openinverter.org wiki - User contributions [en]

Toyota/Lexus GS300h CVT

2022-09-26T12:23:37Z

Thornogson: /* Resolvers */ added more detail/Toyota nomenclature

'''NOTE : This motor is as of yet untested in a real world application.'''

Forum board : https://openinverter.org/forum/viewtopic.php?f=14&t=949#p15109

https://openinverter.org/forum/viewtopic.php?t=949

General overview : https://slideplayer.com/slide/14432904/

[[File:Gs300h-cvt.jpg|thumb]]

== Description ==
The L210 is a continuously variable transmission (CVT) which can be found in the Lexus gs300h. It is very similar in design to the gs450h CVT. It contains two motor-generators - MG1 and MG2. When used as originally intended, MG1 is spun by the ICE, via a planetary gear system, and acts primarily as a generator. MG1 also acts as a starter motor for the ICE. MG2 is connected to the output shaft via a second planetary gear system to provide traction directly to the rear wheels.

The ratio between MG1 and the output shaft is 2.6:1. The ratio between MG2 and the output shaft is 3.333:1.

The official power output of the CVT is [https://lexus.pressroom.com.au/press_kit_detail.asp?kitID=336&clientID=3&navSectionID=6 105kW and 300Nm of torque], but this has yet to be tested.

For use in a pure EV application, the ICE input shaft can be locked stationary with a plate or bar. This allows traction to be provided by both MG1 and MG2.

=== Part Numbers ===
Part numbers include 30920-30030. The CVT can be found in the Lexus GS300h, Lexus IS300h, and Toyota Crown Hybrid(G9200-30131). The matching inverter is part number G9200-30132, which is a Gen 3 inverter.

=== Dimensions ===
Bellhousing diameter =400 mm ,

Length bellhousing face to drive flange face 720mm

Diameter main body 330mm front to 250 rear

Tailshaft length 210mm

Weight 90kg

== Oil pump ==
The L110 CVT, found in the gs450h, has two oil pumps. An internal mechanical pump and an external 12V electric pump. The internal mechanical oil pump is driven by the ICE. Locking the ICE input shaft to allow MG1 to provide traction means that the internal oil pump no longer functions. This makes the external 12V electric oil pump essential when using the CVT in a pure EV application.

One key difference between the L210 (gs300h) and the L110 (gs450h) is that the L210 only has an internal oil pump. However, the internal oil pump is driven by both the ICE and/or the rotation of MG2. So, even when you lock the ICE input shaft to allow MG1 to provide traction, MG2 will still drive the oil pump whenever the car moves. Since there are no gears/speeds in this CVT (and hence no clutch packs, etc.), the oil is only required for cooling and lubricating the bearings.

== Connections ==
[[File:9200-30131-inverter side.png|thumb]]

=== Inverter ===
The part number for the inverter connector is 90980-12992<ref>Forum Source: https://openinverter.org/forum/viewtopic.php?p=43421#p43421</ref>.

Inverter/trans pair can be controlled by OI Zombieverter VCU Here [[ZombieVerter VCU]]

=== Left hand side ===
[[File:Gs300h-cvt-lhs-annotated-2.jpg|alt=|thumb|Left hand side connections]]
# MG1 3-phase power connection
# MG1 resolver (and temperature) port
# MG2 resolver (and temperature) port
=== Right hand side ===
[[File:Gs300h-cvt-rhs-annotated-2.jpg|alt=|thumb|Right hand side connections]]
# Input/output from/to oil cooler radiator
# Mechanical shifter and shift sensor port
# Ground strap
# MG2 3-phase power connection

=== Resolvers ===
Sumitomo 6189-1240 8-WAY

Motor side connection

1 2 3 4

White Red Yellow White ( colours inside motor )

TMP1 CS SN RF

TMP2 CSG SNG RFG

White Black Blue Green ( colours inside motor )

5 6 7 8

For connections to inverter, MG1 connections have prefix G... MG2 have prefix M...

But check for yourself as per Damien's tuning video

=== Shift sensor ===
[[File:GS300hShiftsensor.png|thumb]]
part number: 89451-30010

Connector: SUMITOMO 90980-12362

Position 1 being the sprung return and 5 being park

Pin 3 is common, you can see there is a direct connection to

a pin for each position and a secondary connection to either 2,5,9

this could be used as an error check

https://openinverter.org/forum/viewtopic.php?t=949&start=125

::;
:;

=== Output flange ===
Bolt pattern: About 100mm from hole to hole (~58mm radius) (compared to GS450H's 91mm (or 52.5mm radius)).

=== ICE input shaft coupling ===
23mm shaft diameter , 21 spline

OEM numbers : Daihatsu 31250-14090; Lexus 31250-14010; Toyota 31250-12040;

Confirmed that Blueprint ADT33102, ADT33127 <ref>Forum Source: https://openinverter.org/forum/viewtopic.php?p=43211#p43211</ref> clutch plate or equivalent is a good fit.

== References ==
<references />

[[Category:OEM]] [[Category:Toyota]] [[Category:Motor]]

Toyota/Lexus GS300h CVT

2022-09-18T09:20:07Z

Thornogson: /* Inverter */

'''NOTE : This motor is as of yet untested in a real world application.'''

Forum board : https://openinverter.org/forum/viewtopic.php?f=14&t=949#p15109

https://openinverter.org/forum/viewtopic.php?t=949

General overview : https://slideplayer.com/slide/14432904/

[[File:Gs300h-cvt.jpg|thumb]]

== Description ==
The L210 is a continuously variable transmission (CVT) which can be found in the Lexus gs300h. It is very similar in design to the gs450h CVT. It contains two motor-generators - MG1 and MG2. When used as originally intended, MG1 is spun by the ICE, via a planetary gear system, and acts primarily as a generator. MG1 also acts as a starter motor for the ICE. MG2 is connected to the output shaft via a second planetary gear system to provide traction directly to the rear wheels.

The ratio between MG1 and the output shaft is 2.6:1. The ratio between MG2 and the output shaft is 3.333:1.

The official power output of the CVT is [https://lexus.pressroom.com.au/press_kit_detail.asp?kitID=336&clientID=3&navSectionID=6 105kW and 300Nm of torque], but this has yet to be tested.

