Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - View Single Post - Paul and Sabrina's Cheap 3 Phase Inverter (AC Controller) with Field Oriented Control

cajunfj40 · 02-19-2019, 11:21 AM

Hello MPaulHolmes,

Thanks for that!

You jogged a memory that I'd seen something, so I dug this up: https://www.energy.gov/sites/prod/fi...ess_2013_o.pdf

Teardown of 1st gen Leaf inverter shows 3 IGBT modules per switch, 18 modules total for the full 3-phase bridge. Each IGBT estimated to be ~1000V/300A rated. So that puts the assembly at ~900A peak. The cap is rated at 600V. At 80kw continuous rating, 360V nominal battery voltage, that's about a 222A continuous rating for the tripled modules, seems conservative.

Also found this: https://www.diyelectriccar.com/forum...-179922p2.html

Post #12 links to a 404'd paper, but poking around confirms some of the numbers.

Volt 1st Gen Inverter unit A 220/150 Peak/Cont. Arms, unit B 425/150 Peak/Cont. Arms.
Volt 2nd Gen Inverter 325/150 Peak/Cont. Arms for both units.

With your information that the Volt inverter driver clamps/dies/crashes at 405-410V, probably can't go much higher than the nominal 360V pack. That puts the 2nd Gen Volt inverter at 117/54 Peak/Cont.kW on both inverters, for a combined 234/108kW Peak/Cont. unit with the 2ML70 transmission.

If we use the 2nd Gen Chevy derating curve (325/150 = peak is 217% of continuous) on the Leaf, then we can run the Leaf at 481 Arms peak. 1st gen Inverter B ratings are higher, with peak being 283% of continuous. On the Leaf, that would be ~630A. With a 360V nominal pack that's a 227/80 Peak/Cont. kW rating on that inverter. Voltage may be pushable higher - not sure how close to the 600V cap rating one should get?

So roughly comparable power available from both inverters, though the Volt divvies it up across two outputs, so need 2 motors.

Definitely two quite viable candidates! Thanks again for all your work!

Now I need to see which chargers and DC/DC converters and EPS units and HVAC compressors, etc. have been hacked... I'd love to repurpose a 2nd Gen Leaf heat-pump setup, for example.

02-19-2019, 11:21 AM	#3388 (permalink)
cajunfj40 Lurking Eco-wall-o-texter Join Date: Dec 2015 Location: MPLS, MN area Posts: 128 Thanks: 0 Thanked 65 Times in 45 Posts	Hello MPaulHolmes, Thanks for that! You jogged a memory that I'd seen something, so I dug this up: https://www.energy.gov/sites/prod/fi...ess_2013_o.pdf Teardown of 1st gen Leaf inverter shows 3 IGBT modules per switch, 18 modules total for the full 3-phase bridge. Each IGBT estimated to be ~1000V/300A rated. So that puts the assembly at ~900A peak. The cap is rated at 600V. At 80kw continuous rating, 360V nominal battery voltage, that's about a 222A continuous rating for the tripled modules, seems conservative. Also found this: https://www.diyelectriccar.com/forum...-179922p2.html Post #12 links to a 404'd paper, but poking around confirms some of the numbers. Volt 1st Gen Inverter unit A 220/150 Peak/Cont. Arms, unit B 425/150 Peak/Cont. Arms. Volt 2nd Gen Inverter 325/150 Peak/Cont. Arms for both units. With your information that the Volt inverter driver clamps/dies/crashes at 405-410V, probably can't go much higher than the nominal 360V pack. That puts the 2nd Gen Volt inverter at 117/54 Peak/Cont.kW on both inverters, for a combined 234/108kW Peak/Cont. unit with the 2ML70 transmission. If we use the 2nd Gen Chevy derating curve (325/150 = peak is 217% of continuous) on the Leaf, then we can run the Leaf at 481 Arms peak. 1st gen Inverter B ratings are higher, with peak being 283% of continuous. On the Leaf, that would be ~630A. With a 360V nominal pack that's a 227/80 Peak/Cont. kW rating on that inverter. Voltage may be pushable higher - not sure how close to the 600V cap rating one should get? So roughly comparable power available from both inverters, though the Volt divvies it up across two outputs, so need 2 motors. Definitely two quite viable candidates! Thanks again for all your work! Now I need to see which chargers and DC/DC converters and EPS units and HVAC compressors, etc. have been hacked... I'd love to repurpose a 2nd Gen Leaf heat-pump setup, for example.