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

[sparkey]

Thanks for the reply!

I've seen Damien (aka: jack bauer) run this motor on 40-odd volts, so voltage isn't the issue (feel free to prove me wrong!). Also, in test mode, the motor runs. So unless i'm missing someting, this must either be a tuning or setup issue.

Sorry, can't help with your question

[MPaulHolmes]

That looks great!! My goodness, I haven't looked at the code in quite a while. Could you type "config" and post that here?

Do you have max-regen-position < min-regen-position < min-throttle-position < max-throttle-position?

Here's a sample that would be good if your range of throttle was
0 throttle == 315
max throttle == 800

Try this:
max-regen-position 320
min-regen-position 400
min-throttle-position 450
max-throttle-position 800

[MPaulHolmes]

I'm getting super close to driving my Nissan Leaf around my yard with no mechanical brakes (only regen) and controlling it by the cell phone. Don't worry, it's a big yard. This is going to be fun!! It will be like in Back to the Future. A giant remote controlled car. Well, I don't have the steering hooked up to the phone, so I'll have to turn that myself. It's shocking how much stuff in there isn't needed. I took an angle grinder to the whole wiring system.

[sparkey]

Thanks for the reply! I've updated my throttle settings to what you suggested, but still no movement.

Here is my current config. I've put in comments to show where I got the values from where approproate

motor-type=4 // from the code...
kp=11284 ki=00182 // from a comment in the code for MGR motors at 48V
current-sensor-amps-per-volt=0320 // hass 200 current sensors
max-regen-position=0320
min-regen-position=0400
min-throttle-position=0450
max-throttle-position=0800
fault-throttle-position=0005
max-battery-amps=0015 amps
max-battery-amps-regen=0015 amps
max-motor-amps=025 amps
max-motor-amps-regen=025 amps
precharge-time=0050 tenths of a sec
angle-offset=167 // based on the angle-offset test
saliency=0000 // not sure what this is
pole-pairs=004 // from the motor's specificatoins
max-rpm=06000 rev/min
throttle-type=0
encoder-ticks=0256 ticks/rev // not sure what this should be for my current motor mode
pi-ratio=062
raw-throttle=0316

Below shows the stream of throlttle and poscnt, first when i'm pressing the throttle, then ween i'm turning the motor by hand. Notice how the position isn't between 0-511. This is my current focus of debugging, but I'm not sure what behavior should be given I'm using the motor-mode 4

rawThrottle,poscnt,
...pressing the throttle
0316,13209,
0316,13209,
0325,13208,
0422,13209,
0475,13208,
0535,13209,
0604,13208,
0681,13208,
0754,13208,
0796,13208,
0499,13208,
0316,13209,
...now turning the motor by hand
0316,13208,
0317,13209,
0317,13209,
0316,12083,
0315,11446,
0316,10662,

[MPaulHolmes]

Could you try increasing the max motor amps? I can't tell what's happening from your comments, but 25amp may not be enough to get it rolling.

[sparkey]

Success!

After a number of days of trial and error, I discovered that the lack of throttle response was caused by the temperature not being sensed correctly. My thermistor or my wiring is buggered, so it was reading much higher than reality, causing the inverter logic to think that the plate was too hot, and hence stopping the throttle from responding.

I've got a new thermistor on order, but while that's waiting to arrive, I've just set the max temperature threshold to as high as I can, and presto! The motor spins like a dream!

Thanks so much for the quick responses, Paul. I really appreciate it.

[sparkey]

Paul,
Do you have any objection to me putting your assembly instructions and photos on a github wiki for future reference? The wiki is here:

github.com/knoxsp/AC-Controller/wiki

Currently it is just a compilation of all the instructions copy-pasted into a vague structure, but before I continue I'd like to make sure I'm not treading on any toes.

Once done, I propose to merge this into your own AC-Controller repository wiki, so it's available at the official location.

Also, are thesch and pcb files on github? I'm interested in redesigning the board so that it can be ordered from jlcpcb, which in theory it would mean it arrives with all surface mount components in place. Is there any interest in facilitating this?

[thingstodo]

Originally Posted by sparkey

Paul,
Do you have any objection to me putting your assembly instructions and photos on a github wiki for future reference? The wiki is here:

github.com/knoxsp/AC-Controller/wiki

I have a bunch of files for the AC controller that Paul sent me during my various tests. I have some files for the IGBT DC controller as well.

I can forward or upload somewhere if you like. It will take me a bit to collect stuff (I'm not exactly organized) ... but it would be great to get this collected and make it available to anyone interested!

I won't speak for Paul .. but in the past he has been enthusiastic about anyone who was setting up a repo.

Let me know!

[MPaulHolmes]

Ya you can do that if you like! I have some documentation I could email you too.

Quick poll:
If you were going to re-use a nissan leaf motor controller, would you want to go to the extra possible expense of having the stock external 15 pin connector that goes with the motor controller, or would you prefer something like a waterproof cable gland with the 15 wires coming out of it (all shrink wrapped so that the cable gland could grip tightly around it, and then a 15 wire pigtail, with something like insulated quick disconnects? Or some other alternative?

[thingstodo]

Originally Posted by MPaulHolmes

Quick poll:
If you were going to re-use a nissan leaf motor controller, would you want to go to the extra possible expense of having the stock external 15 pin connector that goes with the motor controller, or would you prefer something like a waterproof cable gland with the 15 wires coming out of it (all shrink wrapped so that the cable gland could grip tightly around it, and then a 15 wire pigtail, with something like insulated quick disconnects? Or some other alternative?

I know nothing about this connector ... so I answered the question 5 times

Hmmm. In my opinion, the stock external 15 pin connector is only helpful if you are using the parts of the leaf that make use of that connector, or you have a cable harness that includes the connector. I don't think that is likely if you are 're-using' the controller.

If you have a 15 wire pigtail, the ends have to land somewhere.

If there a high voltage junction box that this normally goes to, I'd vote for the pigtail.

If the 15 pin connector is for control stuff coming from the dashboard, keep the connector.

If some goes to the dash, some to the throttle, and some other places ... I'd stay with the pigtail since you will need a box for terminations and to open up for troubleshooting.

I don't think that will help your poll very much