Gs450h zombieverter loss of regen intermittent

[joeflickers]

Hi.. I've been all eager to update the zombie with regen.. I've run versions 2.15 and now running lastest vcu firmware 2.17..sometimes I loose regen and sometimes when I have regen the motor feels shaky of low speeds and then it dissapers.. Rebooting the vcu two or 3 times regen resumes.. The other issue I get is when I hit start, precharge happens well as usual.. Car read inverter temparures etc select drive and there's no response and theres is no error..

Also noted is when regen is available, changing the gear selector from Drive, neutral reverse the motor shakes.. What could be the issue?

[barracuda816]

What is the battery SOC when it happens? also Best to post params and logs if you have them.

[joeflickers]

What is the battery SOC when it happens? also Best to post params and logs if you have them.

I'm running my car with Orion bms 2 and don't rely on the zombie for soc calculations.. I'm running 96s lithium (400-300volts)77kwh Battery... This happens when battery is either full, mid or just about empty...

[joeflickers]

{
"Inverter": 2,
"Vehicle": 3,
"Transmission": 0,
"interface": 0,
"chargemodes": 0,
"InverterCan": 0,
"VehicleCan": 1,
"ShuntCan": 0,
"LimCan": 0,
"ChargerCan": 1,
"BMSCan": 1,
"OBD2Can": 0,
"CanMapCan": 0,
"DCDCCan": 1,
"GearLvr": 0,
"MotActive": 0,
"potmin": 336,
"potmax": 1471,
"pot2min": 497,
"pot2max": 2790,
"regenrpm": 1500,
"regenendrpm": 100,
"regenmax": -5,
"regenBrake": -16,
"regenramp": 4,
"potmode": 1,
"dirmode": 1,
"reversemotor": 0,
"throtramp": 3,
"throtramprpm": 20000,
"revlim": 11000,
"bmslimhigh": 50,
"bmslimlow": -1,
"udcmin": 290,
"udclim": 520,
"idcmax": 500,
"idcmin": -258,
"tmphsmax": 70,
"tmpmmax": 70,
"throtmax": 100,
"throtmin": -100,
"throtmaxRev": 95,
"throtdead": 3,
"RegenBrakeLight": -15,
"throtrpmfilt": 10,
"Gear": 1,
"OilPump": 36,
"cruisestep": 200,
"cruiseramp": 20,
"regenlevel": 2,
"udcsw": 295,
"cruiselight": 0,
"errlights": 0,
"CAN3Speed": 0,
"BattCap": 22,
"Voltspnt": 395,
"Pwrspnt": 1500,
"IdcTerm": 0,
"CCS_ICmd": 0,
"CCS_ILim": 100,
"CCS_SOCLim": 80,
"SOCFC": 50,
"Chgctrl": 1,
"ChgAcVolt": 240,
"ChgEff": 90,
"DCdc_Type": 0,
"DCSetPnt": 14,
"BMS_Mode": 0,
"BMS_Timeout": 10,
"BMS_VminLimit": 3,
"BMS_VmaxLimit": 4.18,
"BMS_TminLimit": 5,
"BMS_TmaxLimit": 50,
"Heater": 0,
"Control": 0,
"HeatPwr": 0,
"HeatPercnt": 0,
"Set_Day": 0,
"Set_Hour": 0,
"Set_Min": 0,
"Set_Sec": 0,
"Chg_Hrs": 0,
"Chg_Min": 0,
"Chg_Dur": 0,
"Pre_Hrs": 0,
"Pre_Min": 0,
"Pre_Dur": 0,
"Out1Func": 6,
"Out2Func": 7,
"Out3Func": 3,
"SL1Func": 0,
"SL2Func": 0,
"PWM1Func": 0,
"PWM2Func": 4,
"PWM3Func": 2,
"GP12VInFunc": 12,
"HVReqFunc": 11,
"GPA1Func": 0,
"GPA2Func": 0,
"ppthresh": 2500,
"BrkVacThresh": 2500,
"BrkVacHyst": 2500,
"IsaInit": 0,
"Type": 0,
"Tim3_Presc": 719,
"Tim3_Period": 7200,
"Tim3_1_OC": 3600,
"Tim3_2_OC": 3600,
"Tim3_3_OC": 3600
}

[tom91]

Log your rpm, it is possible your communication between the Zombie and GS450h drops out.

