Subaru e-mpreza (Impreza) 96 - AWD with 2 Outlander rear motors

[arber333]

I am doing this a lot.
You need to watch out for correct direction of twist though... i found it is better to have a convention of RIGHT twist every time.

[Zapatero]

Pretty much!

you need:
steering(done!)
Brake(half way there?)
throttle(done)
vss (done!)
radar (easy)

Here’s the open pilot fork for old cars : https://github.com/Lukilink/openpilot

What i figured out is that i need the steering angle sensor, too.
Unfortunately it doesn't fit properly in my steering column.

Any suggestions for easy to install steering sensors?

[Zapatero]

Also it seems they use newer versions of the power steering. Is the Prius 2007 EPS working for openpilot, too? Maybe someone knows?

[arber333]

Also it seems they use newer versions of the power steering. Is the Prius 2007 EPS working for openpilot, too? Maybe someone knows?

Hm... you could install clio or corsa epas...rally cars have them installed a lot. But that goes under the steering wheel.

[Scubascooby]

Find a legacy diesel, they have eps.

[Zapatero]

I already added eps from a Prius 2007 but it seems you need an eps that already supports LKAS (Lane keep assist)

[EV_Builder]

I already added eps from a Prius 2007 but it seems you need an eps that already supports LKAS (Lane keep assist)

Maybe that's an option which can be activated?
Saying that most diagnosis software wants to see a almost complete car.

[Bratitude]

what crimp tool are you using?

[Zapatero]

what crimp tool are you using?

i have several, but sometimes also not the appropriate one. Still i can crimp most things

[Zapatero]

I loaded the car on my trailer to paint it one last time. At one rear fender the metal morphed a bit too much while welding and i had to redo it. So we decided to paint the whole car again for a perfect finish.

Finally the Impreza is mostly put back together.
Just a few more days of work and then full attention can be paid to the EV-conversion again.

[Zapatero]

Meanwhile the long ordered Orion BMS from EV-Shop Europe in Romania arrived. I ordered the Orion the second time with them as they are very reliable and also have the cheapest offer in Europe.

I then fabricated a proper mount for the BMS:

In this position the original boot carpet has a door for the car lift and spare wheel tools. Now one can access the BMS there.

[Zapatero]

before painting the car again i installed the CCS charging port (uninstalled it for painting, again)

Also i received my custom drive shafts from motomax.pl. I had the contact out of this forum and must say they did awesome work for just 150Eur a drive shaft. I just sent them the two cut halfes of each side. Couldn't be happier with that and definately will let them do the front ones, too!

[EV_Builder]

Also i received my custom drive shafts from motomax.pl. I had the contact out of this forum and must say they did awesome work for just 150Eur a drive shaft. I just sent them the two cut halfes of each side. Couldn't be happier with that and definately will let them do the front ones, too!
PXL_20220603_084903922.jpg

Yeah just like mine! Perfect price for good product (complete new shafts).
When i'm ready for the fronts they get mine too!

[Zapatero]

I'm still assembling the car, but another EV-Detail has been installed today: 3 Phase CCS Charging Socket!

[Zapatero]

I've build another EPAS that has support of can bus controlled driving. The EPAS is out of a 2018 Toyota Yaris:

I now have a steering wheel from a way newer Subaru that has the cruise control buttons and also radio control buttons.
Also it has the steering angle sensor, that is needed for comma.ai

This EPAS control unit is out of a 2018 Toyota Corolla and it is compatible comma.ai

I also bought the radar sensor that will go in the front of the car and is compatible with comma.ai, too:

[Bratitude]

im really excited your adding open pilot to this project. definitely one of the coolest builds I've seen in a while

[Zapatero]

I'm test fitting to front motor. In the next few days it should be finally in the car.

I'm determining at the moment how i solve the battery-puzzle. I need some opinions here:

I realized that it would be very difficult to put all 96 cells in the car (actually there are 98 in the Kona but the version of the Orion BMS i have can only handle 96 cells).

i can easily fit 86 cells like this:

That would result in:

Kona OEM 98 Cells /// 86Cells
KWh: 64 /// 56
Kg: 333 /// 292
Volt: 294 - 401 /// 258 - 352

Johannes told me that i have to derate KW linear by the amount of cells i'm taking out.
86/98 = 88% of the original capacity.
That would mean the Kona had 160Kw and i could only pull 140 Kw.
The maximum of charge power the Kona sees is 78 Kw so that would be 68 Kw.