For use in a pure EV application, the ICE input shaft can be locked stationary with a plate or bar. This allows traction to be provided by both MG1 and MG2.

=== Part Numbers ===
Part numbers include 30920-30030. The CVT can be found in the Lexus GS300h, Lexus IS300h, and Toyota Crown Hybrid(G9200-30131). The matching inverter is part number G9200-30132, which is a Gen 3 inverter.

=== Dimensions ===
Bellhousing diameter =400 mm ,

Length bellhousing face to drive flange face 720mm

Diameter main body 330mm front to 250 rear

Tailshaft length 210mm

Weight 90kg

== Oil pump ==
The L110 CVT, found in the gs450h, has two oil pumps. An internal mechanical pump and an external 12V electric pump. The internal mechanical oil pump is driven by the ICE. Locking the ICE input shaft to allow MG1 to provide traction means that the internal oil pump no longer functions. This makes the external 12V electric oil pump essential when using the CVT in a pure EV application.

One key difference between the L210 (gs300h) and the L110 (gs450h) is that the L210 only has an internal oil pump. However, the internal oil pump is driven by both the ICE and/or the rotation of MG2. So, even when you lock the ICE input shaft to allow MG1 to provide traction, MG2 will still drive the oil pump whenever the car moves. Since there are no gears/speeds in this CVT (and hence no clutch packs, etc.), the oil is only required for cooling and lubricating the bearings.

== Connections ==
[[File:9200-30131-inverter side.png|thumb]]

=== Inverter ===
The part number for the inverter connector is 90980-12992<ref>Forum Source: https://openinverter.org/forum/viewtopic.php?p=43421#p43421</ref>.

Inverter/trans pair can be controlled by OI Zombieverter VCU Here [[ZombieVerter VCU]]

=== Left hand side ===
[[File:Gs300h-cvt-lhs-annotated-2.jpg|alt=|thumb|Left hand side connections]]
# MG1 3-phase power connection
# MG1 resolver (and temperature) port
# MG2 resolver (and temperature) port
=== Right hand side ===
[[File:Gs300h-cvt-rhs-annotated-2.jpg|alt=|thumb|Right hand side connections]]
# Input/output from/to oil cooler radiator
# Mechanical shifter and shift sensor port
# Ground strap
# MG2 3-phase power connection

=== Resolvers ===
Sumitomo 6189-1240 8-WAY

1 2 3 4

White Red Yellow White

White Black Blue Green

5 6 7 8

1+5 Temp sensor , 2+6 ,3+7 Sin/Cos , 4+8 exciter . Both the same.

But check for yourself as per Damien's tuning video

=== Shift sensor ===
[[File:GS300hShiftsensor.png|thumb]]
part number: 89451-30010

Connector: SUMITOMO 90980-12362

Position 1 being the sprung return and 5 being park

Pin 3 is common, you can see there is a direct connection to

a pin for each position and a secondary connection to either 2,5,9

this could be used as an error check

https://openinverter.org/forum/viewtopic.php?t=949&start=125

::;
:;

=== Output flange ===
Bolt pattern: About 100mm from hole to hole (~58mm radius) (compared to GS450H's 91mm (or 52.5mm radius)).

=== ICE input shaft coupling ===
23mm shaft diameter , 21 spline

OEM numbers : Daihatsu 31250-14090; Lexus 31250-14010; Toyota 31250-12040;

Confirmed that Blueprint ADT33102, ADT33127 <ref>Forum Source: https://openinverter.org/forum/viewtopic.php?p=43211#p43211</ref> clutch plate or equivalent is a good fit.

== References ==
<references />

[[Category:OEM]] [[Category:Toyota]] [[Category:Motor]]

Toyota/Lexus GS300h CVT

2022-09-18T08:29:35Z

Thornogson: /* Shift sensor */

'''NOTE : This motor is as of yet untested in a real world application.'''

Forum board : https://openinverter.org/forum/viewtopic.php?f=14&t=949#p15109

General overview : https://slideplayer.com/slide/14432904/

[[File:Gs300h-cvt.jpg|thumb]]

== Description ==
The L210 is a continuously variable transmission (CVT) which can be found in the Lexus gs300h. It is very similar in design to the gs450h CVT. It contains two motor-generators - MG1 and MG2. When used as originally intended, MG1 is spun by the ICE, via a planetary gear system, and acts primarily as a generator. MG1 also acts as a starter motor for the ICE. MG2 is connected to the output shaft via a second planetary gear system to provide traction directly to the rear wheels.

The ratio between MG1 and the output shaft is 2.6:1. The ratio between MG2 and the output shaft is 3.333:1.

The official power output of the CVT is [https://lexus.pressroom.com.au/press_kit_detail.asp?kitID=336&clientID=3&navSectionID=6 105kW and 300Nm of torque], but this has yet to be tested.

For use in a pure EV application, the ICE input shaft can be locked stationary with a plate or bar. This allows traction to be provided by both MG1 and MG2.

=== Part Numbers ===
Part numbers include 30920-30030. The CVT can be found in the Lexus GS300h, Lexus IS300h, and Toyota Crown Hybrid(G9200-30131). The matching inverter is part number G9200-30132, which is a Gen 3 inverter.

=== Dimensions ===
Bellhousing diameter =400 mm ,

Length bellhousing face to drive flange face 720mm

Diameter main body 330mm front to 250 rear

Tailshaft length 210mm

Weight 90kg

== Oil pump ==
The L110 CVT, found in the gs450h, has two oil pumps. An internal mechanical pump and an external 12V electric pump. The internal mechanical oil pump is driven by the ICE. Locking the ICE input shaft to allow MG1 to provide traction means that the internal oil pump no longer functions. This makes the external 12V electric oil pump essential when using the CVT in a pure EV application.

One key difference between the L210 (gs300h) and the L110 (gs450h) is that the L210 only has an internal oil pump. However, the internal oil pump is driven by both the ICE and/or the rotation of MG2. So, even when you lock the ICE input shaft to allow MG1 to provide traction, MG2 will still drive the oil pump whenever the car moves. Since there are no gears/speeds in this CVT (and hence no clutch packs, etc.), the oil is only required for cooling and lubricating the bearings.

