openinverter forum

Edit: Photo

Great project

Gives me the functionality of an Outback with the coolness of a vintage VW and the satisfaction of "I DID IT!"

Good work - keen to follow along!

I'm planning something similar with the Lexus MGR to drive an aircooled VW.

I think I had come to similar conclusions as you, but similar to you, hadn't realised some of those finer points around the inverters! From your experience in research, it sounds like you'd recommend using the Gen 3 inverter with Damian's control board? Does it require any additional boards - my impression was that it's all integrated, but perhaps I've missed that!

Good luck!

I better do some re arranging to lift my standards before posting any pictures, as you're looking very serious Nice.

RetroZero wrote: ↑Sat Apr 25, 2020 7:34 am I better do some re arranging to lift my standards before posting any pictures, as you're looking very serious Nice.

Thanks for the kind words, but it is out of necessity.... I cannot work in disorder.

It's saying you've defined the same function - basically a set of instructions to do, with the same name, in two places.

In this case there is a function called setup in both FSBrowser.ino and another file (probably sketch_apr25a.ino).

You probably have the code in the same project twice.

-Matt

Let the Magic Smoke out

Fortunately only the motor jumper wires are affected and have plenty more of them

Is my understanding that the Inverter and motor phases are wired the same and that switching the outboard wires will only result in a direction reversal? All my searching suggests that is so, but if anyone knows differently, please do share.

For the MGR you need the FOC software and here it is important how the wiring is.

The inverter must know the position of the rotor in order to control the appropriate coil, so the position and the direction of the resolver (sin, cos) and the phases must match. If the direction of rotation and resolver is correct, you can correct a phase shift with the offset value. In addition, the current direction of the measurement must be correct, otherwise the control will not work either.

Number of pole pairs from the motor should be 4 and 2 for the resolver.

Thanks!

I understood that in "test" mode, the motor should spin smoothly regardless, but I suppose if the incorrect software is used (Sin v FOC), the outputs might not be correct.

This SCARES ME BIG TIME I have never, ever successfully updated one of these ESP8266s with either SIN or FOC ware..

Here

Goes

EVERYTHING!

Well, that went... WELL!

Downloaded FOC to the PC, connected to inverter7 via WiFi and selected the "Update" option. New firmware with absolutely no drama!

Excellent work Johu!

Good to hear! I'm watching intently.

Since this "Magic Smoke" event, I have not been able to get any output from the Inverter. I switched back to SIN from FOC and no change in results.

There is no evidence that the short touched the inverter case and being able to handle 350A or more, I cannot see how it could have been damaged by the (relatively) low over current event. But w/o an oscilloscope scope, I can neither inject PWM into it, nor effective verify the VCU is outputting to the inverter.

Begging the question, with typical shop tools, how can I verify VCU output? I have measured ~16V on the three VCU output wires (U,V,W) so can I use lightbulbs to verify variable PWM to the inverter somehow?

Having some voltage on the VCU optputs suggests the inverter is logic is OK, so I hate to replace it needlessly.

.

"New" inverter, same results. Looks like I damaged the VCU somehow, really wish I knew what happened because the most important thing is not to repeat the failure!

I also switched back to "FOC" and have no resolver signal, it is stuck on 106*, and wire voltages do not change with rotation

BTW, here is a tip, remove the blue seal from the Cinch box and green seals from the connector housings until you are done with wire up and placing it in your project because it is MUCH easier to latch/unlatch the tabs with the seals removed! Trust me, you will be connecting/disconnecting a few times and it is worth the 5 seconds to remove the seals. If you are mounting the VCU inside, you *could* leave the seals out completely.

More Christmas in July

Leaf contactor assembly showed up today, for the inquiring minds...

PC Coil = 105ohms
B+/- Coils = 33.3ohms

There are four male spade connections that are tied to the HV side:

Black Housing:
Pink = B+
Gray = B-

Brown Housing = B+
Gray Housing = B-

The B- spades connect to the OUTboard DC- Relay terminal, the B+ spades connect to the INboard DC+ terminal.

OK, I have the resolver working again

After correcting the phase wiring per the updated instructions, I still have no output from the STM32 to the ULN2003, where it's pins (5, 6 & 7) "U, V & W" are all 14.7Vdc with no pull-down in Manual Run with fslipcnt & ampnom = 1 and I am running out of ideas

Project Update: I hear whining

There is voltage on the motor wires and it fights manual rotation more with more manual id, but the amps are WAY high for no rotation, like 30A!

But, there is light at the end of the tunnel and it does not sound like a train

I have some VERY smooth MGR spinning in Fwd @ 12v and Rev @ 48, but bi-directional goodness is thus far, mutually exclusive.

Do the current sensors have to be recalibrated for higher voltage?

TheSilverBuick wrote: ↑Tue Aug 11, 2020 2:12 am Do the current sensors have to be recalibrated for higher voltage?

Nope, voltage will not affect them.

Isaac96 wrote: ↑Tue Aug 11, 2020 2:46 am

TheSilverBuick wrote: ↑Tue Aug 11, 2020 2:12 am Do the current sensors have to be recalibrated for higher voltage?

Nope, voltage will not affect them.

That's good to hear.

Johannes posted custom FOC commands and I tried them with apparent success!

Now off to "tune" the syncoffs settings, but am very happy that I have 100% confirmed the VCU and inverter work as designed and power the MGR

BTW, I spun the MGR to 1800 RPM today @ 48Vdc, if the rpm/v is linear, that means 240v ~ 9000 motor rpm, or 1300 ish output rpm, OR 98 MPH! That is CRAZY fast in a 1970 VW Squareback! I'm thinking that 70mph is about the limit of my intestinal fortitude.

success ! now for that ubiquitous spinning rear wheel shot

TFirenza wrote: ↑Wed Aug 12, 2020 8:47 pm success ! now for that ubiquitous spinning rear wheel shot

Not with only 50kW and a rear-engine car, unless I use "traction reducing liquids" LOL!

haha, maybe a bit of fairy liquid