[DRIVING] VW Beetle 2003

Tell us about the project you do with the open inverter
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Re: VW - Beetle 2003

Post by Pete9008 »

Just getting logging going on my F405 port and while looking at the logging thread to remind myself how to set up pulseview came across this Logged Plot Link.

It's pretty clear from the plot that the current ADC inputs are clipping. I commented on the funny flat top to the waveform at the time but didn't twig what it was. The flat top is the clipping and then the funny edge after it is the control loops recovering from the overshoot!
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Re: VW - Beetle 2003

Post by Bigpie »

Ahh yes, I remember. I've got the resistors but not got round to changing them yet.

Got pack 3 back out, need to manually balance a module, had a 0.2v delta and didn't have the patience for the balance resistors
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Re: VW - Beetle 2003

Post by Pete9008 »

Just noticed that you can see the effect of the clipping on the idc trace too. It looks like it goes up by 25%-33% during the clipping so that would suggest that the phase current might be going up from the 450A limit to 550-600A! That would definitely explain why it tripped!

Pain having to pull the cells back out, was the delta there when you got the cells or has it developed since?

Edit - forgot that idc is calculated not measured so the increase seen is just due to the change in PWM. The current increase could actually be higher than that!
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Re: VW - Beetle 2003

Post by Bigpie »

Was there from the start. I don't know what I was thinking not sorting it out before. At least they're just attached in the boot at the moment so only takes an hour to get out.
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Re: VW - Beetle 2003

Post by Bigpie »

Had the 3rd pack back in a couple of weeks now and very happy with the range boost. Not tested fully, but it's looking like 80 miles won't be an issue.

So, what's next?

Now I've got the GTE contactor/monitor board reverse engineered and can now request isolation tests, I'm working on a 3D printed case for the board so I can monitor isolation.

This car is probably mostly done now, maybe just some 12v wiring to tidy up and some rust to address. If it was a long term car I'd probably try and fit pack 3 where the fuel tank was.
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Re: VW - Beetle 2003

Post by Ev8 »

Awesome stuff Jamie, I’m looking and getting the extra 3 modules in mine in the next few weeks and then I’m mostly done also! Already thinking about the next project?
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Re: VW - Beetle 2003

Post by Bigpie »

Yea, got a leaf motor, VW charger, Yaris inverter and outlander AC pump already. Beetle was intended as a cheap learning project.

I've got a RAV4 2.2 diesel that only gets used for long trips or where I need a lot of space, possibly too rusty to convert but crazily considering it.

It's also a 2006 so still would be taxed. Need to decided what car, check it'll be insurable at a reasonable rate first.

Eventually want to get back to 1 vehicle
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Re: VW - Beetle 2003

Post by Alibro »

Bigpie wrote: Wed Jun 07, 2023 6:53 am Yea, got a leaf motor, VW charger, Yaris inverter and outlander AC pump already. Beetle was intended as a cheap learning project.

I've got a RAV4 2.2 diesel that only gets used for long trips or where I need a lot of space, possibly too rusty to convert but crazily considering it.

It's also a 2006 so still would be taxed. Need to decided what car, check it'll be insurable at a reasonable rate first.

Eventually want to get back to 1 vehicle
If I ever finish my project (or even get it on the road) my next car will be pre April 2001 and probably RWD so I can use a Lexus drive train.
Probably :lol:
Be careful of anything around 2006 as the tax went stupid around then.
I need a bigger hammer!
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Re: VW - Beetle 2003

Post by Bigpie »

We're on a trip to Wales :D Took 2 charge stops to get here, probably could've done just 1, but went with 2 to play it safe.
IMG_20230722_165048940_HDR.jpg
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Re: VW - Beetle 2003

Post by Bigpie »

Recently replaced the Teensy based BMS with ESP32 and that seems to be working great.
IMG_20230807_171329850.jpg
I made an intermediary connection so I could swap between Teensy and ESP32, but now happy enough to commit and remove the white Molex connector

Car also passed MOT today, 1 advisory that a numberplate bulb is out.