== Connections ==
[[File:9200-30131-inverter side.png|thumb]]

=== Inverter ===
The part number for the inverter connector is 90980-12992<ref>Forum Source: https://openinverter.org/forum/viewtopic.php?p=43421#p43421</ref>.

=== Left hand side ===
[[File:Gs300h-cvt-lhs-annotated-2.jpg|alt=|thumb|Left hand side connections]]
# MG1 3-phase power connection
# MG1 resolver (and temperature) port
# MG2 resolver (and temperature) port
=== Right hand side ===
[[File:Gs300h-cvt-rhs-annotated-2.jpg|alt=|thumb|Right hand side connections]]
# Input/output from/to oil cooler radiator
# Mechanical shifter and shift sensor port
# Ground strap
# MG2 3-phase power connection

=== Resolvers ===
Sumitomo 6189-1240 8-WAY

1 2 3 4

White Red Yellow White

White Black Blue Green

5 6 7 8

1+5 Temp sensor , 2+6 ,3+7 Sin/Cos , 4+8 exciter . Both the same.

But check for yourself as per Damien's tuning video

=== Shift sensor ===
[[File:GS300hShiftsensor.png|thumb]]
part number: 89451-30010

Connector: SUMITOMO 90980-12362

Position 1 being the sprung return and 5 being park

Pin 3 is common, you can see there is a direct connection to

a pin for each position and a secondary connection to either 2,5,9

this could be used as an error check

https://openinverter.org/forum/viewtopic.php?t=949&start=125

::;
:;

=== Output flange ===
Bolt pattern: About 100mm from hole to hole (~58mm radius) (compared to GS450H's 91mm (or 52.5mm radius)).

=== ICE input shaft coupling ===
23mm shaft diameter , 21 spline

OEM numbers : Daihatsu 31250-14090; Lexus 31250-14010; Toyota 31250-12040;

Confirmed that Blueprint ADT33102, ADT33127 <ref>Forum Source: https://openinverter.org/forum/viewtopic.php?p=43211#p43211</ref> clutch plate or equivalent is a good fit.

== References ==
<references />

[[Category:OEM]] [[Category:Toyota]] [[Category:Motor]]

File:GS300hShiftsensor.png

2022-09-18T08:17:23Z

Thornogson:

https://openinverter.org/forum/viewtopic.php?t=949&start=125

Main Page Old

2021-03-16T20:23:00Z

Thornogson: /* Conversion Projects */ added link to specs website

Welcome to the openinverter.org Wiki Site. Everyone registered at the [https://openinverter.org/forum/index.php forum] can login here with the same username and password and can make changes.

= Before you begin: =
'''Please take the time to read.''' The information provided on this wiki and the support forums is intended as information only. The Open Inverter project and it's contributors take no responsibility for how you use the information contained within these pages, nor any liability for injuries, or death, that may result from your actions.

You undertake '''your''' project at '''your own risk.'''

= Introduction =
Open inverter is a suite of open source hardware and software projects for building, modifying and controlling a variety of power electronics.

projects originates from Johannes Hübner building a opensource ac motor controller, dubbed the "open inverter".

The project now has spanned over many different areas in ev and hybrid vehicles components, such as:
* AC motor controllers
* 1-3 phase power converters
* dc/dc converts
* buck/boost converters
* battery management systems

.

With the rising popularity and avalibity of hybrid and electric vehicles, there is a growing supply of parts. The open inverter community's goal is to repurpose many of these components for ev conversions and other projects.

The open inverter community is growing and moving quite quickly, to stay up-to-date with the latest developments and findings, please check out the [https://openinverter.org/forum/index.php forums]

consider contributing to [https://www.patreon.com/openinverter www.patreon.com/openinverter] and to https://www.evbmw.com/

=== The open inverter motor controller project consists of three main aspects: ===
{| class="wikitable"
|+
!Hardware
!Firmware
!Web Interface
|-
|The design and development of the [[Main Board Version 3|control hardware]] based around an STM32F103 chip. This provides the control signals to the power stage and on to the attached components.
|The development of the code that goes on the STM32F103 chips and determines, amongst other things what signals are sent to the power stage and the attached components.
|Using an ESP8266 chip, the development of a simple web based interface to adjust the parameters on the firmware chip and to display values returned from the chip, for example motor speed (RPM).
|}

= Getting Started =
=== Inverter variants available: ===
{| class="wikitable"
|+
!
==== Open Inverter (Core Project) ====
!
!
==== Open Inverter Related Projects / Control Boards ====
|-
|'''core universal hardware and software components'''

| rowspan="6" |
|'''custom hardware and software designed to work with particular components.'''
'''which are based on the core open inverter hardware or software stack.'''

|-
| rowspan="3" |
====== Open Inverter Hardware ======
* [[Hardware Theory of Operation]]
* [[Schematics and Instructions]] - for the "vanilla" inverter kit.
* [[Main Board Version 3]]
* [[Main Board Version 2]]
* [[Main Board Version 1]]
* [[Sense Boards]]
* [[Gate Driver]]
* [[Sensor Board|Legacy Sensor Board]]
* [[OEM Repurposing]]

|'''[[Tesla|Tesla Small Drive and Large Drive Units:]]'''
commonly there is a large drive unit and small drive unit available.

