So, recap:
- It has 2 inverters, the stronger one capable of 400A or so
- Uses 1200V IGBTs
- It has a buck converter (seen from the inverter side to the battery)
- It has a DC/DC converter HV -> 12V that runs independently down to ~150V, up to 300V?
- It has a 3rd auxiliary inverter that also runs independently but is not yet figured out
I do consider sticking to Toyotas original design and locate the logic board OUTSIDE of the inverter because there are no mounting points inside of it. You could stick it onto the main cap with some hot snod, but eeh...
I'll have to check whether adapter + V3 mainboard fit in a ModICE enclosure. I would use the 20+20 version and loose 6 of the 26 controller pins. 12V/GND come from the inverter, emcy_stop, mprot, and 2 outputs will be dropped.
Software-wise I'd just add a new "pwmpol" option like "unipolar" that only enables the high side pins when driving and uses one low side pin when charging. Inverter charging code can be used as is I suppose, it already reads both current sensors, takes the absolute larger value and filters it.
The adapter board would
- Get ignition 12V from 2-pole connector inside the inverter
- Enable inverter with MSDN using DC switch output
- Tie GCNV and GINV to GND
- Run MG2 inverter (MUU, MVU, MWU) with the 3 high-side signals
- Multiplex both MG1 and MG2 current sensors onto the il1, il2 inputs - Switch inputs by means of a charge signal and a relay?
- Read MG2 inverter temperature from MIVT
- Read bus voltage from VH
- Run buck converter from phase 2 lowside output
- Enable buck converter with CSDN signal - when?
- Route MFIV to desat input
5. To all analog people is there a more elegant way to always have the current with the larger absolute magnitude show up on the output?
6. Temperature curve?
9. Could the buck converter remain permanently enabled?
So the kit would consist of:
- 32-pole inverter connector
- 2-pole inverter 12V power connector
- 2x20 pin Molex connector for the ModICE enclosure
- Appropriate cable
- The ModICE enclosure (20+20)
- Adapter board
- V3 main board /w wifi
Final question: does anyone feel like making a ModICE compatible adapter board in KiCAD? I can draw the schematic if needed.