Prius Gen2 adapter board development thread

[MattsAwesomeStuff]

Would a Nissan Leaf motor be a suitable match or can anyone suggest another motor that might do the job?

The inverter will drive just about motor, so, you don't have to worry about compatibility there. Beyond that, it's a bit offtopic for this development thread as to which motor is suitable for your project. You could start a project thread I suppose.

[johu]

Finally I have on my desk what you've all been waiting for Almost at least. There are a couple of issues:
- The STM32 is rotated 90° It must be JLCs fault this time, the pin marker looked correct on my order
- The 3V3 pin on the programming points is not connected to 3V3 - my fault
- The reset pin on the programming is interrupted - my fault, but irrelevant, it is not needed for programming

The the last two items are easy fixed, the first one is a pita. Since I don't have a hot air station I cut the processor off and replaced it with a fresh one.

So far I've tested:
- new excitation circuit: works a treat! Even my 4Ohm (plus 10 Ohm resistor) test speaker doesn't make it run overly hot. Even though it consumes 1.4W. With the typical 30 Ohm exciter coil it should run cool.
- precharge and dcsw output mosfets: work, don't mind the turn-off spike
- Desat/power stage over current detection: at 5V5 it switches over to "all good"
- digital inputs: work

Will do more testing now, I think the current sensor circuit needs correction as I've upped the "5V" rail to 5.4V to have sufficient resolver amplitude but forgot to adjust the divider resistors for the offset voltage.

[RetroZero]

I've got goose bumps .... Gen 2 lock up gear in the design stage. Will be thicker than mock up and spot welded to carrier... Can't wait for the two to be introduced....I will post in gen 2 transaxle link later.

[ZooKeeper]

Oooooo, such GREAT news!

[Jack Bauer]

That's really bad luck with the stm32. I have never had them do that. One thing I did learn early on though was to put nice big markings on the silkscreen for polarity sensitive parts and pin 1 of packages. It might be worth turning the wifi header around on the next build.

[RetroZero]

Once your tests and mods are complete, I could be interested in a board, and have the STM rotated locally...Off in search of prius battery for testing purposes

[SciroccoEV]

I think the current sensor circuit needs correction as I've upped the "5V" rail to 5.4V to have sufficient resolver amplitude but forgot to adjust the divider resistors for the offset voltage.

That's why I derived the reference voltage from the 3V3 rail. Adding the buffer means it's a nice low impedance source so I can also use it for the resolver offsets too.

[MattsAwesomeStuff]

Since I don't have a hot air station[...]

You what?

How do you do all the things you do, and yet you've never spent $50 on a cheap hot air station?

How do you own a scope, without owning a hot air station?

The mind boggles.

However, can't wait until testing!

[RetroZero]

Thanks again, really useful when in lock down.

[RetroZero]

Oops, sorry, the message was for the posting of pin layouts inside the inverter.

[johu]

[Kevin Sharpe]

Great video Johannes

[konstantin8818]

Das ist toll!

[ZooKeeper]

....Video Update....

NICE!

I can hardly wait!!!!!

[Stephen Darbey]

Great Stuff Johannes.
Looking good. The board, not your head. !!

Regards and continued success.
Stephen

[Alibro]

WOO HOO!!!!!
Great stuff. I bought a Gen 2 Inverter a couple of weeks ago (£75 delivered ) thinking I would be using Damien's Blue Pill board but This looks like it will be easier to get working.

[RetroZero]

Hi the Johu, I assume Gen2 Version2 is in process?

[johu]

Yes it is but before reordering I have to discuss with JLC why they twisted the STM32 in the first place. There is a marker on the silk screen and I checked placement when ordering, not sure why they screwed up.

[RetroZero]

[Jack Bauer]

Johannes sent me one of the Gen 2 boards to have a play. So Colonel Kurtz and myself got to work. I think I see why JLC got the stm32 orientation wrong. The designator for C16 is just perfectly overlapping the stm32 footprint corner to make it look like a pin 1 mark!

[johu]

Yes it really does! I hope they don't repeat this in the current order. I did notify them of the mistake though.

[RetroZero]

Such attention to detail Colonel Kurtz, where would you be with out him!

[johu]

Aha, the next batch will arrive here on Monday. Hopefully with the processor aligned correctly.
I think they'll just get a quick optical inspection and power-up test so they can go on the shop sooner.

[RetroZero]

STOP THE TORTURE !
I would even pre order one to make sure I don't miss out..My precious

[johu]

Stopping the torture: https://openinverter.org/shop/index.php ... duct_id=63

The kit includes all connectors (except the 2-pin gate drive power connector)