677
Posts: 407
Joined: Sat Jul 27, 2019 10:53 am
Location: UK

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by xp677 »

The SAM microcontroller has an onboard USART, which is necessary for this project. There are plenty of other microcontrollers which have this. The STM32F7 series springs to mind. An advantage of the SAM3X8E is that is is found in the Arduino Due, so is easy to find information on. The Due is also an open source board, so much of the work in integrating the microcontroller has already been completed by Arduino. The SAM controller is also well priced, and is well featured for a powertrain controller. I have "maxed out" the SAM controller in my personal project, tasking it with controlling a cooling system, integrating cruise control, etc. So there is plenty of potential in these controllers.

I imagine that a set of RS422 or RS485 drivers would work fine, depending on their capability. CAN transceivers are plentiful, cheap, familiar to many of us, and fit the specification, but that doesn't mean that there aren't other equally valid options around! I chose a different transceiver to Damien, I used the MCP2562, which is a 5V transceiver with selectable logic levels on Tx/Rx, important for the 3V3 SAM microcontroller.
User avatar
arturk
Posts: 146
Joined: Wed Oct 02, 2019 3:58 am
Location: United States, MD

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by arturk »



I am happy to informed I got my Lexus GS450h drive-train spinning.

After two years of planning for my EV conversion finally I have key components ready.
I am not trying to hijack this thread for my build (I may create my own at some point) but to express my appreciation to group of brilliant individuals who made it possible.

Here is few details on my project:
Drive-train is going to be installed in my 1998 Jaguar XJR (my equivalent of Damien's "Super Yacht" ;) )
It seems to be the best option for large rear drive sedan.
I am driving it by 2007 Toyota Camry Hybrid inverter which is nearly identical to Lexus GS450h and it is even more affordable.
To control inverter I have built SAM3X8E controller based on Damien's plans and software. The only update I made to software was adding support for pre-charge relays.
On my test bench I am powering it by old Prius battery configured as ~110
Everything seems to work well and I cannot wait to install it into Jag.

Anyways, I wanted to share my progress with the community. Video is quite terrible but that's best I can do for now.
1998 Jaguar XJR, GS450h drivetrain, 48kWh/96s BMW battery
User avatar
sfk
Posts: 288
Joined: Mon Jan 14, 2019 8:29 pm
Location: Wellington, NZ

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by sfk »

Congratulations! This tech is an important break though.
-< Mazda Eunos JC Cosmo rotary -> EV conversion w/ Lexus GS450H gear >-
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

Fantastic:)
I'm going to need a hacksaw
User avatar
Kevin Sharpe
Posts: 1345
Joined: Fri Dec 14, 2018 9:24 pm
Location: Ireland and US

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Kevin Sharpe »

arturk wrote: Sun Nov 17, 2019 2:23 am I am not trying to hijack this thread for my build (I may create my own at some point) but to express my appreciation to group of brilliant individuals who made it possible.
Please do create a project thread... it really helps us grow the community and promote open source :D
arturk wrote: Sun Nov 17, 2019 2:23 am Video is quite terrible but that's best I can do for now.
It's a great video and gets the point across perfectly, well done!
This is a personal post and I disclaim all responsibility for any loss or damage which any person may suffer from reliance on the information and material in this post or any opinion, conclusion or recommendation in the information and material.
Dre.esky
Posts: 9
Joined: Mon Nov 11, 2019 3:59 am

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Dre.esky »

arturk wrote: Sun Nov 17, 2019 2:23 am

I am happy to informed I got my Lexus GS450h drive-train spinning.

After two years of planning for my EV conversion finally I have key components ready.
I am not trying to hijack this thread for my build (I may create my own at some point) but to express my appreciation to group of brilliant individuals who made it possible.

Here is few details on my project:
Drive-train is going to be installed in my 1998 Jaguar XJR (my equivalent of Damien's "Super Yacht" ;) )
It seems to be the best option for large rear drive sedan.
I am driving it by 2007 Toyota Camry Hybrid inverter which is nearly identical to Lexus GS450h and it is even more affordable.
To control inverter I have built SAM3X8E controller based on Damien's plans and software. The only update I made to software was adding support for pre-charge relays.
On my test bench I am powering it by old Prius battery configured as ~110
Everything seems to work well and I cannot wait to install it into Jag.

Anyways, I wanted to share my progress with the community. Video is quite terrible but that's best I can do for now.
Congratulations 👍🏼 Looking forward to seeing more. You guys are truly an inspiration
User avatar
arturk
Posts: 146
Joined: Wed Oct 02, 2019 3:58 am
Location: United States, MD

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by arturk »

As far as REVERSE mode.

My understanding was that MG2 sniping in opposite direction to DRIVE mode would be used to accomplish it.
I was trying to update Damien's code to make MG2 spin in the opposite direction without luck.
When I request negative torque (per inline comments):

Code: Select all

mg2_torque=get_torque(); // -3500 (reverse) to 3500 (forward)
motors will not spin at all :(

Was anyone able to get REVERSE working?
1998 Jaguar XJR, GS450h drivetrain, 48kWh/96s BMW battery
User avatar
Jack Bauer
Posts: 3414
Joined: Wed Dec 12, 2018 5:24 pm
Location: Ireland
Contact:

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Jack Bauer »

Not tried reverse as yet. Will do in a few days.
I'm going to need a hacksaw
Dre.esky
Posts: 9
Joined: Mon Nov 11, 2019 3:59 am

Re: Communicating with the Lexus GS450h Inverter/Converter

Post by Dre.esky »

Jack Bauer wrote: Sun Oct 27, 2019 1:54 pm and the video :
Still waiting on my inverter and transmission, been following the thread so I can accumulate parts. Can you show in detail the connection between the inverter and your VCU and do I have to get the OEM connector for the inverter. Was hoping for a detail video on how the connect and program/operate the controller on inverter.
Post Reply