These combine the inverter and motor into a single package. The

control boards for these replace the existing control board within them.

|-
|'''[[Lexus GS450h Inverter|Lexus GS450h Inverter / VCU:]]'''
the GS450h provides a gearbox (where the motors are located)

combined with the original inverter, this board looks to control

the inverter and the gearbox itself to provide a powerful set up

suitable for rear wheel drive set ups, replacing the existing

longitudinally mounted gearbox.

|-
|'''[[Toyota Prius Gen3 Board|Prius Generation 3 Inverter:]]'''
a cheap available inverter from the popular Prius hybrid, this

board goes inside that inverter and allows you to control the features of it.
|-
| rowspan="2" |
====== '''Open Inverter Software''' ======
* [[Using FOC Software]]
* [[Downloads]]
* [[Features]]
* [[Web Interface]]
* [[Battery Charging]]
* [[Errors]]
* [[CAN communication]]
* [[Parameters]] (Tune your inverter)
* [[Configuration Files]]
* [[Software Theory of Operation]]
* [[Open Inverter Testing]]
|'''[[Auris/Yaris Inverter:]]'''
similar to the Prius board, there's subtle differences between them and

therefore the need for a separate board.

|-
|'''[[Nissan Leaf VCU|Nissan Leaf VCM:]]'''
this vehicle control board plugs into the Nissan Leaf inverter externally

and controls it via CAN

|-
|
|
|

'''[[Nissan Leaf Gen2 Board]]'''

replaces the nissan OEM logic board with a rev 3 openiverter board for full control

|-
|
|
|[[OEM Repurposing|All Control Boards / OEM Inverters]]

|-
|
|
|
|-
| colspan="3" |
====== CAN communication ======
Common across boards is the ability to communicate with a CAN Bus, which is a 'control area network' or a technical way of saying how various components, sensors, controls, etc communicate with one another within the car. '''Read more about [[CAN communication|CAN Communication]]'''

There is also a project to standardise the messages across the various control boards, [[Introduction CAN STD|read more]]

|-
| colspan="3" |
|-
| colspan="3" |
====== Use inverter as a battery Charger ======
Both the open inverter and some OEM inverters can be used as a battery charger, further saving on component costs. You can read more about how the open inverter and the theory of charging [[Battery Charging|here]]

|}

=== Further Components ===
Once you have the [[Inverters|inverter]], you will need additional components for your EV conversion:
* [[Motors]]
* [[Batteries]]
* [[Charger]]
* [[DC/DC Converter]]
* [[HV Junction Box]]
* Other various components
** Vacuum Pumps
** Heaters
** Air Conditioning
** Information Displays
** etc.

Existing information on these items can be found on the [[EV Conversion Parts]] page.

= FAQs =
* [[Common Inverter FAQ]] - questions common to all hardware variants
* [[Tesla Inverter FAQ]] - questions regarding Tesla Large Drive Units and Small Drive Units

= Open Inverter CAN std. =
* [[Introduction CAN STD|Introduction]]
* [[CAN table CAN STD|CAN table]]
* [[Getting started with CAN bus]]

= Glossary of Terms =
* [[Glossary of Terms]]

= Legalities =
* [[Legalities|Legalities around conversion projects]]
Different countries have different legislation, if you want you car to certified for the road in your country please take the time to review this section.

= Conversion Projects =
* [[VW Polo 86C Conversion]]
* [[Touran Conversion]]
* [https://openinverter.org/forum/viewtopic.php?f=11&t=326&hilit=gt86 toyota gt86 nissan leaf motor]
* [https://openinverter.org/forum/viewtopic.php?f=11&t=210 Porsche Boxster 986 Tesla conversion]
* [https://openinverter.org/forum/viewforum.php?f=11 Further Projects on the forum]

= OEM Parts =
* https://www.ultimatespecs.com/electric-hybrid-cars
* [[BMW]]
* [[Isabellenhütte Heusler]]
* [[Mercedes]]
* [[Nissan]]
* [[Tesla]]
* [[Toyota]]
* [[Chevrolet]]
* [[Mistubishi]]
* [[Volkswagon]]

Toyota Auris/Yaris Inverter

2021-03-12T20:54:10Z

Thornogson: added links to build and tuning videos

Auris/Yaris Inverter Board is an open source project to repurpose Toyota Auris/Yaris (and Prius -C , Prius Aqua and Lexus CT200H) inverters for DIY EV use.

These are nearly identical to Toyota Prius Gen 3 inverters with a smaller format logic board to fit under a sloped casing. It is believed to have a smaller main capacitor and hence be of lower power capabilities [* Needs testing to confirm and adding here ]

They are very cheap (<£100 in UK at the start of 2021) and suitable for a variety of EV /Charger and other inverter projects.

The Project consists of a open inverter circuit board (adapted from Prius Gen3 board) and programming which replaces the OEM logic board in the Auris/Yaris inverter.

This allows independent control of mg1 power stage, mg2 power stage, buck/boost converter and the dc/dc converter.

=== Resources ===
Support thread is here : https://openinverter.org/forum/viewtopic.php?f=14&t=767

For using it as a charger , thread is here : https://openinverter.org/forum/viewtopic.php?f=14&t=825

Resources and design files on Github : https://github.com/damienmaguire/Yaris-Auris-Inverter

Available on the EVBMW.COM webshop : [https://www.evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards/auris-yaris-inverter-logic-board-kit evbmw.com Yaris/Auris boards] in partial built and full kit format.

There is a Auris/Yaris version of the dual motor board which allows both MG1 and MG2 of Toyota transmissions or (any 2 other suitable motors) to be powered by the same inverter, support thread here: https://openinverter.org/forum/viewtopic.php?f=14&t=1051

=== Timeline ===
17/05/20 : Prototype build commenced at JLCPCB.

28/06/20 : Block 2 boards with corrections to incorrect pinouts and component values now available from the evbmw webshop. https://www.evbmw.com/index.php/evbmw-w ... -board-kit

24/09/20 Firmware now available to run the buck/boost module as an AC onboard charger: HERE: https://github.com/celeron55/prius3charger_buck

Schematic and pcb layout uploaded to github : https://github.com/damienmaguire/Yaris-Auris-Inverter

Design files available to Patrons only as of this date. <nowiki>https://www.patreon.com/evbmw</nowiki>

Schematic and pcb layout for Dual Motor boards on Github here : https://github.com/damienmaguire/Prius-Gen3-Inverter/tree/master/Small%20board%20V1d

=== Buildup and setup ===
Most of the build up /setup is identical to the V1C Prius board here: [[Toyota Prius Gen3 Board]]

Video build tutorials here : https://www.youtube.com/watch?v=QE-zym8iIgM&t=439s ,here : https://www.youtube.com/watch?v=Nu5_OBOPk4s&t=319s and here<nowiki/>https://www.youtube.com/watch?v=xoNs2NqjXd8

FOC Setup and tuning is as per Prius gen3 here : https://www.youtube.com/watch?v=tirDQJ6iH28&t=2306s

=== Also Note ===
But also note : (Source https://openinverter.org/forum/viewtopic.php?f=14&t=767 )

# On the Yaris boards (block111 and before) when using resolver you would need to remove the two pullups R30 and R29. See schematic :

https://raw.githubusercontent.com/damie ... ematic.pdf

2. There is an error on early boards (block 111 and before) : MG1 resistor divider values are wrong. R41 and 42 should be 6k2 not 4k7 and R46 and R45 should be 3k6 not 4k7.

