BMW 525d F11 conversion

[cavok]

I start the conversion of my BMW 525d now officialy

My prioritys are:
- range over power (daily use)
- seamless integration (using existing gauges and handles)
- AC and DC CCS2
- V2L
- using OEM (roadlegal easy)
Driveprofile:
- city
- countryroads
- rarely on highways (max. 150 kph is OK for me)
My first ideas:
- placing the drivetrain in the rear subframe as replacement of the differential gearbox and custom made driveshafts, to get as much space that I can get (enginecompartment, gearboxcompartment, tunnle, and fuletankcompartment) for batteries charge- and V2L-Equipment.

My first steps:
- More research
- get my backyard-barn ready as a usable workshop
- get as much can-information as possible, while the n47 still fires up (rod-knocking)
- Remove the engine, gearbox, central driveshaft, differential gearbox, exaustsystem, fueltank and determin the weight of every component.

To be continued….

[crasbe]

Oh, this is exciting. Remember though that the F10 generation already uses a lot of LIN-Bus too.
I don't know if the DDE uses it too, but certainly something to be kept in mind.

Also: why not go Lexus GS450h/IS300h?

[tom91]

F generation also does Flexray... for the ABS/ESP

[marcexec]

Flexray... for the ABS/ESP

-> a candidate to keep the original ECU and replicate engine sensor readings to keep it happy?

[cavok]

It's going on...

...but first thank you, for your tipps.

Oh, this is exciting. Remember though that the F10 generation already uses a lot of LIN-Bus too.
I don't know if the DDE uses it too, but certainly something to be kept in mind.

Also: why not go Lexus GS450h/IS300h?

Wanted to reduce as much weight as i can, but i think the GS450h should be the better decision. For the Installation in the rear axle i need to open the Trunk floor, and here in Germany you can get problems with roadlegality, when you modify frame parts, like the rear axle . I´m not completely through with it, but for the moment i plan with a GS450h.
I found many many plans and repairmanuals. What i see now, is that the F10/11 uses LIN Bus in CAS, exterior and interior lighting and auxiliary battery charg BCU. With a little luck not relevant.

-> a candidate to keep the original ECU and replicate engine sensor readings to keep it happy?

Maybe this will be a little tricky, but i found out that the E60 uses FlexRay too and the connection diagram seams to be very similar. So maybe i can get some support from someone who converted an E60/61.

So next steps are now: watch the Market for the GS450h transmission and starting with Savvycan...

[tom91]

The E series bmw's do not use flexray. Maybe only few exceptions.

You will struggle unless you find someone who has done an engine swap to something not BMW or an older engine ecu.

[cavok]

OK my Research goes on. Flexray will be a Problem to be solved. Biggest Issue is, that there are 4 ECUs that establish the initialisation of the Flexray Bus and DDE is one of them. The Others are ZGW, DSC and ICM.
The ZGW as the Master of puppets Starts the process of initialising and it needs 2 of the other 3 ECUs. So it could be possible to do this without the DDE. But if there are any issues with one of them, the whole vehicle might be dead. Let the DDE stay in the Car will cause a lot of Errorcodes to Handle with.

Based on the information i got, that it is possible to deaktivate the FlexRay-path to the DDE by coding in the ZGW via e-Sys/ISTA/tool32, there are two „easyer“ways to solve this and a hard and expensive Way.

First the easiest:
Remove the DDE, teminate the FlexRay-Pins in the Plug with 45 Ohms. Then deactivate the DDE and the FR-Port to the DDE in the ZGW. The Parameters Engine Torque and RPM can be transmitted from the EV-VCU via Pt-CAN witch will distribute it to the FR for the other ECUs on that Bus Like DSC and ICM.
Pro: easy and cheap
Con: unsave, one fault ECU may lead to a total shut down of the car.

Second:
Very similar to the First. Only the DDE has to be deactivated in the ZGW. A blank DDE (flashed without Engine) works as a FR-hub that can establish the initialisation so that we have the three ECUs for this task (one redundant). The rest is the same.
Pro: relatively easy, Safe
Con: 500,-€ extra for the tuned DDE

Third and hardest:
Emulating a fully functional Flexray node with a Infineon TC277 / TC297 TriCore Evaluation Board (used in any BMW-ECUs) or a FPGA solution to bring the needed parameter like engintorque from the EV-VCU directly to the FR-Bus. Like a Flexray interface for the Zombiverter.

Pro: I‘ll be the Star of the Community
Con: I‘m Not a Software engineer , i‘m not a PCB-engineer , i‘m not a Pro in FlexRay or FPGA and a a workload of 500+ h of programming for a Pro means impossible for me .

OK Folks thats it for the Moment and the Journey will Go on and thankyou for the comments….

[Jack Bauer]

Interesting project. imho it depends what you want out of the project. If you want to get running and driving option 2 is the way. If you want to have fun and learn it's option 3. This might be some help : https://github.com/dynm/pico-flexray

[cavok]

Maybe i bring it backk on the road with 2 and then i work on 3.

I found a similar Project from 2020 on github where they moved the steeringwheel of an Audi Q8 with a joystick. But they didn't use "cheap" hardware, when i remember it right. But thats can be a good alternative with a Raspi pico and two flexraytranscivers. Thanks for that.

Now i have to get my barn back. Our youngest daughters fiancé has occupied it as a paintshop for his Motorbike. Looks like a basement of a motorcycle serialkiller, black motorcycleparts are hanging everywhere from the celing.
And i have to make a drivetrain decision.

[marcexec]

Play it safe with a L210, plenty of other stuff to tinker with.

[Jack Bauer]

I don't want to pollute your build thread but I've been down quite a rabithole on flexray and it seems the folks working on various openpilot and others have gone a long way to making flexray more accessible. I'm gonna try and source an F10/F11 dme and see if I can listen to it on the bench.

[cavok]

I ordert the TJA1082 Flexray-Transceivers with DIP-Adapters and a Raspi Pico 2 is still in any Box. First try is with a breadboard. If that works, i‘ll solder it on a pervboard. Thank you all (especially to Damian) for your suggestions.