What do you think, could i still pull 160Kw out of the 86 cells?
70Kw charge power would be alright for me, so that's not gonna be an issue.

[EV_Builder]

The maximum peak amperage per cell is the same. So if you lower the voltage then Kw peak will be lower. So it depends on the margin/ amperage of the cells.

[Zapatero]

The maximum peak amperage per cell is the same. So if you lower the voltage then Kw peak will be lower. So it depends on the margin/ amperage of the cells.

Are there specs where a cell starts to deteriorate because of pulling to many amps out of it?
one single Kona-Cell has 218 Wh and can deliver by default 544 Wh (160.000W / 98 / 3) That results in 2,5C
i would pull 620 Wh out of it (160.000W / 86 / 3) That results in 2,85C
That means 14% more...

[EV_Builder]

Are there specs where a cell starts to deteriorate because of pulling to many amps out of it?
one single Kona-Cell has 218 Wh and can deliver by default 544 Wh (160.000W / 98 / 3) That results in 2,5C
i would pull 620 Wh out of it (160.000W / 86 / 3) That results in 2,85C
That means 14% more...

You can try looking it up but i have no data or reference about that cell.
Do you know whats inside? Who made it?

On internet the best resource i found are: https://www.batemo.de/products/batemo-c ... rary/e66a/
(as per example my TayCan cells).

I guess/think that temperature and SoC have allot of influence on the C rating.

[arber333]

Are there specs where a cell starts to deteriorate because of pulling to many amps out of it?
one single Kona-Cell has 218 Wh and can deliver by default 544 Wh (160.000W / 98 / 3) That results in 2,5C
i would pull 620 Wh out of it (160.000W / 86 / 3) That results in 2,85C
That means 14% more...

I have seen (and heard) Kokam LiPo cells go dead from too much amps. They get quite hot at that but they seem to have a backup. When they die a copper link resolves between electrodes which makes a direct path for the current to go through. I could drive my car further on the highway! A safety measure as alternative would surely mean fire. I dont know if LiIon have similar mechanism. Just be carefull, Kona cells dont have the best reputation.
Maybe better to use Audi etron cells which are similar format but have bigger electrode tabs.

[4markowen]

Could additional batteries be mounted in the transmission tunnel? given it had an exhaust and prop shaft running down it.

I presume you might have already offered them up to that space though.

[EV_Builder]

I'm packing 16Taycan modules in my tunnel and fuel tank place. Lots of work though because the shape and construction isn't straight forward.

[Zapatero]

You can try looking it up but i have no data or reference about that cell.
Do you know whats inside? Who made it?

On internet the best resource i found are: https://www.batemo.de/products/batemo-c ... rary/e66a/
(as per example my TayCan cells).

I guess/think that temperature and SoC have allot of influence on the C rating.

i found it, they have the cell of the Kia Niro which is the same as the cell of the Hyundai Kona:

Kia Niro
The Batemo Cell of the lithium-ion battery cell SKI Kia Niro is a high-precision, physical battery model with global validity. As a digital twin it seamlessly integrates into your research, development and battery analytics by basing your decisions on simulations.

cell report of the SKI Kia Niro.

Cell Origin extracted from Kia Niro (2019)
Cell Format pouch
Dimensions 300.5 x 108.5 x 15 mm
Weight 899.3 g
Capacity C/10 62.3 Ah
Current continuous 120 A peak 284 A
Energy C/10 230.8 Wh
Power continuous 422 W peak 968 W
Energy Density gravimetric 257 Wh/kg volumetric 607 Wh/l
Power Density gravimetric 1.08 kW/kg volumetric 2.55 kW/l


That means that 86 cells are well capable of still delivering the 160Kw, of course not continuously

[EV_Builder]

Monitor temperature or even better cool it