EV Conversion using prius gen 2 inverter/transaxle

[tom91]

https://openinverter.org/wiki/Toyota_Pr ... Controller

I guess Johannes stopped selling it.

[johu]

Yeah demand was like 3 boards per year, not worth taking up space. I might do short revival as I'll need one board myself and always have to order 5.

[voti]

Is it possible to load throttle parameters in graph form?
I don't have the figures in front of me, but vaguely remember setting throttle. From what I remember:
There are 2 potentiometers.
Pot is for 0 to 4095 (digits)
Pot2 is the reverse 4095 to 0 (digits)

Setting Pot: note value when NOT pressed (example 500) - set your min value LARGER than this (example 550).
Now press throttle completely & note value (example 4500 - set pot max to LESS than this value (example 4200).
Pot 2 is done the same, except its the reverse of values because it reads in the opposite direction 4095 to 0.
Plot your graphs.
What you are trying to create are values where when no pedal is pressed, Pot is at 0, with a slight margin of play. The same is done for potmax.

Based on Retros response quoted above, I've attached two screenshots of potnom values before and after the throttle was pressed and not pressed.

Do I need to get json files or the screenshot will do.

Ok so basically when the throttle was not pressed pot1 790 and pot2 was 1875, And when pressed both gave values of 4095.
So now as Retro said that I should set NOT pressed value to a larger value, I added 50 to the 790 and got a value of 840. When throttle is pressed I subtracted 300 from 4095 and got 3795 like Retro explained.

Moving on to pot2. As mentioned that with pot2 things are vice versa now. When NOT pressed i got 1875 so I added 50 to that value and got 1925 and from 4095 of fully pressed i subtracted 300 and got 3795 again.

Now coming to adding the values in parameters,
On potmin I put our larger value of 790+50=840
On potmax I put our less value of 4095-300= 3795. This value was above potmax limit which is 3500 so I kept it at that 3500 value.
Then pot2min i added the values vice versa like instructed to, meaning for pot2min i added less value 4095-300=3795 and pot2max 1875+50=1925.
What is noted is that in parameters both pot2min and pot2max had values of 4095. While pot had potmin 0 amd potmax 3500. "Pleaser see attached screenshot.

Others parameters that i had set were:
Set ocurlim -1
Syncofs 10120
dirmode DefaultForward
Udcsw 0
ManualStart On

Manualid and manualiQ were left at 0.

RESULTS
The motor didn't spin.
I tried changing the values in parameters for pot and pot2, tried adding and reducing them to try and see if I get any different results but still the motor didn't spin.

Is there smelting im doing wrong. Did I miss Retros instructions, am I adding in the right values ??

[RetroZero]

Just to be sure. Without the throttle pedal connected, you can spin the motor in manual Mode without juddering? What battery voltage are you running?

[voti]

The motor is finally spinning
Please watch the video below to see what happens when I increased fslipspnt

The first time I had the motor spinning I was still using version 5.35.R-sine. And yes the motor did jitter as i increased fslipspnt. I've been test spinning the motor with 12v.
When I did a test pin with version 5.35R FOC. I remember the motor only spun in the forward direction and I couldn't get it to go into reverse. I think I remember it jittering aswell. Ill confirm this weekend

[blasaab]

Can someone tell a newbie what 1-5 pin is on vcu (resolver?)
Is there wiring diagram for Connector?

[MattsAwesomeStuff]

Can someone tell a newbie what 1-5 pin is on vcu (resolver?) Is there wiring diagram for Connector?

I've never dealt with this because I've never used the Prius transaxle. But, I did dig this up:

https://share.qclt.com/%E4%B8%B0%E7%94% ... recu40.pdf

And it indicates a couple wiring colors Red with Green stripe, and Yellow with Brown stripe for GSN and GCS. It doesn't help much other than just say those two are resolver signal wires.

I couldn't find anywhere on our wiki anyone who's documented the Prius Gen 2 transaxle, (there must be some, @Gregski has documented almost everything about his Gen 2 build, I just can't see if it's in the wiki anywhere) but this whole 5 pin connector seems to be a plug on the transaxle that connects to Johannes' board.

