Lexus Inverter Hacking

Topics concerning the Toyota and Lexus inverter drop in boards
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PacEmaker
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Re: Lexus Inverter Hacking

Post by PacEmaker »

Cyruscosmo wrote: Fri Feb 14, 2020 2:35 am Hello all.

I have a question for you. Would it be possible to use this "inverter hack" to power only the larger of the two motors from the GS450h transmission case for acceleration and regen braking/battery charging?

What I would like to accomplish is adding an electric assist and regen braking to my truck making it like a hybrid except that if the system goes dead the truck will still function.

What I would like to do is as follows. Remove the larger of the two motors from the GS450h case along with supporting hardware, build a new case for the removed GS450h parts and then install this device between the transmission and rear differential of my truck.

The 4x4 version of my truck has a transmission with a rear flange that the transfer case mounts too. I would like to mount the new GS450h motor case in place of the transfer case in my two-wheel-drive truck essentially turning the whole thing into a hybrid without it being an actual "Hybrid".

My reason for doing this is that Washinton has recently jacked up the licensing fees for electric and hybrid vehicles. I thought the whole point was to encourage people to buy electric and hybrid vehicles. Anyway, I sold my electric Geo after the price hike and have been following this thread since day one having followed Damian over here from the Open Revolt forums. It is time I get into the AC Drive game. ;-)
Hello Cyruscosmo! What is this 'truck' of which you speak? In some parts of the world 'truck' sometimes seems to mean a 'pick-up truck' (i.e. those slightly over-size utes that you guys in the USA drive) whereas some of us in other parts of the world use the term 'truck' to describe an actual truck.

Also, agreed it is indeed time to get into the AC Drive game... ;-)
Geoff

Is this smoke trying to tell me something ... :twisted:
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Re: Lexus Inverter Hacking

Post by xp677 »

Jack Bauer wrote: Thu Feb 06, 2020 10:02 am Here is a look at the back of the board with the enable line. The yellow wire needs to be pulled to ground if memory serves. I'll power it up over the weekend and confirm.
Thanks Damien, I've had a look. It doesn't appear that there are any traces coming from the resistor (R648) you removed, on my board or yours. Not sure what's going on there. Maybe a via directly beneath the pad, not sure why they would do that as there is ample space nearby.

Pulling the yellow wire to ground is the same as shorting across the diode, as the Anode of that diode (D613) is at GND, so my plan is to just replace D613 with a 0R resistor and remove R648.

If you can let me know how you get on with confirming the converter before I start digging into this board, that would be great.
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Re: Lexus Inverter Hacking

Post by Jack Bauer »

I'm up to my eyes here guys. I can't get to everything.
I'm going to need a hacksaw
Cyruscosmo
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Re: Lexus Inverter Hacking

Post by Cyruscosmo »

To SFK...
In my research of the GS450h unit, it appears that I will be able to mount all the components into a smaller purpose-built case but I will not know until I get my hands on one and disassemble it. Before I do that it would be nice to know that what I propose would work electronically.

From my understanding of the discussion on this forum, I would need the rotor, stator, and reluctor from the original unit to make a complete drive. Sealed bearings would work in the new case but it is my understanding that oil is also applied to the motor coils for cooling so an appropriate oil pump and the cooling circuit would be needed as well.

To AlexStarex...
At this point, I have not seen the inside of a Prius transmission case so I am not sure if it would be as easy as the Lexus system. I will take a look at the Prius as well. Thank You

To jnsaff...
Removing the rear axle of my truck would defeat the purpose of making an “add on” unit. It would also change the GVW of the vehicle which would void parts of my insurance and require a re-inspection of the truck via the state patrol at which point they would add the hybrid or electric tag to the truck which is what I do not want.

I am working towards an “Add On Unit” that could potentially be sold as a kit to extend the range of my truck as well as others. Switching over to, and building an all-electric car for me was easy. To the majority of the population, it is as close to VooDoo as you can get without Hollywood subtitles. Also, the majority of the world is not in a monetary position to buy an electric anything because they are very very expensive. So I am working towards a simple kit that would be a bolt-in solution. Say if you had an older classic car you could add one of these, set a small battery bank in the trunk, fit a new shorter drive-line and now you have a basic hybrid that does not require cutting the car all to hell.

To PacEmaker...
The Truck in question at this point is a mid-size 2 wheel drive 2000 Dodge Dakota. I also have a 69 Ford F250 4X4 and a 1959 Ford F100 factory original 4X4. They are collector plated and don't get driven much as the 69 drinks fuel like it is water. I would love to get my hands on a Ute from down under to play with but the import cost is a bit much at this time for experimenting with. Maybe someday. ;-)
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Re: Lexus Inverter Hacking

Post by xp677 »

Jack Bauer wrote: Fri Feb 14, 2020 4:14 pm I'm up to my eyes here guys. I can't get to everything.
Thanks Damien, I appreciate all you've done, and thanks for the advice on the converter in the thread.

I did the PCB modification that you mentioned earlier, and it seems to work :). To boost the "input", I had to add a square wave to both gate driver inputs, not sure what's going on there, I guess that the converter logic board sorts that out - I'd have expected that driving both sets of IGBTs would short the input, but apparently not.

A 32% duty cycle takes a 12.5v input up to 117v. This is unloaded, however. I'll need to see what happens when I load this up.

Also need to look at bucking the DC bus. A great way to spend a rainy afternoon!

I'll have a play with the code and will start a thread on this converter with a "how - to".
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Re: Lexus Inverter Hacking

Post by Jack Bauer »

You can't short the input. Remember those Toyota engineers thought of everything:) Glad its working:)
I'm going to need a hacksaw
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Re: Lexus Inverter Hacking

Post by xp677 »

Jack Bauer wrote: Sat Feb 15, 2020 2:47 pm You can't short the input. Remember those Toyota engineers thought of everything:) Glad its working:)
Yep, not sure what logic goes on in there, I know there is a second driver board inside the "IPM" (IGBT assy), I guess that deals with it.

I was getting what I thought was short circuits when I triggered both inputs, turns out it was just my PSU hitting current limit.
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Re: Lexus Inverter Hacking

Post by xp677 »

Converter controller is here:

viewtopic.php?f=14&t=538&p=6582
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