Re: BMW LIM based CCS2 Controller
Posted: Thu Sep 23, 2021 12:35 pm
I've got boards in process at JLCPCB. Will post to GH after I verify that that the smoke stays inside.
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They’re rated at 25wbitterandreal wrote: ↑Sun Sep 26, 2021 8:32 am Are those 15 ohm resistors (R21, R22) actually capable of handling constantly 12W (~900mA @ 13.4V)?
Assuming BMW followed the datasheet of the TE contactors they will be PWM fed with a 50% dutycycle, so dissipation will be half that. But anyway, 2x6W will generate quite some heat on the PCB..bitterandreal wrote: ↑Sun Sep 26, 2021 8:32 amAre those 15 ohm resistors (R21, R22) actually capable of handling constantly 12W (~900mA @ 13.4V)?
Resistor power ratings are pretty meaningless on their own. The heat has to go somewhere - in real conditions, 25W is a pulse rating only.jon volk wrote: ↑Sun Sep 26, 2021 11:50 amThey’re rated at 25wbitterandreal wrote: ↑Sun Sep 26, 2021 8:32 am Are those 15 ohm resistors (R21, R22) actually capable of handling constantly 12W (~900mA @ 13.4V)?
But the H-bridge drivers are very efficient, they only have to switch the power for the motors not dissipate the power.
Excellent work!jon volk wrote: ↑Sun Sep 19, 2021 6:55 pmGot it, 1.44 centered common mode. Re-doing doing the calculations just needed to replace my R28 with the same 6080 ohm value. Values seem to align close enough and with the parallel resistor circuit, that gives me plenty of options for tweaking in the future. Without this change, it seems values would have been 0HVDC @ ~2.3v and 500HVDC @ ~5vmuehlpower wrote: ↑Sun Sep 19, 2021 1:42 pmi don't think it will work. OUTP and OUTN are not 0V with an input of 0V, its 1.44V. At 500V OUTP = 2.44V and OUTN = .44V approx
Thanks for the help.
I’ll post the final files to my GitHub after I’m done. It’s going on a board with an STM32F413 to handle two Volt BMS systems and any other battery related needs. Have the BMS code generally done but untested. Need to port the necessary CCS from Damien over to c/st-hal.
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Yeah; i agree the current VCU controller would be usable because it has 2 CAN interfaces. One for the LIM and one for the vehicle integration.I think a separate controller for the ccs with the CAN interface would be ideal. Then others can easily adapt it to their own chargers, inverters, BMS, vcu etc....
In my setup there is a DUE that communicates with the LIM and my Tesla GEN3 charger via CAN 1. It also has the necessary 6 hardware lines for the charger and a simulation for the fuel filler flap for the LIM. It also queries the temperature at the CP and a button to cancel charging. The connection to the car, especially with the BMS, current sensor and cooling system is via CAN 0. This DUE is only in operation during charging, AC or DC, and also controls precharge and main contactors, which are switched by Damien's LDU board while driving.EV_Builder wrote: ↑Sat Oct 02, 2021 1:07 pmYeah; i agree the current VCU controller would be usable because it has 2 CAN interfaces. One for the LIM and one for the vehicle integration.I think a separate controller for the ccs with the CAN interface would be ideal. Then others can easily adapt it to their own chargers, inverters, BMS, vcu etc....
So that's covered.
Yeah that's what i meant a two legged controller.muehlpower wrote: ↑Sat Oct 02, 2021 2:29 pmIn my setup there is a DUE that communicates with the LIM and my Tesla GEN3 charger via CAN 1. It also has the necessary 6 hardware lines for the charger and a simulation for the fuel filler flap for the LIM. It also queries the temperature at the CP and a button to cancel charging. The connection to the car, especially with the BMS, current sensor and cooling system is via CAN 0. This DUE is only in operation during charging, AC or DC, and also controls precharge and main contactors, which are switched by Damien's LDU board while driving.EV_Builder wrote: ↑Sat Oct 02, 2021 1:07 pmYeah; i agree the current VCU controller would be usable because it has 2 CAN interfaces. One for the LIM and one for the vehicle integration.I think a separate controller for the ccs with the CAN interface would be ideal. Then others can easily adapt it to their own chargers, inverters, BMS, vcu etc....
So that's covered.
I'm also planning to use a separate charge controller as a gateway between the vehicle CAN bus and the charging CAN bus. How is your DUE code comparable with Damien's LIM code for the zombieVerter? And is it open source?muehlpower wrote: ↑Sat Oct 02, 2021 2:29 pmIn my setup there is a DUE that communicates with the LIM and my Tesla GEN3 charger via CAN 1. It also has the necessary 6 hardware lines for the charger and a simulation for the fuel filler flap for the LIM. It also queries the temperature at the CP and a button to cancel charging. The connection to the car, especially with the BMS, current sensor and cooling system is via CAN 0. This DUE is only in operation during charging, AC or DC, and also controls precharge and main contactors, which are switched by Damien's LDU board while driving.EV_Builder wrote: ↑Sat Oct 02, 2021 1:07 pmYeah; i agree the current VCU controller would be usable because it has 2 CAN interfaces. One for the LIM and one for the vehicle integration.I think a separate controller for the ccs with the CAN interface would be ideal. Then others can easily adapt it to their own chargers, inverters, BMS, vcu etc....
So that's covered.
Did you figure out the part numbers for the mating sockets to all those harnesses on the original i3 charge port cable or you cut off the connectors and using hard wiring?
Jon I'm in was in the same boat. Do you have an empty project setup for that?jon volk wrote: ↑Mon Oct 04, 2021 11:22 am I use STs HAL due to the simplicity of project setup with Mxcube. It saves quite a bit of time for me and if I run into a problem there hasn’t been an instance where I didn’t find the solution with some time on google. I’m also a newbie to code and want to stick with the C to not confuse myself further.
I agree.jon volk wrote: ↑Mon Oct 04, 2021 11:22 am I use STs HAL due to the simplicity of project setup with Mxcube. It saves quite a bit of time for me and if I run into a problem there hasn’t been an instance where I didn’t find the solution with some time on google. I’m also a newbie to code and want to stick with the C to not confuse myself further.
looks great!jon volk wrote: ↑Thu Oct 07, 2021 9:21 pm Boards arrived so hopefully some initial testing after an insulation resistance test and wrapping up some code. I did end up adding a big heat sink as those resistors did heat up quick by themselves on the bench. I guess never underestimate power dissipation.