Motor stuttering on test bench, help needed [SOLVED]

[hox]

Hello everyone, this is my first attempt at using the OI prius G3 board by Damien.

I have setup the connections and testing with a 55V HV battery with appnum set to 100 and fslip set to 10 but the motor keeps stuttering and struggling to rotate. I have checked connections and verified they are intact. Testing on both MG1 and MG2 motors produce the same result and I am at a loss on what to do next.

Please help.

[johu]

Try starting at a lower frequency in fslip, like 2 or 3 Hz and increase slowly. Also sometimes lower ampnom is beneficial. Sync motors don't run very well in this test mode

[hox]

Thank you @johu.

I got it to spin by increasing boost to 25,000. Is that safe?

Also do you have an idea if there's a link to read about all the parameters?

[johu]

https://openinverter.org/wiki/Parameters

[hox]

I appreciate. I am now preparing for FOC tuning

[johu]

I am now preparing for FOC tuning

FOC DOES NOT RUN Tesla SDU/LDU

Edit: sorry, correction below

[uhi22]

It would be great, if the guys who did not know this would add this lesson in the wiki, in a way which is understandable for beginners. This would help a lot in the future, and avoid confusion.

[johu]

Wait, what on earth was I writing. Mixed up the threads where a guy ran foc on his Tesla LDU
Sorry about this

[hox]

It’s okay, I’m back for more help.

I was unable to get it to spin using manualid in FOC. Is the wiring right in this format?

Inverter MG2 port —- 1,2,3 connected to transaxle MG2 port —- 1,2,3 in that order


When applying manualid with any current value, the motor doesn’t spin but gets very hard to turn by hand. Any pointers where I could be wrong?

[johu]

Actually it means your syncofs is already correct. It should spin backwards and forwards with - +manualiq

[hox]

Great, I returned to post about the success after moving over to MG1 but retrying on MG2 I discovered the parking brake is engaged and I am unable to disengage it, is there anyway I can disable the parking brake?

Also, after switching over the first and last phase cables I was able to get MG1 spinning and also control with throttle pedal

[hox]

So another update, it seems parking brake isn't the issue with the MG2 but the motor won't rotate. Pressing the throttle pedal will make it want to move but will give a clunking sound and stutter. I have switched phase connections around without success.

I am quite confused on what to do now.

[johu]

Can you manually turn it?

[arber333]

So another update, it seems parking brake isn't the issue with the MG2 but the motor won't rotate. Pressing the throttle pedal will make it want to move but will give a clunking sound and stutter. I have switched phase connections around without success.

I am quite confused on what to do now.

Verify your resolver connection. PMSM motors will do that if they dont see correct rotor position info.
Do you use OEM cable? How do you connect resolver on inverter side?

I also think you may need more dc voltage. More than 60Vdc would be good...

[hox]

Can you manually turn it?

Yes, I can turn the wheel shaft cup facing the splined shaft. Turning the cup rotates the splined shaft but I’m unable to turn the cup for the other wheel facing the external oil pump.

[hox]

Verify your resolver connection. PMSM motors will do that if they dont see correct rotor position info.
Do you use OEM cable? How do you connect resolver on inverter side?

I also think you may need more dc voltage. More than 60Vdc would be good...

The resolver connections are correct because they work fine on MG1.

I will try with higher voltage today. Thank you.

[hox]

@arber333 A very big hug from me to you. After hours troubleshooting, I decided to recheck my MG2 resolver wiring and discovered that I had wired it backward as a result of wrong orientation. It is working now on MG2 though I am still getting pauses while it's running.

@johu Thank you too for the immense support.

[arber333]

@arber333 A very big hug from me to you. After hours troubleshooting, I decided to recheck my MG2 resolver wiring and discovered that I had wired it backward as a result of wrong orientation. It is working now on MG2 though I am still getting pauses while it's running.

@johu Thank you too for the immense support.

Good to e of help
Inteerrmttent jumps mean either (1) is a lot of EMI on the line or (2) your position does not quite go with phase advance. If that case you need to recalibrate the FOC parameters.

If problem one, then connect at least 6mm2 cable between motor case and inverter case
If problem persists try to use shielded cable for resolver and couple it from motor to inverter.

[hox]

I will try that.

What will you advice I look into to resolve a situation where the motor keeps running on max speed if throttle is applied fast and won't obey throttle press until inverter is stopped?