Peugeot Bosch SMG 180/120 with Gen 2 inverter [SOLVED]

[bliznakavd]

Hi,
The motor is on a bench PMSM Bosch SMG 180/120 with resolver with Toyota Prius Gen 2 and Openinverter PCB of course!!
3 times watch the Video tutorial for FOC
I do everything as a Johannes and D. Maguire said in video, but when try to Test the motor NOTHING, i make a couple of photos how i connect the Motor+Inverter+Controller!

[johu]

Nicely documented.
what isn't shown if opmode changes to run. If you did nothing about the PRECHARGE error then it won't. Lower udcsw to 100 and read here https://openinverter.org/wiki/Errors

[bliznakavd]

After lower the udcsw to 100v show RUN and the 220v bulb rise up with -10A BUT PRECHARGING stay

[uhi22]

Silly question: What is the condition to clear the lasterror? Does it need a power-off-on of the VCU? Or other?

[bliznakavd]

I try 3 times to restart it off/on the vcu

[bliznakavd]

Yes, the motor spin with -25, -45 A but show message OVERCURRENT when try to spin via throttle

[bliznakavd]

Hi, today after 3-4 hours working found that motor is not spin, i post the video because i can’t make photo, try to spin but have noisy vibration… What to do now, please help
me.

[johu]

Id doesn't spin, iq does
Read this https://openinverter.org/wiki/Using_FOC_Software

There is only one correct syncofs, one seemingly works but misbehaves at higher speeds the other spaced 32767 apart is then correct

If you never get any spin resolver sin/cos is swapped. You can set pinswap=7 with custom command to try that

[bliznakavd]

Doesn’t spin in both direction with up to -50A to 50A on a manual run, i make a video with Angle plot for Resolver signal, is it looking ok? my brother rotate the motor via driveshaft of the rear axle of Peugeot 508(407) hybrid. I read the Wiki link above, test many syncofs (also= 32767)but motor only vibrations but not spin even 1 RPM, i set pinswap=7, pinswap=5 but NO NO even 1 RPM spin, just noisy vibration… i post the video with parameters, i watch and read a lot of information but somewhere i have a BIG mistake!!

[johu]

How did you arrive at polepairs=6 and respolepairs=1 ? it's a bit strange combination

[kiwifiat]

The Bosch 180/120 has 6 pole pairs and the resolver has 6 lobes so the correct setting is 6 and 6.

[bliznakavd]

I found the information about “polepairs=6” for this kind of motor in other forum Bosch SMG180/120 PMS Motor has:
12 Poles and 6 Pole-pairs.
The Resolver MCR605
Speed: 6-speed (so 6 pole-pairs)
Excitation_Voltage: 7Vrms
Excitation_Frequency: 10kHz
The “respolepairs=1” found in link Wiki that the sin/cos is always 1, but now i will change them and will try again.
“polepairs=6” and “respolepairs=6” !
THANK YOU

[bliznakavd]

WE DO IT!! change the “respolepairs=6” and “pinswap=7” the motor spin very well.(will upload a video in youtube)
First test:
Voltage 131v
The motor go to ~1600rmp with il1 and il2 to ~80A
131v X 80A = 10 kw ~13hp
Second test:
Votage 198v
The motor go to ~2200 rmp with il1 and il2 to ~24A
198v X 24A = 4.75kw ~ 6.2hp Why why why
when select the direction with +12v on a PCB the Forward spin in reverse and reverse spin forward they are swapped.
Also when remove the direction switch on “reverse” position the motor continue to spin with high rpm and can’t stop only way is to remove the power supply.
The parameters that i need for this rear axle is 200v 100A and 2500 rpm, what i need to calibrate first, now the motor is not load…

[kiwifiat]

To calculate power input use battery current not phase current. From your rpm/Volt figures I would speculate that your syncofs is not quite correct, retarded timing I suspect.

[johu]

Yes that and you are in dirmode=DefaultForward. Put it to Switch or SwitchReversed then you can switch to neutral by removing forward and reverse.

When done right it works right

[bliznakavd]

Ok friends may be now is OK, Test many “syncofs” but finally found may be the correct one. “syncofs=30250” on manualid=10,20,50,100 even 120A does not spin the motor, just a bit vibration, than manualid=0.1 with manualiq= -3 and 3 the motor spin smooth in both side with a bit different RPM, -3A= ~360rpm and 3A=~340rpm. The test with trottle spin in both side on a “switch” mode with +12 power supply, but when release the trottle the motor continue to spin with high RPM in both position. The MAX RPM on ~198v is 1600-1800… I post the 5 min. video with many details.

[bliznakavd]

This morning i do “syncofs=30250+32768=~63030” the motor spin in both side with +-3A, in both side ~2000 rpm, may be the new “syncofs=63030” is the correct one.

[johu]

Basically the correct one is where the stators "south" lines up with the rotors "north". The other one that also doesn't yield movement lines up the "northes" and "southes". With that field weakening becomes field strengthening. And because it doesn't have the desired effect once the FW point is passed FW current will "latch" on keeping the motor spinning at low torque because of minor misalignment.

With the new you don't have runaway I guess?

[bliznakavd]

With the new i don't have runaway, when release the trottle the motor stop spining in both side, is that mean the “syncofs=63030” is the correct one, also the rotate dir. on my wheels now is correct, Is it ok to use the motor with this “syncofs”

[bliznakavd]

Hi, with “sincofs=63030” the motor spin very quiter, i like it!! With right direction,manualiq=35A-40A the motor spin with ~3200RPM, 196v X 16(volt/rpm) = ~3200RPM max for this voltage, so with 35-40A run on max rpm but when is with full throttle press only 2000RPM, What i need to calibrate now to use max potential of battery/voltage/current??
Make a video with details.

[bliznakavd]

Replace the throttle pedal with new one but is some, when press just hit 2200-2300 rmp but not smooth rotation, when change the “throtcur=3-4 or 5” the motor just stuck and not rottate.

[johu]

It looks like you're hitting the rev limiter (fmax).

[bliznakavd]

Correct! Thank you, change the value to 400Hz on “fmax”, hit 4000-4500 rpm, but when release the throttle continue to spin with high rpm, aslo in a middle rmp stuck.#bosch SMG 180/120

[bliznakavd]

what need to do next?

[johu]

Post your parameters.
I suppose you activated field weakening. On an unloaded motor the residual torque can cause what you observe