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

[freebeard]

I tried to extract the relevant information from the Toyota MGR thread using the Mac OSX Summarize Text service; but I only got six pages in.

There must be a way to query the vBulletin back end and get a thread as a single block without the metadata; I haven't made much headway in Forum News & Feedback.

Summarize Text would ingest that in one gulp.

[ricemodder]

I have an older generation (no surface mount) controller. Since it's been a while since I've had a chance to play, I tried to update the flash with newer code located here:

https://github.com/MPaulHolmes/AC-Controller/branches

Seems like some of the pins have been changed and added. I'm planning to buy a new version board eventually but would like to get the latest version for this board.

Do you guys know where I can get this?

[thingstodo]

Originally Posted by ricemodder

I have an older generation (no surface mount) controller.

What version do you have? Actually, I'm not sure which version I have either ... so do you have a picture of the board?

I have several firmware upgrades that I loaded as my testing uncovered bugs and Paul released some new features, like save and putting the tests into the same firmware as the running controller code.

I have a few of the source files matched with the firmware.

i think I have serial number 2, so it may be too old to be of use to you. But we can try!

[ricemodder]

At one point it was running really well. But since I tried to get the regen working with the newer FW, it hasn't behaved since.

Thanks,

[thingstodo]

Originally Posted by ricemodder

At one point it was running really well. But since I tried to get the regen working with the newer FW, it hasn't behaved since.

Thanks,

I'll check the arrangement of my board when I get home on Monday evening ... or would you rather that I just post what I have and you can try it?

I don't know how to update the wiki either, or how to do the forks for the different source and firmware for the various versions of the hardware. I am happy to post/update if someone is more familiar and wants to do a bit of a tutorial

[ricemodder]

Originally Posted by thingstodo

I'll check the arrangement of my board when I get home on Monday evening ... or would you rather that I just post what I have and you can try it?

I don't know how to update the wiki either, or how to do the forks for the different source and firmware for the various versions of the hardware. I am happy to post/update if someone is more familiar and wants to do a bit of a tutorial

Thanks thingstodo! I found the version that works with this motor. It's strange, the newer FW version seems to just make lots of noise and then trip the overcurrent.

I'm considering getting the newer board (SMT) so I can use that as the main traction motor controller, then couple the shafts with the old one and use it as a regen / dyno. If I measure the amount of power going into the battery pack, I should be able to 'guestimate' the power output of the unit. This all hinges on how much brake torque the regen can generate.

Worst case scenario I have a prius IPM motor that I can rectify and variably load dissipate since it doesn't really require a controller to regen.

I also wanted to play with the IPM motors as traction motors. I didn't see resolver the encoder boards for sale. Anybody know if these are still available?

Anyways lots of different ideas to tinker with.

[thingstodo]

Originally Posted by ricemodder

Thanks thingstodo! I found the version that works with this motor. It's strange, the newer FW version seems to just make lots of noise and then trip the overcurrent.

It's good you found the right version .. and kinda weird that the newer firmware does bad things.

I'm considering getting the newer board (SMT) so I can use that as the main traction motor controller, then couple the shafts with the old one and use it as a regen / dyno. If I measure the amount of power going into the battery pack, I should be able to 'guestimate' the power output of the unit. This all hinges on how much brake torque the regen can generate.

The testing I did with a DC motor (and Paul's DC controller) coupled to an AC motor (and Paul's AC Controller) leads me to believe that you generate power with regen down to a certain speed. Like maybe 500 rpm. Lower than that it actually draws power from the pack to stop with regen.

Worst case scenario I have a prius IPM motor that I can rectify and variably load dissipate since it doesn't really require a controller to regen.

I also wanted to play with the IPM motors as traction motors. I didn't see resolver the encoder boards for sale. Anybody know if these are still available?

The resolver to encoder boards were there last time I looked. Maybe Paul ran out and has not re-ordered the boards?

IPM motors as traction is interesting ... let us know how it goes!

[MPaulHolmes]

The default settings for the new code is a nissan leaf permanent magnet motor. Are you using an induction motor?

[ricemodder]

Originally Posted by MPaulHolmes

The default settings for the new code is a nissan leaf permanent magnet motor. Are you using an induction motor?

Yes it is an induction motor with an older board. I have downloaded firmware that is dated Oct 26, 2016. It looks like the latest and runs the motor.

I am still trying to configure the regen for the motor. It works when the motor is running at a certain rpm but then starts to drive the motor. Can you point me in the right direction as to what values to change to make this work better.

Thanks.

[ricemodder]

This is neat. I took apart a 2017 Kia inverter and took a peek at the layout.
*Edit 2015 Kia inverter

It has 2 resolver inputs to a 10/12 bit digital input to a MPC5500 NXP processor.