[DRIVING] VW Touran powered by Nissan Leaf [FINISHED]

[Jack Bauer]

Its been ages since I played with this but I have a fleeting memory of needing to set the limit voltage way higher to avoid the evse shutting down on overvoltage. In fact I think the jld505 software handles the current taper once target is reached.

[johu]

Another attempt today. Good news: I can finally charge without ignition on

BMS current limits are relayed to the EVSE so I also don't need a sane target voltage. I set it to 450V and 460V limit only to discover that I still had the 410V constant in the CAN code

The longest stint was 2.5 kWh. After some random time it simply quits charging "as commanded by the vehicle". I couldn't see a state transition to ChargeEnd which would happen if the BMS signals a full battery. Also the commanded charge current was non-zero. Will retry later with the elevated voltage limit, maybe that was it.

Anyway the conclusion is that you do not need a dedicated CAN bus for ChaDeMo and also the EVSE doesn't care about the extra CAN messages.

[Jack Bauer]

Nice work. What brand was the fast charger? I remember some of them had terrible current regulation and would cause a kick in voltage that would trip the overvoltage limit. The higher the soc the more likely it was to occur.

[johu]

It's the one on the picture. ABB if I remember correctly

[johu]

Working through the list. Finished the rear brakes today, rerouted the charging cable, replaced the indicator inside the mirror. Before I replaced all cooling hoses with proper automotive hose and tidied up the LV wiring.

Only wishbone bushing to go.

There is also something with my battery mount, don't know specifically what exactly though. Hard to reach anyone. I'm hoping it won't open up a rabbit hole.

[arber333]

There is also something with my battery mount, don't know specifically what exactly though. Hard to reach anyone. I'm hoping it won't open up a rabbit hole.

What do they say exactly? I know if you have the battery inside the cargo compartment you need to fasten it to the force of 10G.
But if you have it under some sacrificial construction then you can make a finite element analysis (bolts) and approximate shear force to 4G since the metal around battery will help hold it in case of collision. Same goes for the under the hood battery. There hood cover helps you retain battery in case of frontal impact. I allways use tempered steel 10.9 bolts to fasten battery down. I think 12.9 are overkill and a bit brittle.

[johu]

It says "Befestigung Batteriesatz ungenügend" - "Mounting of battery insufficient". But no further details. I looked up data sheets for the mounting brackets and each is rated 2300N (I use 3). The rear ones are rated 10kN. The middle ones I couldn't find data for, it is a 3mm 50x50mm aluminium profile.
So say the total supported force would be 3x2300N + 4000N (assuming thats what the aluminium holds) we would be at 10.9kN. One brick weighs 90kG so at 4G we are talking 3.6kN. In other words the mounting would withstand 12G.

Apart from that I made a new video:

[Kevin Sharpe]

Apart from that I made a new video:

Great video

FYI it's still showing as "unlisted" on YouTube

[johu]

Great video

FYI it's still showing as "unlisted" on YouTube

Thanks First time with camera woman.

Yes it's unlisted: first appears for Patreons, then forum, then for all.

Thanks for sharing on twitter!

[rikohm]

"Mounting of battery insufficient" could they mean your 12v battery? Couldn't make out from the video if it was fastened inside the box..

[RetroZero]

Nice one Johannes, enspiring video!

[arber333]

"Mounting of battery insufficient" could they mean your 12v battery? Couldn't make out from the video if it was fastened inside the box..

I think you need to extrapolate in your technical report what you wrote here. So make an "engineering judgment" by using finite element analysis = bolts and prove them you were accounting for normal eventualities. They should be OK with that.

Oh... i just remembered that "screws" are used to only carry load in one direction (up - down) due to threads along their whole length which weaken them for shear loading. You get them in temper 8.8 which i deem insufficient. Its bearing strength is almost on par with construction Al alloy.

While "bolts" which have smooth surface for a good length of their body with threads only at the end are also used to carry some shear loads. They are usually to be found in different tempered states. Like i say i use 10.9 temper.
Maybe they think you should have used more bolts?
Also i use bolts and washers so that smooth part of the bolt is outside the bearing member for a milimeter or two and washer is raising nut so there are still 2 or 3 threads left...

Did you use bolts or screws on your mounts? I dont remember anymore. Could be that they deem they cant withstand shear (side) loading in an impact.

[johu]

"Mounting of battery insufficient" could they mean your 12v battery? Couldn't make out from the video if it was fastened inside the box..

Yes I was hoping for that. It is indeed not fastened - just by its terminal Used to be 40Ah cells that fit vertically but they were deep discharged and destroyed... So quick replacement.
The co-engineer told me it was something with the main pack.

I think you need to extrapolate in your technical report what you wrote here. So make an "engineering judgment" by using finite element analysis = bolts and prove them you were accounting for normal eventualities. They should be OK with that.

Yes I did, only the 12G estimate was something I came up with after reading your post again. Will give them a call tomorrow to clear things up.

Did you use bolts or screws on your mounts? I dont remember anymore. Could be that they deem they cant withstand shear (side) loading in an impact.

Only screws with threads all the way. You know the chassis has 5 "nuts" integrated and you drilled the other 3 holes

[arber333]

Only screws with threads all the way. You know the chassis has 5 "nuts" integrated and you drilled the other 3 holes

Right!

[johu]

Got mail from celeron55 today 3D-printed ChaDeMo plug complete with pins and cable - thanks very much!

Not using the CAN line yet as the charger still uses a Gen1 mainboard w/o CAN.

Apart from that it works fine and prevents the car from driving off while plugged in.

[JaniK]

Great stuff celeron55

And johu, much easier to develop code now?

[johu]

So another TÜV visit today. No result yet, he will check next week.

More importantly I fast charged from 20-80% without interruption and with 35kW

On the way I accelerated to 160kph in 4th I think there is more in a higher gear.

[mdrobnak]

So another TÜV visit today. No result yet, he will check next week.

More importantly I fast charged from 20-80% without interruption and with 35kW

On the way I accelerated to 160kph in 4th I think there is more in a higher gear.

Nice! Were the fixes for the fast charging difficult, or one of those 'the details will get you' kind of thing?

-Matt

[johu]

I don't even remember exactly. I think two main things I was asserting the charge allow flag to late and I stopped charging when the charger signaled "stop". Which really just meant "I have not yet started charging".

Look here: https://github.com/jsphuebner/stm32-car ... dfa101ad31

[johu]

It's done
Picked up Touran from TÜV today.
I would say it was not so hard. Just a bit pricey at roughly 600€, 300 of which were for the rather redundant noise test.

[celeron55]

Nice! Receiving one of those "not exactly for the average citizen" papers is always fun.

[RetroZero]

FÉLICITATIONS, CONGRATULATIONS .
Here's to many more Johu!

[mike77cos]

Congratulations on passing

[Kevin Sharpe]

It's done
Picked up Touran from TÜV today.

Well done, that's very cool

[johu]

Thank you all very much
So next video will be "taking Touran from Kassel to Saarbrücken (400km)". Lets see what surprises the German fast charging network comes up with