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Re: Morning trips
Posted: Sun Dec 03, 2023 9:41 am
by FFMan
Bigpie wrote: ↑Sun Dec 03, 2023 9:36 am
Mine shows LORESAMP, not sure that's a real problem.
ok that's interesting, mine doesn't but, i couldn't get anything to happen with it either, it did nothing and reported LORESAMP so i figured that was a show stopper. Maybe the earlier boards had a tendency to do that ? They have more than a few differences to my board.
Might be worth me trying that again if no progress on the bypass today.
Re: Morning trips
Posted: Sun Dec 03, 2023 10:12 am
by Bigpie
I don't think that's your issue either. If you jack up one wheel can you turn the motor by turning the wheel in the air?
Re: Morning trips
Posted: Sun Dec 03, 2023 4:55 pm
by FFMan
another full day on this to no avail. The mechanical side seems fine, car rolls ok, motor can spin in neutral and when it feels like it it can turn suspended wheels but any load and it trips.
We've bypassed the contactor box entirely to rule that out, and tried the loan board (which is something of an unknown quantity) that reports LORESAMP but that won't spin the motor but it doesn't trip. My board, trips at the first sign of load.
Conclusion is I have 2 faulty V1c boards, my original one, and the loan one of which the history is a little unclear.
Looking into zombie route now as its cheaper and potentially less complicated, or is that just naïve ?
Re: Morning trips
Posted: Sun Dec 03, 2023 5:54 pm
by johu
LORESAMP means the swing of the resolver signal is too low (or mostly non-existant) for a usable position sensing. So the position isn't tracked and it's indeed a showstopper. Needs a multimeter to find out where the problem is. Exciter should be about 3V AC RMS, one of the return signals about 1V AC rms right down to the STMs pins.
To be honest I don't see how a broken board would successfully idle spin a motor but not under load. Usual culprits as always is going over pinswap and syncofs. But then again I don't see how the car would drive fine on other occasions if these parameters were off. Unless they were changed unintentionally. Ever tried a different inverter? Could the coolant flow be blocked?
Re: Morning trips
Posted: Sun Dec 03, 2023 7:22 pm
by FFMan
johu wrote: ↑Sun Dec 03, 2023 5:54 pm
LORESAMP means the swing of the resolver signal is too low (or mostly non-existant) for a usable position sensing. So the position isn't tracked and it's indeed a showstopper. Needs a multimeter to find out where the problem is. Exciter should be about 3V AC RMS, one of the return signals about 1V AC rms right down to the STMs pins.
To be honest I don't see how a broken board would successfully idle spin a motor but not under load. Usual culprits as always is going over pinswap and syncofs. But then again I don't see how the car would drive fine on other occasions if these parameters were off. Unless they were changed unintentionally. Ever tried a different inverter? Could the coolant flow be blocked?
I have tried a different inverter and get the same. I thought today i had found a weakness in the HV feed in that one of the brass top hat posts was 1mm too short and i wondered if contact to the inverter was suspect, but i deepened the housing to ensure it was ok to no effect. There was also no burn or other hot marks indicating an issue there.
How quickly would an inverter trip without coolant. It's been in and out so many times i've not always bled the system fully so for some tests it may have had little or no flow. Would that cause a near instant trip ? does the Prius inverter 'know' when it has coolant in it somehow ?
Re: Morning trips
Posted: Sun Dec 03, 2023 8:57 pm
by johu
It at least has die temperature sensors that would react rather quickly on local overheating
Re: Morning trips
Posted: Sun Dec 03, 2023 9:18 pm
by Bigpie
Need some realtime logs
Re: Morning trips
Posted: Sun Dec 03, 2023 9:28 pm
by FFMan
Bigpie wrote: ↑Sun Dec 03, 2023 9:18 pm
Need some realtime logs
yep sorry forgot today. have added il1 & il2 so will put my board back in and log that tomorrow and post
Re: Morning trips
Posted: Sun Dec 03, 2023 9:29 pm
by FFMan
johu wrote: ↑Sun Dec 03, 2023 8:57 pm
It at least has die temperature sensors that would react rather quickly on local overheating
did you say in an earlier post that OVERCURRENT was something of a catchall or even something the prius inverter couldn't report, so could be a bit misleading.
for example, could it report overheat or is that masked ?
Re: Morning trips
Posted: Sun Dec 03, 2023 10:08 pm
by johu
Not super knowledgeable about the gen3 but on the gen2 it would be catch all
Re: Morning trips
Posted: Mon Dec 04, 2023 1:34 am
by Zieg
Maybe a stupid suggestion, but I'd give the resolver wiring a good jiggle and check continuity from pin to pin if you haven't already. I had a LORESAMP popping up only after spinning the motor and traced it to high resistance in one wire. Crimps both seemed good but after replacing the run, the error went away.
Re: Morning trips
Posted: Mon Dec 04, 2023 7:08 am
by FFMan
Zieg wrote: ↑Mon Dec 04, 2023 1:34 am
Maybe a stupid suggestion, but I'd give the resolver wiring a good jiggle and check continuity from pin to pin if you haven't already. I had a LORESAMP popping up only after spinning the motor and traced it to high resistance in one wire. Crimps both seemed good but after replacing the run, the error went away.
thanks for the suggestion, but it can't be the wiring as when i put my board in the inverter it is fine. it also checks out with a meter statically.
appreciate all ideas, nothing is daft at this stage.
Re: Morning trips
Posted: Mon Dec 04, 2023 11:17 am
by johu
Not sure why I just remember now, but one Prius Gen2 inverter signalled a fault (or my board registered a fault) even though there was none. I compiled a firmware that ignores the fault signal and it then worked flawlessly.
https://github.com/jsphuebner/stm32-sin ... n.cpp#L406 (change to disable_break)