[DRIVING] VW Beetle 2003

[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!

[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

[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!

[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.

[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.

[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?

[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

[Alibro]

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
Be careful of anything around 2006 as the tax went stupid around then.

[Bigpie]

We're on a trip to Wales Took 2 charge stops to get here, probably could've done just 1, but went with 2 to play it safe.

[Bigpie]

Recently replaced the Teensy based BMS with ESP32 and that seems to be working great.

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

Not perfect, but I guess it'll do.

Hopefully wont look too bad with a bit more faffing and some clear coat.

[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.

Hopefully that's all that's dead on the board.

[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

[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

[Alibro]

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?

[Bigpie]

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 It's almost as if we all need multiple projects.

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.

[Bigpie]

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.

[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

[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!

[Bigpie]

Same. Hated driving the diesel last couple of days, only positive is to that has half working Aircon

[Bigpie]

Erm, new problem. Some of my car has gone.
I've got a date with a welder.

[Ev8]

Ouch, shame your not more local as I’d happily do the welding for you

[Alibro]

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.

[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.

[Gregski]

fantastic build, can I ask how many total electronic miles do you have on her by now?

[arber333]

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.