Presumably it's the resolver that you've been using this whole time? If not, what have you been connecting to Johannes' board in terms of resolver wires?

[voti]

Can someone tell a newbie what 1-5 pin is on vcu (resolver?)
Is there wiring diagram for Connector?

Have you seen the collab video of Damien and Johannes where they teach us how to go about connecting the VCU to the transaxle and putting in the "TEST SETTINGS" ?

[voti]

https://openinverter.org/forum/viewtopic.php?t=5075

I was reading around tryna find the right throttle pedal settings when I came across this topic by Johu. He gave a list of affected boards and the prius gen 2 is part of that list. He said " On many older logic board designs and that includes all Tesla boards, the throttle input is 0-3.3V. In contrast the throttle output of many typical automotive pedals is 0.8-4.2V. So it will max out the ADC and potmax must be set to 4095 to operate in such a setup. This disables the upper range check because 4095 is considered a valid pedal position and values greater 4095 are not physically possible.

To address this, a 10k resistor MUST be put in series with the pedal like so " please click link above to see the attached image. He further said " This forms a voltage divider with the onboard pull down and results in a maximum valid throttle value of around 2000-3000 digits. With that configured the range check is active, will treat values > potmax+200 as invalid and cut out throttle/coast to standstill.

Addition: alternatively if you have a dual channel pot and only choose to use one, use the channel with the smaller 0.4 to 2.1V range

Then recalibrate your throttle setting."


My question is do I have to connect the 10k resistor because currently I didn't have it ?. Is this what im missing to get my throttle working properly

[johu]

It's not what is holding you back but you can still do it. It's a safety measure, not a functional problem

[Keo]

Hi, where can I get the design files for the gen2 Prius board. I can't find the board on the webshop

[voti]

Just to be sure. Without the throttle pedal connected, you can spin the motor in manual Mode without juddering? What battery voltage are you running?

Im back to this comment once again Retro, i did some tests today.

So first thing was I had to confirm my resolver graph if it does hit 0 to 360 and yes it does. Then I went on to syncofs and I had to redo it to confirm if 10120 is indeed the correct value. What I noticed was I was able to get the motor spinning when I put the value 3 on Manualiq, and it spun in the right direction which is forward. But now when I set syncofs to 0 and put 3 on manualid the motor spun in reverse which then confused me. I was following Damiens tutorials but what I saw what his spun in forward direction at this stage.
QUESTION- HOW DO I MAkE MY MOTOR SPIN FORWARD AT THIS STAGE.

Going on, I set the value 10120 on syncofs and now the motor neither spun backwards nor forward.
QUESTION- DOES THAT CONFIRM THAT THE VALUE 10120 IS CORRECT. AND IF YES, HOW THEN DO I PAIR THIS PARAMETER SETTINGS TO THE THROTTLE BECAUSE MY MAIN AIM IS TO CONTROL THE MOTOR WITH THE THROTTLE?.

I did a bit of further research and watched zookeepers tutorials on setting throttle, he disable pot 2 and only set pot l, he did it exactly as Retro said that the value for potmin should be a bit higher than the value that is present for pot on spot values.

My last question is that list, after getting the right value for syncofs, should I load it and then then also put in the value for pot on potmin which is a bit higher as explained, should I keep my potmax at 3500 because that is the maximum I found under throttle parameters while on the other hand when I press my throttle I can a maximum of 4095. And also what values am I suppose to put on Manualid and Manualiq before saving all these parameters to flash so that when i press my throttle automaticallyis moves the motor.

So:
Syncofs: 101200
Potmin : pot values + 50 maybe to make it higher like Retro explain
Potmax: I'll keep it at the default maximum which is 3500, is that ok?
Manualid: ????
Manualiq: ?????

[voti]

Anyone please

[MattsAwesomeStuff]

QUESTION- HOW DO I MAkE MY MOTOR SPIN FORWARD AT THIS STAGE.

