GS450H gearbox with Camry inverter G9200-33171 [SOLVED]

[tom91]

ully charged, isa shunt max Amp report is around 120-129A, throttle all the way down

Can you please plot this for me. There might be some tweaking you can do to your Zombie code to get a few more amps out.

[PetersonOctavius]

im at 350volts now, should i charge first?

[tom91]

No need, I want to see the sag reported. Please plot left UDC and invUDC and right IDC

[PetersonOctavius]

after 1 plot, the vcu will not start another plot

[tom91]

Was this flat out? Can you do IDC right and Potnom left?

Just want to see how much "throttle" is left

[PetersonOctavius]

throttle to the bottom!

[PetersonOctavius]

throttle wasnt fully pressed (user error, to focus on the logging and the end off the road ahead)

[tom91]

Can you please post your params.

[PetersonOctavius]

freshly downloaded

[tom91]

So you can change the values here in GS450h.cpp

Code: Select all

758        htm_data[81]=(10000)&0xFF;  // discharge ability of battery
759        htm_data[82]=((10000)>>8);

I changed them to this to get more power before, I would say change it to 12500 and test if you get more power. If not there may be another limit like the Torque requested which we can also look at.

[PetersonOctavius]

New code will be then:

758 htm_data[81]=(12500)&0xFF; // discharge ability of battery
759 htm_data[82]=((12500)>>8);

[tom91]

Yes, the line numbers are for reference. I do not know if you added new lines.

[PetersonOctavius]

changed the code to 12500, both lines.
went for a test drive, 124Amps at 340 volts

[Gregski]

My pack is made of samsung sdi cells, 67Ah, 3C peak
96 cells
That would be 67 x 3 = 201A
Fully charged, isa shunt max Amp report is around 120-129A, throttle all the way down

It feels more like a torque request limit

possibly have you logged your torque yet? when I did that on my VW Rabbit with the 3rd Gen Prius Inverter you can clearly see it pegs out at 3500 and wont go above that setting

[PetersonOctavius]

possibly have you logged your torque yet? when I did that on my VW Rabbit with the 3rd Gen Prius Inverter you can clearly see it pegs out at 3500 and wont go above that setting

im going to log torque now

[tom91]

possibly have you logged your torque yet? when I did that on my VW Rabbit with the 3rd Gen Prius Inverter you can clearly see it pegs out at 3500 and wont go above that setting

Nope thats a fixed zombie setting request. Made no difference raising it on your setup.

Potnom direct translates to it.

[PetersonOctavius]

quick run i did a while ago, potnom vs speed
never went above 6k rpm
negative rpm MG2 is forward on my setup

[PetersonOctavius]

after quite some days of driving around, same oil pump problem came back.
driving...after while the pump turns of. i've been running it with a separate PWM generator, 1kHz, 16%duty

i started to think its the oil pump controller.
i ve been building drones for almost 10 years now, so i have some ESC (electronic speed controller aka inverter in the ev world) laying around.
i soldered one on the oil pump, it spun really slow but i managed to move the car. drones esc's are sensorless, just plug it in, give it pwm, it spins away.

so can i say its the pump controller?

[Gregski]

i would go super basic and check and clean all them oil pump plugs and connectors and triple check its grounds

the little black side connector likes to break off and or bend its pins

[PetersonOctavius]

i ordered this pump

i opened, it seems to be a brushed dc motor, runs smooth.

on the bottom side, there s a + mark

when connected to 12.7volts, it pulled around 3-4 Amps.

its has a bigger and a smaller hole.
when i connected positive to positive, (as marked next to the pins) its sucks at the bigger hole, and pushes at the smaller hole.
with reverse polarity, it does the opposite which matches the gs450h pump, sucks from the smaller hole and pushes through the bigger hole.

im pretty sure it will make enough pressure to drive the car, for now i need an adapter so i can mount the pump to the gearbox.

[PetersonOctavius]

Turns out My oil pump is "dead".
the main reason those pumps die seems (to me) to be water getting in the brushless motor of the pump, which then kills the resolver board. without a resolver the controller will not turn the pump. that s why i could make the brushless motor spin with a sensorless ESC.

that being said i have 2 gs450h pump controller which i butchered the connectors, but they still work, but i have no pump because the resolver board is damaged.

in other news, im trying to fit the BMW oil pump to 450h gearbox, i 3D printed an adapter to directly mount the pump to the gearbox, but the pump's mounting holes and the gearbox's hole interfere with each other.

oil lines will be the way to go. now i gotta but that 99$ adapter for the GS450H

[robertwa]

Just a thought - I wonder if it would be possible to remove the impeller from the stock pump, mount it back in place, and add an inline pump across the two ports that are used for an optional oil cooler circuit....

[PetersonOctavius]

i m trying to do something similar, but still using the original oil pump head

[jrbe]

You could add an oval pocket for the oil flow. Or you could drill on an angle to connect the 2. It complicates it but you could do a double stack plate with the oval port between them. And flush head bolts are your friend for things like this.

You could also consider a vesc to run the dead pump. You can write a Lua script to set the pump rpm to maintain a pressure. Pretty sure you can use a vesc analog input from a pressure sender to reference. Just make sure the vesc you pick can run comfortably at your 12v voltage and check the Lua script limitations first.

[PetersonOctavius]

Hey jrbe, that's quite a sketch you made there. i understood it partially, im not that good of a designer, and here on the island the machineshops couldnt fabricate something like that.

the easiest way would be indeed to use the "dead pump" , ive attached a drone esc to it, it did spin and create some pressure to move the car, but not enough as the would go into free spin time to time.

the oil pump has 12 coils in the black casing and 8 magnets on the rotor, not sure if the coils are in a Y of ^ config
the esc im using is rated 26volts 35Amps.
i dont have much options on the esc to try to make it run faster at 12-14 volts