EV car conversion hardware

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Bratitude
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Re: EV car conversion hardware

Post by Bratitude »

Cookie6000 wrote: Tue Dec 01, 2020 1:51 pm Hi all

Just something I stumbled across today. I was out in the car and showing it to my local mechanic who also specialises in rally and track 1960's Mini's. He showed me what is used as a weapon of choice in small rally cars these days and according to him, takes an incredible amount of abuse and very rarely fails... unless you have a big crash :lol: . The Corsa C steering column, motor plus its own ECU which just needs 12v. Very tidy unit and it even fits the limited space offered under the dash of a 60's Mini. Loose when you are doing slow turning (they like it especially for autotest cars) and it tightens up when you are at speed. They usually hook it up to a speed sensor on a rear wheel but like my own, I could take the feed from the elec speedo pulse coming from the gearbox.
Corsa C Steering.png
Corsa C Steering ID.png
https://www.ebay.co.uk/itm/13136672-ste ... SwmtFfrEgQ
Has anyone fitted one of these before? They have come way down in price and from looking at eBay, they sit between £60-£150 which is incredible. They used to sit around £400. I am going to pick one up and see if it is a viable option for the 8e to remove the constant whine from the TRW Zafira pump. I may even be able to maintain the Audi's rack and be able to remove all hydraulic to free up space.

it’s very popular to fit Toyota Prius or Corolla eps columns. thousands of videos and posts about them. In the rally forums, there’s quite a few guys running them in there cars. plenty of old classics, etc.

they are cheap! Few places even have weld on/clamped splined Shaft collars to make the swaps very easy.


I’m looking at the Corolla eps and getting the ecu with LKE, so I can interface it with open pilot ;)
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Re: EV car conversion hardware

Post by Cookie6000 »

AH, very good. You are way further down the road thinking of Open Pilot than me :D Brave move. I am still at the stage where I am jumping at every noise the car makes... even though they probably made them when ICE powered.
New rabbit hole for me to jump down so! Thanks
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Re: EV car conversion hardware

Post by zippy500 »

This look interesting bit of kit to add to the corsa steering box

https://www.ebay.co.uk/itm/142463712424
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Re: EV car conversion hardware

Post by Bigpie »

@arber333, do you know if AEV14012 require an economiser?
VW Beetle 2003
Outlander front generator
Prius Gen 3 inverter (EVBMW logic board)
Outlander charger
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Chademo Charging
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Re: EV car conversion hardware

Post by arber333 »

Bigpie wrote: Wed Feb 10, 2021 4:05 pm @arber333, do you know if AEV14012 require an economiser?
Nope, it is triggered by normal 14V/12V and it is draining some 1/2A.

I tried with my old 30V variable PSU. I also reduced current to 300mA and voltage was 6V (CC mode) and it was still holding.
So theoreticaly you could use econo with it. But i would do some G testing on relay latching capability at that current.
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Re: EV car conversion hardware

Post by Bigpie »

Excellent. I'll not bother with one then, thanks.
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Re: EV car conversion hardware

Post by muehlpower »

I managed to get my VW / Audi air conditioning compressor running today. It works with a nominal 352V and is controlled with a LIN bus.
So far I haven't read much about the LIN bus here. But it's easier than CAN. There is a master (my controller) that sends headers, followed by 2 to 8 bytes of data and a checksum. Or only the header is sent and a slave (A/C kompressor) replies with 2 to 8 data bytes and a checksum.
In my case I have to send commands on ID 32 and get measured values ​​and status messages back on ID33. I have to send the desired speed, an activation bit and a start bit, then it runs and receives the current HV voltage, the actual speed and a temperature.
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Re: EV car conversion hardware

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Re: EV car conversion hardware

Post by arber333 »

chentron wrote: Sat Mar 13, 2021 5:16 pm what your opinion to use this for relay precharge ?

https://omronfs.omron.com/en_US/ecb/pro ... ej-1-e.pdf

or this ...
https://www.mouser.es/datasheet/2/164/f ... 285186.pdf
I have Omron 15A and i want to use it with a heater. But i still dont know if it will be OK. My heater is almost 5kW which is 12A at 400Vdc...
I highly recommend it as precharge relay.
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Re: EV car conversion hardware

Post by Bratitude »

Found this little company that makes a variety of Tesla charging ports and adapters
http://www.umc-j1772.com/index.php?rout ... duct_id=83
1775D862-3EC3-4750-88ED-D647AFA894E7.jpeg
1775D862-3EC3-4750-88ED-D647AFA894E7.jpeg (23.67 KiB) Viewed 105485 times
they look very well made
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Re: EV car conversion hardware

Post by mdrobnak »

At the price of that port you can buy yourself an actual port with cabling. No thanks.
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Re: EV car conversion hardware

Post by Bratitude »

mdrobnak wrote: Sat Mar 27, 2021 7:12 pm At the price of that port you can buy yourself an actual port with cabling. No thanks.