3. The MG2 current sensor socket has the pins reversed. this can be solved by cutting the socket to allow the plug in upside down or by cutting and resoldering the current sensor wires. Plugging them in will kill the -5v output of PS1 (a SGM3204 SOT if you live in china ) or a LM2776DBVT for europe

4. Conn11 is the external hvil which is not used.

5. vcc+5v may be problematic , it may be at the limit of it's current due to use by Wifi and current sensors possibly causing a reduced Vcc 5v. try adding an external +5v line.. [ * needs confirming]

Toyota Auris/Yaris Inverter

2021-03-12T17:11:51Z

Thornogson: minor tidy up

Auris/Yaris Inverter Board is an open source project to repurpose Toyota Auris/Yaris (and Prius -C , Prius Aqua and Lexus CT200H) inverters for DIY EV use.

These are nearly identical to Toyota Prius Gen 3 inverters with a smaller format logic board to fit under a sloped casing. It is believed to have a smaller main capacitor and hence be of lower power capabilities [* Needs testing to confirm and adding here ]

They are very cheap (<£100 in UK at the start of 2021) and suitable for a variety of EV /Charger and other inverter projects.

The Project consists of a open inverter circuit board (adapted from Prius Gen3 board) and programming which replaces the OEM logic board in the Auris/Yaris inverter.

This allows independent control of mg1 power stage, mg2 power stage, buck/boost converter and the dc/dc converter.

=== Resources ===
Support thread is here : https://openinverter.org/forum/viewtopic.php?f=14&t=767

For using it as a charger , thread is here : https://openinverter.org/forum/viewtopic.php?f=14&t=825

Resources and design files on Github : https://github.com/damienmaguire/Yaris-Auris-Inverter

Available on the EVBMW.COM webshop : [https://www.evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards/auris-yaris-inverter-logic-board-kit evbmw.com Yaris/Auris boards] in partial built and full kit format.

There is a Auris/Yaris version of the dual motor board which allows both MG1 and MG2 of Toyota transmissions or (any 2 other suitable motors) to be powered by the same inverter, support thread here: https://openinverter.org/forum/viewtopic.php?f=14&t=1051

=== Timeline ===
17/05/20 : Prototype build commenced at JLCPCB.

28/06/20 : Block 2 boards with corrections to incorrect pinouts and component values now available from the evbmw webshop. https://www.evbmw.com/index.php/evbmw-w ... -board-kit

24/09/20 Firmware now available to run the buck/boost module as an AC onboard charger: HERE: https://github.com/celeron55/prius3charger_buck

Schematic and pcb layout uploaded to github : https://github.com/damienmaguire/Yaris-Auris-Inverter

Design files available to Patrons only as of this date. <nowiki>https://www.patreon.com/evbmw</nowiki>

Schematic and pcb layout for Dual Motor boards on Github here : https://github.com/damienmaguire/Prius-Gen3-Inverter/tree/master/Small%20board%20V1d

=== Buildup and setup ===
Most of the build up /setup is identical to the V1C Prius board here: [[Toyota Prius Gen3 Board]]

=== Also Note ===
But also note : (Source https://openinverter.org/forum/viewtopic.php?f=14&t=767 )

# On the Yaris boards (block111 and before) when using resolver you would need to remove the two pullups R30 and R29. See schematic :

https://raw.githubusercontent.com/damie ... ematic.pdf

2. There is an error on early boards (block 111 and before) : MG1 resistor divider values are wrong. R41 and 42 should be 6k2 not 4k7 and R46 and R45 should be 3k6 not 4k7.

3. The MG2 current sensor socket has the pins reversed. this can be solved by cutting the socket to allow the plug in upside down or by cutting and resoldering the current sensor wires. Plugging them in will kill the -5v output of PS1 (a SGM3204 SOT if you live in china ) or a LM2776DBVT for europe

4. Conn11 is the external hvil which is not used.

5. vcc+5v may be problematic , it may be at the limit of it's current due to use by Wifi and current sensors possibly causing a reduced Vcc 5v. try adding an external +5v line.. [ * needs confirming]

Toyota Auris/Yaris Inverter

2021-03-12T17:02:32Z

Thornogson: Curated useful knowledge from forums

Auris/Yaris Inverter Board is an open source project to repurpose Toyota Auris/Yaris (and Prius -C , Prius Aqua and Lexus CT200H) inverters for DIY EV use.

These are nearly identical to Toyota Prius Gen 3 inverters with a smaller format logic board to fit under a sloped casing. It is believed to have a smaller main capacitor and hence be of lower power capabilities [* Needs testing to confirm and adding here ]

They are very cheap (<£100 in UK at the start of 2021) and suitable for a variety of EV /Charger and other inverter projects.

The Project consists of a open inverter circuit board (adapted from Prius Gen3 board) and programming which replaces the OEM logic board in the Auris/Yaris inverter.

This allows independent control of mg1 power stage, mg2 power stage, buck/boost converter and the dc/dc converter.

=== Resources ===
Support thread is here : https://openinverter.org/forum/viewtopic.php?f=14&t=767

For using it as a charger , thread is here : https://openinverter.org/forum/viewtopic.php?f=14&t=825

Resources and design files on Github : https://github.com/damienmaguire/Yaris-Auris-Inverter

Available on the EVBMW.COM webshop : [https://www.evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards/auris-yaris-inverter-logic-board-kit evbmw.com Yaris/Auris boards] in partial built and full kit format.

There is a Auris/Yaris version of the dual motor board which allows both MG1 and MG2 of Toyota transmissions or (any 2 other suitable motors) to be powered by the same inverter, support thread here: https://openinverter.org/forum/viewtopic.php?f=14&t=1051

=== Timeline ===
17/05/20 : Prototype build commenced at JLCPCB.

