i3 controller hacking from diyelectriccar.com

golfdubcrazy
Posts: 45
Joined: Thu Jan 28, 2021 6:15 pm

Re: i3 controller hacking from diyelectriccar.com

Post by golfdubcrazy »

as always its been too long, but i decided to make my own custom housing, trying to keep everything compact. just got to cad up the capacitor. hard part is trying to keep all the water cooling but still be machinable
Attachments
i3 inverter mockup .jpg
User avatar
MrX
Posts: 19
Joined: Tue Aug 17, 2021 2:19 pm
Location: Down Under 🦘

Re: i3 controller hacking from diyelectriccar.com

Post by MrX »

So I have had some failures followed by some successes, followed by confusion :lol:

After bricking my Mini Mainboard with a firmware update (bad wifi connection dropout!), buying a Tag-Connect and STLINK, reprogramming following https://openinverter.org/forum/viewtopic.php?p=40323& (thanks for the hint using the .hex file Johannes), we are back to problem solving!

I have gotten closer to trying to solve my lack of drive signals, but more confused.
MrX wrote: Wed May 04, 2022 12:37 pm So it's not the 32V supply that collapses but DC bus voltage? Are all IGBTs good? deadtime set to 63? All gate drive signals sane when they arrive on the IGBT board?
All IGBTs are fine, gatedrive signals at inverter board are good and deadtime is at 63. I need to follow the signals to the gate drive board using the pinouts way back at the start of this thread, to be fair. One point to note: bus voltage is not dropping at the inverter, it remains constant.
MrX wrote: Wed May 04, 2022 12:37 pm Johannes, just in case you had something specific in your setup, was there a minimum voltage you had on the DC bus to make the inverter work? Also, do you have any information on the approximate power consumption on the 12V system when switching? My standby current seems very low, less than 0.5A on the 12V circuit.
This is where it is weird:
If I supply some reasonable voltage to the bus caps (>25VDC), the gate driver powers up and draws ~5W from the supply and then the inverter can read the bus voltage and phase temperatures via SPI. If I then run the inverter in Manual Mode, the inverter will switch the gate driver for ~200ms, bus cap consumption will jump to 0.5A, then the bus cap consumption drops to 0A and the inverter audibly stops switching (obviously, gate driver has no power). This repeats continuously at ~1Hz until I stop the inverter (i.e. on for 200ms, off for 800ms approximately). However, if I give the bus caps less voltage (15-20VDC), the inverter appears to stay switching and consumption increases to about 0.5A @ 20V on the bus caps. However, the 12V input consumption stays constant (@ 0.2A, ~13VDC at my supply). I would have expected the 12V input power consumption to jump up as soon as the inverter starts switching the IGBTs.

Any hints or comparison from your setup Johannes? My guess is that you are the only one who has had this gate drive circuit switching with the mini mainboard.
User avatar
johu
Site Admin
Posts: 3549
Joined: Thu Nov 08, 2018 10:52 pm
Location: Kassel/Germany
Contact:

Re: i3 controller hacking from diyelectriccar.com

Post by johu »

Puzzled that boards still can be bricked :(
I think I mostly tested with 40V on the DC bus. Always observed the expected rise in power consumption. Won't be home for some weeks to come.
There is another DC/DC converter that sends power from the DC bus to the gate driver. Maybe that is related?
Support R/D and forum on Patreon: https://patreon.com/openinverter - Subscribe on odysee: https://odysee.com/@openinverter:9
User avatar
MrX
Posts: 19
Joined: Tue Aug 17, 2021 2:19 pm
Location: Down Under 🦘

Re: i3 controller hacking from diyelectriccar.com

Post by MrX »

johu wrote: Wed Jun 08, 2022 6:22 pm Puzzled that boards still can be bricked :(
I think I mostly tested with 40V on the DC bus. Always observed the expected rise in power consumption. Won't be home for some weeks to come.
There is another DC/DC converter that sends power from the DC bus to the gate driver. Maybe that is related?
A couple of interesting points on the cable running to the gate drive board:

Pin 35 (IGBT PSU 12V on) is low level 0V
Pin 17 (lower gate driver ready) is low level 0V. Notably, Pin 16 (upper gate driver ready) is 5V

Should pin 35 have 12V on it from the adapter PCBA? Mine does not appear to. Does that come from one of the ampseal inputs?