Definitely agree, but for some a oem won’t fit well in old full neck holes.

and it is only a alt j1772. No fast charging, as pins are to small.

when I have some spare cash, I’d like to pick up oem Tesla port and make a functional cad file
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Re: EV car conversion hardware

Post by golfdubcrazy »

muehlpower wrote: Tue Feb 16, 2021 6:24 pm I managed to get my VW / Audi air conditioning compressor running today. It works with a nominal 352V and is controlled with a LIN bus.
So far I haven't read much about the LIN bus here. But it's easier than CAN. There is a master (my controller) that sends headers, followed by 2 to 8 bytes of data and a checksum. Or only the header is sent and a slave (A/C kompressor) replies with 2 to 8 data bytes and a checksum.
In my case I have to send commands on ID 32 and get measured values ​​and status messages back on ID33. I have to send the desired speed, an activation bit and a start bit, then it runs and receives the current HV voltage, the actual speed and a temperature.
HI Amazing work.

please add more detail used on what bits you have have to send the ac pump to start and run it?
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Re: EV car conversion hardware

Post by muehlpower »

golfdubcrazy wrote: Sun Mar 28, 2021 10:19 am
muehlpower wrote: Tue Feb 16, 2021 6:24 pm I managed to get my VW / Audi air conditioning compressor running today. It works with a nominal 352V and is controlled with a LIN bus.
So far I haven't read much about the LIN bus here. But it's easier than CAN. There is a master (my controller) that sends headers, followed by 2 to 8 bytes of data and a checksum. Or only the header is sent and a slave (A/C kompressor) replies with 2 to 8 data bytes and a checksum.
In my case I have to send commands on ID 32 and get measured values ​​and status messages back on ID33. I have to send the desired speed, an activation bit and a start bit, then it runs and receives the current HV voltage, the actual speed and a temperature.
HI Amazing work.

please add more detail used on what bits you have have to send the ac pump to start and run it?

to control the A/C
ID 32 (0x20)
length 6 Byte / ENHANCED Checksum
Byte 0 =RPM (dec 20-250)
Byte 1 bit 2 = aktivate
Byte 1 bit 0 = start
Byte 2-5 = 0

back message:
ID 31 (0x61)
length 8 Byte / ENHANCED Checksum
Byte 0 =1 at HV voltage under 200V, =0 above 200V (below 200V it want work, so its a kinde of HV OK)
Byte 1 =112, always, i dont know why
Byte 3 =RPM as set via PID=32 in Byte 0
Byte 4 =110 below 200V, =14 above 200V, =46 when er running.
Byte 4,5,6 =0, always, i dont know why
Byte 6 =temperature 160 at 24°C, i don't know the scaling and what themperature that is til now
Byte 7 =54 at 109V, =28 at 56V =83 at166V scaling: Voltage/2
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Re: EV car conversion hardware

Post by arber333 »

muehlpower wrote: Sun Mar 28, 2021 11:05 am
golfdubcrazy wrote: Sun Mar 28, 2021 10:19 am
muehlpower wrote: Tue Feb 16, 2021 6:24 pm I managed to get my VW / Audi air conditioning compressor running today. It works with a nominal 352V and is controlled with a LIN bus.
So far I haven't read much about the LIN bus here. But it's easier than CAN. There is a master (my controller) that sends headers, followed by 2 to 8 bytes of data and a checksum. Or only the header is sent and a slave (A/C kompressor) replies with 2 to 8 data bytes and a checksum.
In my case I have to send commands on ID 32 and get measured values ​​and status messages back on ID33. I have to send the desired speed, an activation bit and a start bit, then it runs and receives the current HV voltage, the actual speed and a temperature.
HI Amazing work.

please add more detail used on what bits you have have to send the ac pump to start and run it?

to control the A/C
ID 32 (0x20)
length 6 Byte / ENHANCED Checksum
Byte 0 =RPM (dec 20-250)
Byte 1 bit 2 = aktivate
Byte 1 bit 0 = start
Byte 2-5 = 0

back message:
ID 31 (0x61)
length 8 Byte / ENHANCED Checksum
Byte 0 =1 at HV voltage under 200V, =0 above 200V (below 200V it want work, so its a kinde of HV OK)
Byte 1 =112, always, i dont know why
Byte 3 =RPM as set via PID=32 in Byte 0
Byte 4 =110 below 200V, =14 above 200V, =46 when er running.
Byte 4,5,6 =0, always, i dont know why
Byte 6 =temperature 160 at 24°C, i don't know the scaling and what themperature that is til now
Byte 7 =54 at 109V, =28 at 56V =83 at166V scaling: Voltage/2
Hi

Amazing work. Reaaly good!
Can you also copy those two posts to VW section where it will be easier to find please.