28/06/20 : Block 2 boards with corrections to incorrect pinouts and component values now available from the evbmw webshop. https://www.evbmw.com/index.php/evbmw-w ... -board-kit

24/09/20 Firmware now available to run the buck/boost module as an AC onboard charger: HERE: https://github.com/celeron55/prius3charger_buck

Uploaded to github : https://github.com/damienmaguire/Yaris-Auris-Inverter

Design files available to Patrons only as of this date. <nowiki>https://www.patreon.com/evbmw</nowiki>

schematic and pcb layout for Dual Motor boards on Github here : https://github.com/damienmaguire/Prius-Gen3-Inverter/tree/master/Small%20board%20V1d

=== Buildup and setup ===
Most of the build up /setup is identical to the V1C Prius board here: [[Toyota Prius Gen3 Board]]

=== Also Note ===
But also note : (Source https://openinverter.org/forum/viewtopic.php?f=14&t=767 )

# On the Yaris boards (block111 and before) when using resolver you would need to remove the two pullups R30 and R29. See schematic :

https://raw.githubusercontent.com/damie ... ematic.pdf

2. There is an error on early boards (block 111 and before) : MG1 resistor divider values are wrong. R41 and 42 should be 6k2 not 4k7 and R46 and R45 should be 3k6 not 4k7.

3. The MG2 current sensor socket has the pins reversed. this can be solved by cutting the socket to allow the plug in upside down or by cutting and resoldering the current sensor wires. Plugging them in will kill the -5v output of PS1 (a SGM3204 SOT if you live in china ) or a LM2776DBVT for europe

4. Conn11 is the external hvil which is not used.

5.

Toyota Auris/Yaris Inverter

2021-03-12T15:03:00Z

Thornogson: Started a page to curate knowledge about Auris/Yaris inverters

== A page to document what you need to do to get the Auris/Yaris boards up and running ==

=== A work in progress to extract knowledge from the forum threads ===

Toyota/Lexus GS300h CVT

2021-02-25T10:58:16Z

Thornogson: /* Resolvers */

'''NOTE : This motor is as of yet untested in a real world application.'''

Forum board : https://openinverter.org/forum/viewtopic.php?f=14&t=949#p15109

General overview : https://slideplayer.com/slide/14432904/

[[File:Gs300h-cvt.jpg|thumb]]

== Description ==
The L210 is a continuously variable transmission (CVT) which can be found in the Lexus gs300h. It is very similar in design to the gs450h CVT. It contains two motor-generators - MG1 and MG2. When used as originally intended, MG1 is spun by the ICE, via a planetary gear system, and acts primarily as a generator. MG1 also acts as a starter motor for the ICE. MG2 is connected to the output shaft via a second planetary gear system to provide traction directly to the rear wheels.

The ratio between MG1 and the output shaft is 2.6:1. The ratio between MG2 and the output shaft is 3.333:1.

The official power output of the CVT is [https://lexus.pressroom.com.au/press_kit_detail.asp?kitID=336&clientID=3&navSectionID=6 105kW and 300Nm of torque], but this has yet to be tested.

For use in a pure EV application, the ICE input shaft can be locked stationary with a plate or bar. This allows traction to be provided by both MG1 and MG2.

=== Part Numbers ===
Part numbers include 30920-30030. The CVT can be found in the Lexus ES300h, Lexus IS300h, and Toyota Crown Hybrid. The matching inverter is part number G9200-30132, which is a Gen 3 inverter.

=== Dimensions ===
Bellhousing diameter =400 mm ,

Length bellhousing face to drive flange face 720mm

Diameter main body 330mm front to 250 rear

Tailshaft length 210mm

Weight 90kg

== Oil pump ==
The L110 CVT, found in the gs450h, has two oil pumps. An internal mechanical pump and an external 12V electric pump. The internal mechanical oil pump is driven by the ICE. Locking the ICE input shaft to allow MG1 to provide traction means that the internal oil pump no longer functions. This makes the external 12V electric oil pump essential when using the CVT in a pure EV application.

One key difference between the L210 (gs300h) and the L110 (gs450h) is that the L210 only has an internal oil pump. However, the internal oil pump is driven by both the ICE and/or the rotation of MG2. So, even when you lock the ICE input shaft to allow MG1 to provide traction, MG2 will still drive the oil pump whenever the car moves. Since there are no gears/speeds in this CVT (and hence no clutch packs, etc.), the oil is only required for cooling and lubricating the bearings.

== Connections ==
=== Left hand side ===
[[File:Gs300h-cvt-lhs-annotated.jpg|thumb|Left hand side connections]]
# MG1 3-phase power connection
# MG1 resolver (and temperature) port
# MG2 resolver (and temperature) port
=== Right hand side ===
[[File:Gs300h-cvt-rhs-annotated.jpg|thumb|Right hand side connections]]
# Water input/output for oil to water heat exchanger
# Mechanical shifter and shift sensor port
# Ground strap
# MG2 3-phase power connection

=== Resolvers ===
Sumitomo 6189-1240 8-WAY

1 2 3 4

White Red Yellow White

White Black Blue Green

5 6 7 8

1+5 Temp sensor , 2+6 ,3+7 Sin/Cos , 4+8 exciter . Both the same.

But check for yourself as per Damien's tuning video

=== Shift sensor ===
To do

=== Output flange ===
To do

=== ICE input shaft coupling ===
23mm shaft diameter , 21 spline

OEM numbers : Daihatsu 31250-14090; Lexus 31250-14010; Toyota 31250-12040;

Confirmed that Blueprint ADT33102 clutch plate or equivalent is a good fit.

Toyota/Lexus GS300h CVT

2021-02-25T10:42:35Z

Thornogson: /* Connections */

'''NOTE : This motor is as of yet untested in a real world application.'''

Forum board : https://openinverter.org/forum/viewtopic.php?f=14&t=949#p15109

General overview : https://slideplayer.com/slide/14432904/

[[File:Gs300h-cvt.jpg|thumb]]

== Description ==
The L210 is a continuously variable transmission (CVT) which can be found in the Lexus gs300h. It is very similar in design to the gs450h CVT. It contains two motor-generators - MG1 and MG2. When used as originally intended, MG1 is spun by the ICE, via a planetary gear system, and acts primarily as a generator. MG1 also acts as a starter motor for the ICE. MG2 is connected to the output shaft via a second planetary gear system to provide traction directly to the rear wheels.

