Paul and Sabrina's Cheap 3 Phase Inverter (AC Controller) with Field Oriented Control

[mora]

Mine doesn't even have serial number It is version 0.3.

[thingstodo]

Originally Posted by mora

Mine doesn't even have serial number It is version 0.3.

I guess .. if it HAD a serial number .. it would be 002. I'll have to look up what the version is.

[thingstodo]

Originally Posted by thingstodo

I have a BOM for my version of the AC controller (serial number 2) so it will be close to what you have, but I don't have an updated BOM.

I spoke too soon. It seems that Paul made up a BOM and shared it with me with a link. But it's just for a single IGBT driver, not for the whole AC board. Sorry

BTW, the artwork for the AC board shows rev 0.3 for my AC controller, so it should be the same as mine

[thingstodo]

I powered up the AC controller today with just control power. It printed the powerup message

AC Controller firmware ver 1.0
Throttle out of range! Is it unplugged?

Which, of course, it was. So I powered it down and looked up the pinout (5V, Gnd, Throttle - seen from the edge of the board, looking toward the IGBTs) .

Connect a throttle - a Honda civic hall effect throttle. 5V to pin 3, Brown. Gnd to pin 2 Blu. Throttle to pin 1 yel. Power up the board - same message.

Power down and remove the throttle signal from the controller pin. Power up and check the throttle. 1.00V minimum, up to 4.6V at full throttle. Looks fine.

Start up the controller and begin logging the raw throttle and the scaled throttle. 0000 raw, -4051 for scaled ... that's weird.

Put the throttle signal onto the controller while logging. No change on the logging. Measure the voltage - it is now -0.16V referenced to the throttle ground. How?

Tried the other channel on the Honda throttle. After powering off and moving wires around - 5V to pin 6 Grey, GND to pin5 blu, throttle to pin 4 purple. Disconnect throttle from the controller. Power up. 0.51V minimum, up to 2.33V at max. 1/2 of the other channel. Makes sense since they are supposed to be related.

Connect the throttle signal up while logging and the controller stopped. Looks like it did a reset. I may have touched the 5V signal, but the input should be high impedance - right? it's a hall effect throttle - not much current available!

Paul - any troubleshooting advice?

I think I will order some pin headers so that I am not tempted to use small gator cordsets for this type of stuff. Hopefully I didn't break anything

The logging still lists 0000 and -4051 for raw throttle and throttle. It's almost like the input pin is tied low with a low resistance ... except that it goes below 0V?

[arber333]

Hi Paul

Can you share the origin of clutch coupler for your Leaf setup? I see you use splines from a clutch coupler welded to a lovejoy coupler. Do both motors have the same splines?

I can see 20 splines 21.5mm in diameter for my motor. What car do you suggest to salvage clutch disk from?

EDIT:
Well i found a clutch disk from Fiat Multipla 1.6l car. It is a snug fit for 1st generation motor. It has 20 splines and 22mm max internal diameter. EAN P/N 4005108217882 for LUK part.
Does the 1.1 generation motor have the same output shaft? Or is it different splines etc...

tnx

A

[MPaulHolmes]

I have checked the splines on the EM61 (I think that's what it is) and the EM58 Or whatever it's called, and they both are the same.

thingstodo, did you get the hall effect throttle working?

[thingstodo]

Originally Posted by MPaulHolmes

thingstodo, did you get the hall effect throttle working?

Not yet Paul. Setting up the controller in my basement so I don't have to spend 2 hours re-arranging vehicles in my garage every evening to get 15 minutes of testing done

I will post if I get it working

[arber333]

Originally Posted by MPaulHolmes

I have checked the splines on the EM61 (I think that's what it is) and the EM58 Or whatever it's called, and they both are the same.

thingstodo, did you get the hall effect throttle working?

Tnx Paul

How did the motor - inverter free energy test go?

[MPaulHolmes]

It worked fine, but the issue was, I couldn't spin it very fast because of my crappy alignment. I didn't do a very good job of welding on the spline. I need to get it professionally done.

[arber333]

Yes i can relate. Even in my Mazda i didnt quite pin the center of transmission shaft. And i had it "proffesionally" done. Oh well, my clutch became field replacable part. Get it ? Replace in the field....

A