Edit* did not mention that I am aware of the DCDC off the DC bus caps. That appears to be okay. I see no increase in consumption from the 12V power when in manual run.
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

I'm pretty much there with the physical side of the inverter, I'll be popping a video up soon with the cut lines etc
Thought you might like to see it all together 😉
Attachments
IMG_20220622_170126_241.jpg
IMG_20220622_170119_612.jpg
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
User avatar
EV_Builder
Posts: 799
Joined: Tue Apr 28, 2020 3:50 pm
Location: The Netherlands

Re: i3 controller hacking from diyelectriccar.com

Post by EV_Builder »

Nice job! Well done! This is exactly what I meant. Was it easy/doable? Did you TIG weld it in the end?
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

I have a confession, please don't judge 😅
I ended up glueing it with liquid metal
I have never Tig welded before and my mig welding is questionable.

I figure it's not structural and when bolted together will be strong enough.

I have made two templates for the lower coolant area and will get some Ali cut and show you that when it's done.
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

A little off topic but would this scope be up to the job in hand?
I don't want to spend too much and this popped up locally
Attachments
Screenshot_20220623-081116.png
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
User avatar
EV_Builder
Posts: 799
Joined: Tue Apr 28, 2020 3:50 pm
Location: The Netherlands

Re: i3 controller hacking from diyelectriccar.com

Post by EV_Builder »

No problem offcourse. If you use glue or other stuff you might consider also the use of an extra sheet of alloy at the back modelled to the shape of the case rivets & glue etc.

But if it holds it holds..
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

EV_Builder wrote: Thu Jun 23, 2022 11:14 am No problem offcourse. If you use glue or other stuff you might consider also the use of an extra sheet of alloy at the back modelled to the shape of the case rivets & glue etc.

But if it holds it holds..
Thanks 👍
I'll let you all know how I get on
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

Does anyone have the pinout of the 12 pin from the resolver please?
I have looked through and can only see Hans has detailed the motor temp wires.
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
golfdubcrazy
Posts: 45
Joined: Thu Jan 28, 2021 6:15 pm

Re: i3 controller hacking from diyelectriccar.com

Post by golfdubcrazy »

This should be the pin out for the i3 resolver
Attachments
i3 resolver.png
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

Excellent thanks 👌

So I've been prodding the connectors and I've come up with this to go in tandem with the above pinout.
The grey block from the resolver Hans has already dealt with but I'll add some details too.

Working on the 12 pin connector I've taken pin 1 as the one by the dots.
Pins 1-6 go to the black connector
12 pin number 1 goes to black block pin 4 I think this is Sin H
Number 2 to black block 1 I think this is Sin L
Number 3 to black block 5. Ex H?
Number 4 to black block 2. Ex L?
Number 5 to black block 6. Cos H
Number 6 to black block 3. Cos L

Number 7 to grey block 1 blue
Number 8 to grey block 2 grey
Number 9 to grey block 3 red
Number 10 to grey block 4 grey
Numbers 11 + 12 unused

The question is which Temp wires do we connect to pins 17+18 on the board?
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
Scott166
Posts: 80
Joined: Thu Jun 04, 2020 12:23 pm
Location: Dorset, England

Re: i3 controller hacking from diyelectriccar.com

Post by Scott166 »

Found it!
The two temp sensors go to the stator and rotor (at the bearing)
Attachments
Screenshot_20220624-070620.png
Restoring and converting a Classic Mini, I have mad ideas, semi sensible ideas and NO idea if I’ll ever get it done :lol:
Look me up on YouTube https://youtube.com/channel/UCxmP1hLys6Z5tHZpK5mn6eg to see my progress
User avatar
EV_Builder
Posts: 799
Joined: Tue Apr 28, 2020 3:50 pm
Location: The Netherlands

Re: i3 controller hacking from diyelectriccar.com

Post by EV_Builder »

That documentation is confusing it states 3 sensors are present and only states two connections. I think that one connection has 2 sensors of the stator in parallel. So you will read half the signal.

If you see in the connection list it only states 2x stator but no rotor sensor. The diagram also looks to omit the rotor sensor l..
Post Reply