The ratio between MG1 and the output shaft is 2.6:1. The ratio between MG2 and the output shaft is 3.333:1.

The official power output of the CVT is [https://lexus.pressroom.com.au/press_kit_detail.asp?kitID=336&clientID=3&navSectionID=6 105kW and 300Nm of torque], but this has yet to be tested.

For use in a pure EV application, the ICE input shaft can be locked stationary with a plate or bar. This allows traction to be provided by both MG1 and MG2.

=== Part Numbers ===
Part numbers include 30920-30030. The CVT can be found in the Lexus ES300h, Lexus IS300h, and Toyota Crown Hybrid. The matching inverter is part number G9200-30132, which is a Gen 3 inverter.

=== Dimensions ===
Bellhousing diameter =400 mm ,

Length bellhousing face to drive flange face 720mm

Diameter main body 330mm front to 250 rear

Tailshaft length 210mm

Weight 90kg

== Oil pump ==
The L110 CVT, found in the gs450h, has two oil pumps. An internal mechanical pump and an external 12V electric pump. The internal mechanical oil pump is driven by the ICE. Locking the ICE input shaft to allow MG1 to provide traction means that the internal oil pump no longer functions. This makes the external 12V electric oil pump essential when using the CVT in a pure EV application.

One key difference between the L210 (gs300h) and the L110 (gs450h) is that the L210 only has an internal oil pump. However, the internal oil pump is driven by both the ICE and/or the rotation of MG2. So, even when you lock the ICE input shaft to allow MG1 to provide traction, MG2 will still drive the oil pump whenever the car moves. Since there are no gears/speeds in this CVT (and hence no clutch packs, etc.), the oil is only required for cooling and lubricating the bearings.

== Connections ==
=== Left hand side ===
[[File:Gs300h-cvt-lhs-annotated.jpg|thumb|Left hand side connections]]
# MG1 3-phase power connection
# MG1 resolver (and temperature) port
# MG2 resolver (and temperature) port
=== Right hand side ===
[[File:Gs300h-cvt-rhs-annotated.jpg|thumb|Right hand side connections]]
# Water input/output for oil to water heat exchanger
# Mechanical shifter and shift sensor port
# Ground strap
# MG2 3-phase power connection

=== Resolvers ===
To do

=== Shift sensor ===
To do

=== Output flange ===
To do

=== ICE input shaft coupling ===
23mm shaft diameter , 21 spline

OEM numbers : Daihatsu 31250-14090; Lexus 31250-14010; Toyota 31250-12040;

Confirmed that Blueprint ADT33102 clutch plate or equivalent is a good fit.

Category:Toyota

2021-02-01T21:18:51Z

Thornogson: Added a link to Toyota publication containing all wiring connectors , pictures and part numbers

A landing page to start adding references to Toyota/Lexus and their suppliers part numbers and what vehicles that you might find them in.

The table below shows the part numbers of inverter units as labelled and as referenced by Toyota in their parts catalogue. Assembly part numbers may include a hyphen in the part number on some records. Label part numbers on the Lexus items are based on the lowest assembly part number. Links to part details are to the US sites for Toyota and Lexus.

{| class="wikitable"
|+Toyota/Lexus Inverter/Converter versions and Transaxle models
!Generation
!Board
!Label Part Number
!Assembly Part Number(s)
!Logic Board Part Number(s)
!Power Board Part Number(s)
!Model(s)
!Transaxle
!Model Code(s)
!Model Years
|-
|Gen 1
|[[Lexus GS450h Inverter|Lexus GS450h VCU]]
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CON/69496914/G920030180.html G9200-30040]
|G920030040
G920030051

G920030061

G920030180 (Current)
|
|
|Lexus GS450h
|L110
|GWS191
|2007-2011
|-
|Gen 3
|
|G9200-30132
|G920030132

G92A030052

G927053010

|
|
|Lexus IS300h
Lexus GS300h

Toyota Crown Hybrid
|[[Toyota/Lexus GS300h CVT|L210]]
|AVE30

AWS210/AWS211
|2013-2019
|-
|Gen 1
|
|[https://parts.toyota.com/p/Toyota__/INVERTER-ASSEMBLY---WITH-CONVERTER/63294333/G920033050.html G9200-33050]
|G920033010
G920033020

G920033050

G920033100

G920033101 (Current)
|F1759-30010-01
|
|Toyota Camry Hybrid
|P311
|AHV40
|2007-2011
|-
|Gen 3
|
|G9200-33171
|G920033171

G920033172
|
|
|Toyota Avalon Hybrid
Toyota Camry Hybrid

Lexus ES300h
|P314
|XX40
AVV50R

XVV60
|2012-2018
2012-2017

2012-2015
|-
|Gen 1
|N/A
|[https://parts.toyota.com/p/Toyota__/Drive-Motor-Inverter/69384290/G920047071.html G9200-47070]
|G920047070
G920047071

G920047080

G920047090
|
|
|Toyota Prius
|P110
|NHW11
|2000-2003
|-
|Gen 2
|Toyota Prius Gen2 [https://openinverter.org/shop/index.php?route=product/product&product_id=63]
|G9200-47110
|
|
|
|Toyota Prius
|P112
|NHW20
|2004-2009
|-
|Gen 3
|
|[https://parts.toyota.com/p/Toyota__/INVERTER-ASSEMBLY---WITH-CONVERTER/63391527/G920047150.html G9200-47150]
|G920047150
|
|
|Toyota Prius
|
|ZVW35
|2010
|-
|Gen 3
|
|G9200-47190
|G920047190
|
|
|Toyota Auris Hybrid
|
|
|2010
|-
|Gen 3
|
|G9200-47210
|G920047210
|
|
|Toyota Prius
|
|ZVW30
|2010-2015
|-
|TBC
|[[Lexus GS450h Inverter|Lexus GS450h VCU]] (TBC)
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/62982728/G920050064.html G9200-50040]
|G920050040
G920050060