I wish I understood or had experience with FOC process, I'd walk you through it bit by bit if I could. Half the time when I try to step in based on my very novice understanding, I end up saying things that are wrong, which is usually worse than saying nothing. But you're getting silence so far, so I'll try to help with the bits I can.

Going on, I set the value 10120 on syncofs and now the motor neither spun backwards nor forward. QUESTION- DOES THAT CONFIRM THAT THE VALUE 10120 IS CORRECT.

Generally yes, I think that is the goal of the syncofs process, to find where the motor DOES NOT spin. As I recall, you can try to increase the power to see if it's still true, which might help you narrow down the last little bit of precision.

AND IF YES, HOW THEN DO I PAIR THIS PARAMETER SETTINGS TO THE THROTTLE BECAUSE MY MAIN AIM IS TO CONTROL THE MOTOR WITH THE THROTTLE?.

I don't know if you "pair" it to the throttle, though we might have a language barrier here for that term.

The throttle settings I think are separate from the Synchofs settings. Throttle settings tell the controller how much current you want the motor to have, it's just an input signal. Whatever you do with that, is isolated and unrelated to anything else. Then the controller uses its algorithm combined with other parts of the system, to pulse the motor in such a way that it rotates. Synchofs is obviously part of that, as are many other things.

should I keep my potmax at 3500 because that is the maximum I found under throttle parameters while on the other hand when I press my throttle I can a maximum of 4095.

Short answer is that it won't matter. The consequence might be that you don't get fastest speed (or I'm backwards and you get your fastest speed long before your pedal bottoms out).

It shouldn't be the reason that your motor does or does not spin. Unless maybe it always detects it out of range or something like that, or you get the numbers backwards perhaps.

I do recall Johannes saying recently somewhere that some pedal has a range that is much higher than expected, or something like that? There was some news about some pedal that doesn't work as expected, and there may or may not be a workaround for it. But I don't think it was going to be a yes/no thing with respect to the motor spinning.

And also what values am I suppose to put on Manualid and Manualiq before saving all these parameters to flash so that when i press my throttle automaticallyis moves the motor.

No idea on that one.

[voti]

don't know if you "pair" it to the throttle, though we might have a language barrier here for that term.

What i was trying to say when I said "PAIR" was that when you have 0 on syncofs and you put 3 on Manualiq, the motor spins without the throttle pedal being pressed. Now when we have 10120 on syncofs and 3 on Manualiq the motor doesn't spin. Yes I do understand why that is as Damien explained in the video. The PAIRING now comes to say that when the motor hits that sweet spots when it doesn't rotate when you put a value on Manualiq it means now that the right throttle settings should spin the motor right??? So the right value of syncofs pairs with the right values for throttle potmin and potmax should get the motor spinning when the throttle is pressed right ??, and yes not just this twonsettings but with a whole lot of other settings like you said.

I just hope im making sense

[johu]

Manualiq/d are only testing parameters, throttle operation does not depend on them
Stick with syncofs 10120, that is the standard one for Prius Gen2 and go from there

[voti]

Manualiq/d are only testing parameters, throttle operation does not depend on them
Stick with syncofs 10120, that is the standard one for Prius Gen2 and go from there

What about power, is 12v sufficient?
My amps are also really small, I kept them low because I was afraid of using too much should Incase something goes wrong. My amprages is below 10A

[MattsAwesomeStuff]

What about power, is 12v sufficient?
My amps are also really small, I kept them low because I was afraid of using too much should Incase something goes wrong. My amprages is below 10A

12v and 10a is only 120w. I don't know that that's enough to turn over the motor.

[voti]

It does turn when I put in values in manualid and manualiq.

My only issue is turning the motor with the throttle pedal

[MattsAwesomeStuff]

I'm very rusty and never knew the FOC firmware, but is there somewhere you can input a fake throttle value to test it?

[voti]

Manualiq/d are only testing parameters, throttle operation does not depend on them
Stick with syncofs 10120, that is the standard one for Prius Gen2 and go from there

I dont know if we can call them fake throttle values but they do turn the motor even without having to connect the throttle. Just like johu explained in his comment quoted above