ZombieVerter VCU Support

[Jack Bauer]

Damien, great to see the Zombieverter is lurching ahead! We have our GS450H vehicle which has been running around for a few months, on fairly old code, with no real problems.

But I want to update it now, the main things we are missing are:
* Working regen
* Smooth current limiting
* Settable throttle response curve

I also need to add some CANBUS messaging to work with other components on the vehicle. Firstly accepting a current limit from the BMS.

My question: Is the current code available and build-able? I know it wasn't for a spell which is why we held off and worked on other stuff. I'll resume adding to the wiki!

Thank you.

The DM_Work branch on the repo is building and working in my cars. Ignore the master branch as the only thing left working in that is the web interface! I've had reports of jerky throttle response in 450h applications but of course no one has submitted a fix so if it is a sw problem its waiting on me to get the E39 finished and driving so I can diagnose and fix and push an update.

[Jack Bauer]

12v power supply to inverter without the vcu connected20221109_203056.jpg
All data cables reading 2.5v

That all looks sensible. Last question. Can you please take a high res photo of the ICs you fitted to the board.

[Beemer]

Have tried to attach a short video that's stored in my WhatsApp but it comes up invalid file extension any suggestions what I could do.

[Jack Bauer]

Just need a few pictures of the ics fitted by yourself.

[Beemer]

As requested

[Jack Bauer]

Also IC27,29 and 19 please.

[Beemer]

Last attachment should have been a 30 second video.

[Beemer]

As requested

[Beemer]

IC19

[Jack Bauer]

That all looks perfect thanks. There seems to be no obvious reason other than a wiring error to cause this problem. I think next step is to get the board back to me for a deeper look.

[Beemer]

Can meet up if suits as me and mrs taking short break to castlemartyr from this Wed 16th until Sat 19th

[Jack Bauer]

No thanks just pop in the post.

[Beemer]

Ok, can you confirm return address please

[Jack Bauer]

Sent you an email. Once the board arrives I'll do a diagnosis. A very strange failure mechanism. In other news the E39 is nearing readiness to drive so will now be able to investigate any throttle response problems with the 450h system first hand.

[Jack Bauer]

Annnnd yep we got a problem here. Looks like torque scaling is changed as well as direction handling in the toyota module. Doesnt show up on the bench as I only ever run the motors slowly! Investigating now.

[Jack Bauer]

That was epic. Update soon on the repo.

[FieroJam]

That was epic. Update soon on the repo.

Did you make the gauges work with a direct connection to Zom VCU?

[Jack Bauer]

Can driven from the vcu

[nkiernan]

That was epic. Update soon on the repo.

Nice

[Jack Bauer]

Just pushed an update to the repo :

https://github.com/damienmaguire/Stm32- ... s/tag/1.01

-Update the reported version to 1.01.
-Add use of PWMs as digital o/p. PWM1 use as digital charger enable / disable. PWM2 as digital "Run" mode indication.
-Verify GS450h driving in vehicle

The big ticket item on this release is the Lexus GS450H system control is now verified working in my E39 conversion at full voltage and road speeds. A video will be publicly available in a few days to prove this.

[et0]

The DM_Work branch on the repo is building and working in my cars. Ignore the master branch as the only thing left working in that is the web interface!

Awesome, DM_WORK built and loaded OK. Showing version 1.00 A

I've had reports of jerky throttle response in 450h applications but of course no one has submitted a fix so if it is a sw problem its waiting on me to get the E39 finished and driving so I can diagnose and fix and push an update.

Right, I can confirm that it's not really drivable now! Sort of on/off pulses as you accelerate? I can upload a video if you want.

I'll try to debug this, but can you give me a baseline for what should be working:

Regen: I see the new settings for it, but it still doesn't actually do regen. Should it?

Throttle ramp: Still a pretty aggressive and linear ramp, I've played with throtramp and throtramprpm, they seem to have no effect - should they?


Cheers.


Oops, I hadn't refreshed to see your update - I'll try the new new version!

EDIT: starting again, version 1.01 A now!

Unfortunately I still have the same result - intermittent pulses of power. Not like in your video (It was smooth like that previously though).

What am I doing wrong? I attached the parameters.

Final edit: I get the same behaviour with your .hex from the repo.

[Jack Bauer]

I got the VCU board back from Beemer. A Fan3121 has been fitted in position IC12 in place of the NCV8461. This kit would have shipped without the NCV8461 in any event as they were not available until about a week ago. This would have fed 12v into the 3v3 line and destroyed the microcontroller as well as most other devices I would imagine. Whoever fitted the parts failed to verify the positions on the schematic and BOM for IC12.

I just verified the BOM and schematic are correct :
https://github.com/damienmaguire/Stm32- ... OM_Rel.ods

[Jack Bauer]

Awesome, DM_WORK built and loaded OK. Showing version 1.00 A



Right, I can confirm that it's not really drivable now! Sort of on/off pulses as you accelerate? I can upload a video if you want.

I'll try to debug this, but can you give me a baseline for what should be working:

Regen: I see the new settings for it, but it still doesn't actually do regen. Should it?

Throttle ramp: Still a pretty aggressive and linear ramp, I've played with throtramp and throtramprpm, they seem to have no effect - should they?


Cheers.


Oops, I hadn't refreshed to see your update - I'll try the new new version!

EDIT: starting again, version 1.01 A now!

Unfortunately I still have the same result - intermittent pulses of power. Not like in your video (It was smooth like that previously though).

What am I doing wrong? I attached the parameters.

Final edit: I get the same behaviour with your .hex from the repo.

The difficulty I have is I can't replicate that problem. I bench tested this firmware and then built the drivetrain into a car and took it on the road. Not sure what else I can do. This morning I went 40 miles in the E39 with no problems. Car is on charge right now as it happens. I'm in now way saying there is not a problem its simply that I cant see it here and I've exhausted my options for testing. Perhaps someone else could do some diagnostics and help us all out ???

[Jack Bauer]

Lets try this : Do a plot of speed and torque. Speed on right and torque on left.

[et0]

Lets try this : Do a plot of speed and torque. Speed on right and torque on left.

Will do this tomorrow (I actually did it today but didn't capture it - it did show roughly the same as your plot above though).

Assuming the .hex on github is the same one you are using, I guess the only difference should be a setting. I am using "none" as the car type for example. I will try to debug it anyway.