Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Tell us about the project you do with the open inverter
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Re: Project VW Cadd-E

Post by vwbrady »

also, i decided to go with custom busbars for my batteries, instead of cable, since they will be VERY inaccessible when installed and it will make me worry a bit less about my crimps :)
busbars.png
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Re: Project VW Cadd-E

Post by ZooKeeper »

Yes, bussbar >>> cables!!!
Huebner VCU controlling a Gen2 Prius Inverter powering an MGR
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Re: Project VW Cadd-E

Post by vwbrady »

Busbars!
IRL busbars SCS.jpg
irl busbars1.jpg
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Re: Project VW Cadd-E

Post by RetroZero »

Very professional 👌
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Re: Project VW Cadd-E

Post by vwbrady »

battery reconfiguration done, and installed under the truck. TDL is still very long.

Again, this is a very modest battery pack, @ ≈7kWh, that I chose for it's low cost and small packaging that gets me to a 96s pack.

Batteries with all BMS leads and busbars installed:
batt open on bench.jpg
then back in their enclosures:
batt on bench.jpg
installed under the truck, not noticeable at all:
Batt instled.jpg
My K100 cafe project that's been a fun distraction:
K100.jpg
Before a test spin i need the EVBMW Leaf VCU wired up and some HV junction box stuff mocked up. Also HV cables run.
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Re: Project VW Cadd-E

Post by RetroZero »

You said low cost. May I ask how much for the modules? Might go your route.
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Re: Project VW Cadd-E

Post by vwbrady »

RetroZero wrote: Fri Jul 30, 2021 9:05 am You said low cost. May I ask how much for the modules? Might go your route.
They sold out after a few weeks but they were $100 each. Mercedes L09-1 modules, cells made by Li-Tec in Germany.

At 880Wh new, with the diecast enclosure they come in, I thought it was a good deal. I bought 16 and am only using 8 at first. depending on my range i may add the other 8 in parallel. they did take a decent amount of work to make usable, as you can see in the thread. And when running these in a 96S 1P config each cell tab is carrying full current. So, we'll see how that goes...
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Re: Project VW Cadd-E

Post by RetroZero »

Goodnight to know. With the golf/caddy space and weight is critical, and then the cost. Will wait to see what range you get. For now I have mountings to make 🤔
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Re: Project VW Cadd-E

Post by vwbrady »

made a little more progress before paternity leave ended.

yet again, more laser cut parts from Send Cut Send. Chevy Volt Charger bracket and a bracket for the Leaf acc pedal
SCS board.jpg
Leaf pedal proto and final bracket. GOT to design > proto > test > design > proto > make
acc brkt proto.jpg
installed in truck:
acc pedal instled.jpg
charge bracket mount to Leaf motor:
chg brkt.jpg
Installed:
bay with chg.jpg

Now I need to get to my High Voltage Junction Box and control system wiring.
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

HVJB work has begun:

This is alittle large but i plan for it to contain:

1. HV fusing + distro (DCDC & Charger)
2. pos & neg contactors
3. Isa Shunt
4. precharge relay and resistor

I've 3-d printed mounts so it will fasten directly to the top of the EM57 inverter.
PXL_20210822_193304233.jpg
PXL_20210822_193230426.jpg
Then the DC input to the inverter will be sealed via this 3-d printed assembly
Screenshot 2021-08-23 085113.jpg
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

big update:

HV Junction Box is done, installed, and connected to batteries
HVJB internal.jpg
enginer bay.jpg
VCU is wired to HVJB and leaf inverter.
VCU wiring.jpg
VCU CAN jumpers from header 1 to 2. to connect the Inverter CAN with ISA Shunt communication to pins on HVJB header where ISA shunt resides. I plan to bring this up in the Leaf VCU support thread. It's my understanding that the ISA Shunt and Leaf Inverter share the same CAN bus. I'll have to look at Damien's code to confirm.
can jumpers.jpg
Charge inlet mounting designed and done
chg inlet CAD.png
sendcutsend shipment.jpg
chg inlet installed.jpg
12s battery charger/balancer used to check cell voltages
x12 chrger.jpg
designed and printed a 12v battery tray for a LiFePo4 35Ah
12v batt tray.jpg
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by RetroZero »

You are on the burn. Nice progress
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

RetroZero wrote: Wed Oct 27, 2021 4:17 pm You are on the burn. Nice progress
my god i wish it felt like that, haha. I have very little time to get this going and there is still SO much to do.

appreciate the support though!
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

my doc for tracking wiring: https://docs.google.com/spreadsheets/d/ ... p=drivesdk

i plan to do a full schematic at some point. perhaps in a Miro board.
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

Kind of a big milestone. Full Voltage in the Junction Box.
PXL_20211031_221158142_exported_10265.jpg
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by RetroZero »

👍
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

Slow goes the progress.

Volt charger and DCDC mounted.
PXL_20211211_221121728.jpg
PXL_20211212_011956218.NIGHT.jpg
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

after a bunch of test wiring, then more code review and trouble-shooting, I have a spinning motor!

Precharge works great, Acc pedal calibrated. Next up will be further refinement of the low voltage wiring, and then on to getting my Volt DC-DC and Charger working. Also wiring the Leaf BMS.



and my wiring:
Caddy-E Wiring.pdf
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

I guess if the motor can spin, the wheels can spin too :)

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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by nkiernan »

Nice 8-)
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

changing my BMS strategy. Was intending on using the Nissan Leaf BMS, but have since decided to go the Simp BMS + Tesla route.

You may wonder how, if I'm not using Tesla modules. Well i just bought a bunch of used Model S/X BMS boards off ebay and am going to wire them to my cells. Combining 2 boards get's me the 12S i need for each of my mercedes modules.

CAD:
Screenshot 2022-04-06 102835.jpg
prototyping
PXL_20220404_152544469.jpg
PXL_20220404_154907773.jpg
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by Bratitude »

Nice, bought a gen1 volt bms to do the same thing. never found a good price for Tesla slave boards, how much did you get the full set for?
https://bratindustries.net/ leaf motor couplers, adapter plates, custom drive train components
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by vwbrady »

Bratitude wrote: Thu Apr 07, 2022 3:01 am Nice, bought a gen1 volt bms to do the same thing. never found a good price for Tesla slave boards, how much did you get the full set for?
So, i knew there would be a bunch of loose model S/X boards out there because of so many people using aftermarket BMSs +adapter boards for stationary, or other, use cases. StealthEV who makes an adapter board for these modules had hundreds of these in stock, which they sold to me for $25ea.

So for 16 modules, needed for a 400V system, plus the cost of the Simp BMS:

Simp BMS from kitoffgrid (only place that would ship to the US): $578
Model S/X modules from StealthEV: $400
BTW, I'm hoping to get it set up to share my powertrain contactors and ISA shunt.

I compared this to the Orion BMS for a 96s system at $2000.

Here is my first 12s sub-module test setup, contains 2 tesla boards:
PXL_20220407_131539072.NIGHT.jpg
They will mount to the side of my batteries like so:
Screenshot 2022-04-07 073252.jpg
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by RetroZero »

Nice going 👍
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Re: Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

Post by delgadb2 »

What kind of 3d printer are you using to print those housings? ;)
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