Also started working on trying to address this rust patch
20220817_134147.jpeg
Not perfect, but I guess it'll do.
IMG_20230810_141418703.jpeg
Hopefully wont look too bad with a bit more faffing and some clear coat.
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

And I'm out of action. I've killed the 5v supply on my board. I've got a little buck module on the 5v rail for the wifi module that's external. Connecting a new esp8266 in reverse polarity was a little stupid.
IMG_20230907_143359127.jpg
Hopefully that's all that's dead on the board.
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Re: [DRIVING] VW Beetle 2003

Post by Ev8 »

Sorry to hear hopefully a quick fix, I fear I’ll be off the road soon the sound of impending total failure of gearbox input shaft bearing grows louder every day :(
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

Hoping all it needs is that chip replacing, though it's left a little hole in the top layer so might cheat a little and place it elsewhere an run jumpers
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Re: [DRIVING] VW Beetle 2003

Post by Alibro »

Bigpie wrote: Thu Sep 07, 2023 4:32 pm And I'm out of action. I've killed the 5v supply on my board. I've got a little buck module on the 5v rail for the wifi module that's external. Connecting a new esp8266 in reverse polarity was a little stupid.
IMG_20230907_143359127.jpg
Hopefully that's all that's dead on the board.
OOOPS!
Hopefully an easy fix, can you test the other components in situ?
I need a bigger hammer!
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

Ev8 wrote: Thu Sep 07, 2023 5:52 pm Sorry to hear hopefully a quick fix, I fear I’ll be off the road soon the sound of impending total failure of gearbox input shaft bearing grows louder every day :(
That sounds like a lot of work :D It's almost as if we all need multiple projects.
Alibro wrote: Hopefully an easy fix, can you test the other components in situ?
I've applied 5v and the 3.3v rail powers up, the STM32 is working fine. The -5v comes to life too.
Ive applied 12v and the 26v comes to life. So as much as I can at the moment, it seems ok.
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

IMG_20230908_135106065_HDR.jpeg
New IC on and a jumper wire to replace the blown away trace and everything appears to be ok. Now to reassemble after a couple of coats of conformal coating.
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

It wasn't that easy. All day faffing and swearing but now replaced the -5v ic twice and now we're rolling again. Thankfully Rob has posted me some junk Prius boards
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Re: [DRIVING] VW Beetle 2003

Post by Ev8 »

Glad you’re back on the road, I did a gearbox oil change and sprayed some spray grease at the end on my coupling yesterday which seems to have improved my death rattle! Lol it the daily drive so can’t justify pulling it to pieces until something really breaks!
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

Same. Hated driving the diesel last couple of days, only positive is to that has half working Aircon
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

Erm, new problem. Some of my car has gone.
I've got a date with a welder.
IMG_20230923_160149150_HDR.jpg
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Re: [DRIVING] VW Beetle 2003

Post by Ev8 »

Ouch, shame your not more local as I’d happily do the welding for you
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Re: [DRIVING] VW Beetle 2003

Post by Alibro »

Bigpie wrote: Sat Sep 23, 2023 3:16 pm Erm, new problem. Some of my car has gone.
I've got a date with a welder.
IMG_20230923_160149150_HDR.jpg
Oops, :( hope the rot doesn't go too far.
I need a bigger hammer!
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Re: [DRIVING] VW Beetle 2003

Post by Bigpie »

I really dislike welding sills but oh well, I'll get some practice for if I decide the electric convert the rust bucket RAV4.
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Re: [DRIVING] VW Beetle 2003

Post by Gregski »

fantastic build, can I ask how many total electronic miles do you have on her by now?
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Re: [DRIVING] VW Beetle 2003

Post by arber333 »

Bigpie wrote: Sat Sep 23, 2023 3:16 pm Erm, new problem. Some of my car has gone.
I've got a date with a welder.
Same goes for my Mazda. I managed to just weld sheet metal under the rear wheel well. And i covered it with paint and construction hydro sealant paint Ibitol.
But now i see something rotting at the seams where you lift the car at front wheel wells. I will have to find a real metal former to get this sorted.
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