Yes low speed regen is an issue due to the slop inside the GS450h and the rest of most drivetrains which create undesired oscillations

Also good to plot speed and potnom

[joeflickers]

Log your rpm, it is possible your communication between the Zombie and GS450h drops out.

Yes low speed regen is an issue due to the slop inside the GS450h and the rest of most drivetrains which create undesired oscillations

Also good to plot speed and potnom

I'll do that... So today I was in slow moving traffic and the motor started shaddering very heavily.. Had to reach for the ignition swith... Rebooting it performed as expected... This got me worried.. To mention I have Done 13,000km so far until this issues elapsed last week

[joeflickers]

Log your rpm, it is possible your communication between the Zombie and GS450h drops out.

Yes low speed regen is an issue due to the slop inside the GS450h and the rest of most drivetrains which create undesired oscillations

Also good to plot speed and potnom

I've done several test,
test one
with regen enabled.. Works well until I slow down completely like it traffic.. When I start accerelation the motor starts to shake violently until I swith off

Test two.
Regen disabled I get no issues at all..
I tried to plot potnom and speed but it only logs for few seconds and then spots...

[LRBen]

I've got a similar thing on another GS450H project. It's a pretty light car which I think makes it worse. Although for me it's only around the regenendrpm that it shakes and I don't need to cycle anything to stop it.
To get around it I have an arduino that can maps regenendrpm so we never actually get near it. When coming down the rpm range it will change regenendrpm to a value above the current rpm by a few hundred. Which works quite well, although it does mean regen cuts out noticeably rather than the smooth taper it should have.

Then increasing rpm it will move the regenendrpm back down again, this part is what I haven't fully got running smoothly yet as moving regenendrpm down past the current rpm affects the throttle ramp and isn't very smooth.

As Tom said it's a physical thing with the GS450H and it's only with regen this becomes noticeable. I am most probably going to do some tests with the input shaft unlocked and only running MG2, maybe do something with MG1 running separately to run the oil pump and maybe that will take up the internal slack.

[joeflickers]

I've got a similar thing on another GS450H project. It's a pretty light car which I think makes it worse. Although for me it's only around the regenendrpm that it shakes and I don't need to cycle anything to stop it.
To get around it I have an arduino that can maps regenendrpm so we never actually get near it. When coming down the rpm range it will change regenendrpm to a value above the current rpm by a few hundred. Which works quite well, although it does mean regen cuts out noticeably rather than the smooth taper it should have.

Then increasing rpm it will move the regenendrpm back down again, this part is what I haven't fully got running smoothly yet as moving regenendrpm down past the current rpm affects the throttle ramp and isn't very smooth.

As Tom said it's a physical thing with the GS450H and it's only with regen this becomes noticeable. I am most probably going to do some tests with the input shaft unlocked and only running MG2, maybe do something with MG1 running separately to run the oil pump and maybe that will take up the internal slack.

Good to hear from you Ben.. For now I'll keep regen switched off.. Btw what does
This parameters mean
"idcmax": 5000,
"idcmin": -5000,
"throtmin": -100,

What do they represent?

[LRBen]

idcmin and max are current limits. Ideally you would set them in line with the max current you want to draw from your battery and the maximum amount of current put back into it under regen. Hitting IDCmax will result in derats which is pretty noticeable at full throttle, but it's there for a reason if you want to protect your battery.

throtmin is used as part of the throttle setup, but I have always left it on default.

[joeflickers]

idcmin and max are current limits. Ideally you would set them in line with the max current you want to draw from your battery and the maximum amount of current put back into it under regen. Hitting IDCmax will result in derats which is pretty noticeable at full throttle, but it's there for a reason if you want to protect your battery.

throtmin is used as part of the throttle setup, but I have always left it on default.

Today I changed the Vcu had a spares one.. Flashed same firmware 2.17 and the oscillations seems to have gone away with exactly the same settings.. Regen is smooth on slow speed and no vibrations after stopping as it was before.. What could have escalated this.. I was wondering if keeping on changing the settings and saving to Eepreom be corrupting the stm32?.. Ill conduct and experiment with old ecu by doing a fast chip erase and testing again

[tom91]

Please get logs and share your parameters for evaluations.

The reason for regen not to stop is the breakdown of communications with the Lexus Inverter thus freezing the speed feedback.