G920050061

G920050063

G920050064 (Current)
|
|
|Lexus LS600h L
|[https://parts.lexus.com/p/Lexus_2012_/TRANSMISSION-ASSEMBLY---HYBRID-VEHICLE-WITH-TRANSFER--CABLE/62916922/3093050050.html L110f]
|UVF46
|2007-2018
|-
|Gen 3
|[https://evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards/auris-yaris-inverter-logic-board-kit Auris/Yaris Inverter Logic Board]
|G9200-52010
|G920052010
G920152011
|
|
|Toyota Aqua Hybrid
|P510
|NHP10
|2012-2017
|-
|Gen 3
|[https://evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards/auris-yaris-inverter-logic-board-kit Auris/Yaris Inverter Logic Board]
|[https://parts.toyota.com/p/Toyota__/Drive-Motor-Inverter/62976717/G920059035.html G9200-52011]
|G920059015
G92A052020

G920059035 (Current)
|
|
|Toyota Prius C
|P510
|NHP10R
|2012-2017
|-
|Gen 3
|
|G9200-52031
|G920052031
|
|
|Toyota Yaris Hybrid
|P510
|NHP130R
|2011-2017
|-
|Gen 3
|[https://evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards/auris-yaris-inverter-logic-board-kit Auris/Yaris Inverter Logic Board]
|[https://parts.toyota.com/p/Toyota__/INVERTER-ASSEMBLY---WITH-CONVERTER/69107417/G920059065.html G9200-52060]
|G920059065 (Current)
|
|
|Toyota Prius C
|P510
|NHP10R
|2016
|-
|Gen 3?
|
|[https://parts.toyota.com/p/Toyota__/INVERTER-ASSEMBLY---WITH-CONVERTER/62982729/G920074010.html G9200-74010]
|G920074010
|
|
|Toyota EQ EV
Scion iQ EV
|[https://parts.toyota.com/p/Toyota__/TRANSAXLE-ASSEMBLY---EV-WITH-MOTOR/62916912/3060074010.html 30600-74010]
|KPJ10
|2012-2013
|-
|TBC
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CON/69498445/G920075011.html G9200-75010]
|G920075010
G920075011 (Current)
|
|
|Lexus HS250h
|P311
|ANF10
|2009-2012
|-
|Gen 3
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/63355368/G920079035.html G9200-79015]
|G920079015
G920079025

G920079035 (Current)
|
|
|Lexus CT200h
|P410
|ZWA10
|2011-2017
|-
|Gen 4
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/77706116/G920079045.html G9200-79045]
|G920079045 (Current)
|
|
|Lexus UX250h
|
|MZAH10
|2018-
|-
|Gen 4
|
|[https://parts.lexus.com/p/Lexus__/Drive-Motor-Inverter/75857868/G920079055.html G9200-79055]
|G920079055
|
|
|Lexus UX250h
|
|MZAH15
|2018-
|-
|Gen 3?
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/70034186/G92A011010.html G92A0-11010]
|G92A011010
|
|
|Lexus LC500h
|
|GWZ100
|2017
|-
|Gen 3?
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/63540961/G92A030020.html G92A0-30020]
|G92A030020 (Current)
|
|
|Lexus GS350h
|
|GWL10
|2012-2014
|-
|Gen 3?
|
|[https://parts.toyota.com/p/Toyota__/Drive-Motor-Inverter/62982961/G92A033021.html G92A0-33020]
|G92A033020
G92A033021 (Current)
|
|
|Toyota Avalon Hybrid
Toyota Camry Hybrid

Lexus ES300h
|
|AVX40
AVV50

AVV60
|2012-2017
|-
|Gen 4
|
|[https://parts.lexus.com/p/Lexus__/Drive-Motor-Inverter/73183449/G92A033031.html G92A0-33031]
|G92A033031 (Current)
|
|
|Lexus ES300h
|
|AXZH10
|2018-2019
|-
|Gen 4
|
|[https://parts.toyota.com/p/Toyota__/INVERTER-ASSEMBLY---WITH-CONVERTER/78448014/G92A042070.html G92A0-42070]
|G92A042070
|
|
|Toyota RAV4 Hybrid
|
|AXAH54
|2019-
|-
|TBC
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/66841640/G92A048260.html G92A0-48051]
|G92A048051
G92A048121 G92A048122

G92A048260 (Current)
|
|
|Lexus RX450h FWD
|P313?
|GYL10
|2009-2015
|-
|TBC
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/66841639/G92A048250.html G92A0-48111]
|G92A048111 G92A048112
G92A048250 (Current)
|
|
|Lexus RX450h AWD
|P313?
|GYL15
|2009-2015
|-
|TBC
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/66841636/G92A048230.html G92A0-48230]
|G92A048230
|
|
|Lexus RX450h
|P313?
|GYL20
|2015-
|-
|TBC
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/66841638/G92A048240.html G92A0-48240]
|G92A048240
|
|
|Lexus RX450h
|P313?
|GYL25
|2015-
|-
|Gen 3?
|
|[https://parts.lexus.com/p/Lexus__/INVERTER-ASSEMBLY---WITH-CONVERTER/66841632/G92A042040.html G92A0-78020]
|G92A078020
G92A042040 (Current)
|
|
|Lexus NX300h
|P314
|AYZ10
|2015-2016
|-
|Gen 3?
|
|[https://parts.lexus.com/p/Lexus__/Drive-Motor-Inverter/66841630/G92A042050.html G92A0-58020]
|G92A042050 (Current)
|
|
|Lexus NX300h
|P314
|AYZ15
|2017-
|-
|Gen 4
|
|[https://parts.lexus.com/p/Lexus__/Drive-Motor-Inverter-Rear/75693091/G92B047011.html G92B0-47011]
|G92B047011
|
|
|Lexus UX250h (Rear)
|
|MZAH15
|2019-
|}
450 pages of Toyota wiring connections diagrams and part numbers https://www.toyota-tech.eu/wire_harness_rm/RM06H0E.pdf

Toyota/Lexus GS300h CVT

2021-01-30T15:58:33Z

Thornogson: added dimensions and weight as measured

Toyota/Lexus GS300h CVT

2021-01-30T08:19:15Z

Thornogson: Added a link to a visual resource