BR

A
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Re: EV car conversion hardware

Post by golfdubcrazy »

Hi thanks im trying this now in the garage cant seem to get my compressor to work

im sending the message on
0x20 55 A0 00 00 00 00

inital responce from pump is

0x61 00 70 08 00 00 00 00

followed by a repeated

0x61 00 FB E8 FF FF FF FF

voltage to the compressor is 336V i have not bridged the pilot line as i belive its just a pass thru could there be anything else im missing

muehlpower wrote: Sun Mar 28, 2021 11:05 am
golfdubcrazy wrote: Sun Mar 28, 2021 10:19 am
muehlpower wrote: Tue Feb 16, 2021 6:24 pm I managed to get my VW / Audi air conditioning compressor running today. It works with a nominal 352V and is controlled with a LIN bus.
So far I haven't read much about the LIN bus here. But it's easier than CAN. There is a master (my controller) that sends headers, followed by 2 to 8 bytes of data and a checksum. Or only the header is sent and a slave (A/C kompressor) replies with 2 to 8 data bytes and a checksum.
In my case I have to send commands on ID 32 and get measured values ​​and status messages back on ID33. I have to send the desired speed, an activation bit and a start bit, then it runs and receives the current HV voltage, the actual speed and a temperature.
HI Amazing work.

please add more detail used on what bits you have have to send the ac pump to start and run it?

to control the A/C
ID 32 (0x20)
length 6 Byte / ENHANCED Checksum
Byte 0 =RPM (dec 20-250)
Byte 1 bit 2 = aktivate
Byte 1 bit 0 = start
Byte 2-5 = 0

back message:
ID 31 (0x61)
length 8 Byte / ENHANCED Checksum
Byte 0 =1 at HV voltage under 200V, =0 above 200V (below 200V it want work, so its a kinde of HV OK)
Byte 1 =112, always, i dont know why
Byte 3 =RPM as set via PID=32 in Byte 0
Byte 4 =110 below 200V, =14 above 200V, =46 when er running.
Byte 4,5,6 =0, always, i dont know why
Byte 6 =temperature 160 at 24°C, i don't know the scaling and what themperature that is til now
Byte 7 =54 at 109V, =28 at 56V =83 at166V scaling: Voltage/2
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Re: EV car conversion hardware

Post by golfdubcrazy »

never mind got my binary the wrong way round send 55 05 and it works

Huge Thanks you have been a massive help :)
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Re: EV Auto-Umbau-Hardware

Post by muehlpower »

golfdubcrazy wrote: Sun Mar 28, 2021 12:20 pm never mind got my binary the wrong way round send 55 05 and it works

Huge Thanks you have been a massive help :)
I'm glad to hear that it works

if you want to use the golf pressure sensor 4H0959126B to, you get an answer on PID[0] (0x80) 5 byte long and PID[36] (0x64) 4 byte long.

connector 42121300 1=GND, 2=LIN, 3=12V
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Re: EV car conversion hardware

Post by golfdubcrazy »

Thanks this is what i have found scanning an a3 etron climate but as it wasnt connected to car

64 data in 40 00 28 68 classic ac pressure sensor

a8 data in 0B 02 1d 02 a2 31 2b 02 enhansed air quality sensor

e7 data out FF FF 94 6c 70 00 5a ff enhansed No responces

50 data in 2E 97 06 3d 02 44 80 31 enhansed air quality sensor humidity

f0 data in fan ?(ptc heater ?)
32 data in fan ? (ptc heater ?)

ca data out fe 63 00 3f f3 ff enhansed fan speed output ?
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Re: EV car conversion hardware

Post by muehlpower »

I made a couple of measurements. In the first column is the applied test pressure in mbar, in the second and third the value transmitted by PID 36 and PID 0. 16.38 and 8.18 are the multipliers to get the results in the last two columns. I don't know why these are should these values, it doest'n make sense with any known pressure units.
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Re: EV car conversion hardware

Post by Domt177 »

How are people controlling water pumps / cooling fans when the battery gets too hot from fast charging or track days?
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Re: EV car conversion hardware

Post by arber333 »

I have found a good spring enhancement system with TUV to fight the increased rear weight.
You put spring into spring and you can haul extra 90kg. I think i will buy one set for my Pug too keep it from taking off.
https://mad-suspensionsystems.com/en/
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Re: EV car conversion hardware

Post by arber333 »

Cookie6000 wrote: Tue Nov 03, 2020 2:46 pm You can see here it fits directly into the vac boost servo and the vac pipe out. They all seem to be out there for between €15-€30 so, I might as well get one and give it a test.
ZafiraBoschVacSensor.jpg
Did you ever try that sensor? How did it go?

tnx
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Re: EV car conversion hardware

Post by Cookie6000 »

arber333 wrote: Fri Aug 13, 2021 8:09 am
Did you ever try that sensor? How did it go?
Since I got the VAG sensor working, the GM one went down the priority list. Once I have the cluttered bench cleared of multiple mini tasks, I'll get back to it. I am pretty sure it was something simple I was missing
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Re: EV car conversion hardware

Post by arber333 »

Cookie6000 wrote: Fri Aug 13, 2021 7:28 pm Since I got the VAG sensor working, the GM one went down the priority list. Once I have the cluttered bench cleared of multiple mini tasks, I'll get back to it. I am pretty sure it was something simple I was missing
I jusr ordered one GM sensor. Will publish what i find out.
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