Hot-rodding the Toyota MGR - Page 37 - Fuel Economy, Hypermiling, EcoModding News and Forum

Astro · 02-29-2016, 04:25 AM

Maybe the slight difference in power required depending on rotational direction is due to the oil pumping method. In one direction the oil gets lifted up by one of the gears and thrown into the top of the oiling system. Thereby reducing the amount of oil resting in the sump. In the other direction it would not be lifting the oil into the oiling system but rather just thrashing the oil about. So the oil level remains high causing drag on the gear.
Or some other reason entirely. I also am not a mechanic.

thingstodo · 02-29-2016, 10:37 AM

Quote:

Originally Posted by MPaulHolmes

Here's a video of the motor spinning at 120vDC

Great video - Awesome voice over!

freebeard · 02-29-2016, 04:41 PM

Thanks! 37 views at this time. Sounds like you have a production team.

The 'thing' is a flange, that bolts to an axle half-shaft, or axle flange for short. More importantly, is the preferential direction clockwise of counterclockwise? From the resolver side clockwise is forward.

Those two things on the left in your video with the holes pointed up and down? If they were turned over so they face down my life would be so much easier. I may spot-face the bottom side to make two mounting surfaces there.

Astro · 02-29-2016, 05:49 PM

Quote:

Originally Posted by freebeard

...
Those two things on the left in your video with the holes pointed up and down? If they were turned over so they face down my life would be so much easier. I may spot-face the bottom side to make two mounting surfaces there.

If i understand correctly you want the mounting faces to be on the underside of those protrusions. with the fixing bolts coming up from underneath?
Could you put in an intermediate bracket. A metal bar running across the two existing mounting holes and fixed in place with bolts coming from above and on that metal bar have the mounting holes where the bolts come up from below?

freebeard · 03-01-2016, 12:28 AM

The problem is that the top is clear to the sides for that stock spreader bar, while underneath there are spot faces for washers with ribs (4 total, you can see the side of one) on the sides. It could be as simple as a tubular Y with threads in the ends of the fork, or two tubes on a plate. This could attach to the stock Beetle transmission mount directly below there.

MPaulHolmes · 03-01-2016, 09:21 AM

I don't really know what the orientation of the motor should be. I just have it sitting that way because it seems to have a nice surface to lay like that. I would defer to e*clipse on that one. (Astro has a good idea too! I am waiting to see how you guys do it, because i'm clueless). Here's another video, but this time at 376.5v peak:

https://www.youtube.com/watch?v=BM7tH7oIFuw

freebeard: Notice that the clockwise rotation is a lot faster.

Astro · 03-01-2016, 10:38 AM

Quote:

Originally Posted by freebeard

The problem is that the top is clear to the sides for that stock spreader bar, while underneath there are spot faces for washers with ribs (4 total, you can see the side of one) on the sides. It could be as simple as a tubular Y with threads in the ends of the fork, or two tubes on a plate. This could attach to the stock Beetle transmission mount directly below there.

It is a bit difficult to visualise.
Please forgive my lame drawing. It's late here and all i have on this PC is a MS Paint clone.

Could you put a rectangular piece of plate on top of the two mounting points on the MGR overlapping at the sides and front. Then add a similar rectangular plate on the VW trans mount then box in the forward facing side and the two sides.

freebeard · 03-01-2016, 02:39 PM

That's where I was before, excepting the Beetle transmission mount holes run fore-and-aft so they would be at the front face of the bracket. If the brackets were inverted, it could be just a piece of angle iron.

Everything is upriver in a barn. I need to get out there in the next few days to transplant a cherry tree, so I will get some measurements then—distance from the axle centerline to the mount horizontally and vertically on both the MGR and a Beetle tranny. That will establish the relationship of the holes. Then I just build a bracket around those holes.

I know it fits in there, it's just a matter of pinning down the tolerances.

jackbauer · 03-01-2016, 04:52 PM

Paul , that is a thing of beauty

Was the rpm limit caused by a preset max frequency or running out of voltage? Am not making as much progress myself. Did get the GS450h transmission mg2 up to 1500rpm which was enough to get the engine driven pump turning fast enough to cover a wall in the workshop in oil!

MPaulHolmes · 03-01-2016, 05:02 PM

That was from running out of voltage. The max frequency does a similar thing, but I had made a mistake on computing the RPM when I was cutting and pasting and rearranging stuff, so the rpm was just zero as far as the microcontroller was concerned. I was being over careful with running out of voltage. I was chopping IdRef and IqRef down too much. It worked a little different than that on the induction motor. This motor needs a bit of a tweek, so when it hits the ceiling, I don't knock them down quite as much. So it's a little, gentle bounce against the voltage disk limit rather than a big bouncy ball. haha.

I'd say going fast enough to get oil to splatter everywhere is progress! I already have the table that it's on, as well as the floor covered in transmission fluid, because I refilled it before screwing back on the holes, and putting back on the round things that spin (freebeard told me the name of those, and now I forgot). The neat thing is, now the motors can just glide across the table, since it's saturated in transmission fluid. So it's easy to swap out motors now. haha