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Old 09-26-2013, 10:32 AM   #231 (permalink)
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Ha ha! Good one.

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Old 09-27-2013, 04:47 AM   #232 (permalink)
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Vacuum Pump, Tachometer and BMS Updates

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Old 09-27-2013, 10:57 AM   #233 (permalink)
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You have so many instrument panel labels! (Nerd alert!)

Actually, I'm quite jealous you have so many more useful functions that need labels.

Did your vacuum pump "jitter" when it turned off? Is it doing that less with the light in the circuit?
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Old 09-27-2013, 02:36 PM   #234 (permalink)
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Yeah, the vacuum pump "jitter" is back. Not sure why. It seemed to start again after I installed a vacuum reservoir, but that could be coincidence. I wonder if it is incorrect vacuum switch placement. Right now it is between the reservoir and pump/brake booster. I wonder if it would stop "jittering" if I added another fitting to the reservoir and hooked it up directly there instead of teeing it in wherever......

Here is the schematic for the battery monitoring system:

The reason I power the system voltmeter with a 9V battery is because it is a very cheap eBay voltmeter that has a low-resistance connection between the power side ground and measured side ground. If powered by the car's accessory battery it makes a connection between the traction side and accessory electrical systems, and I have been shocked because of this before.

Last edited by mechman600; 09-28-2013 at 04:15 AM..
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Old 09-28-2013, 09:16 PM   #235 (permalink)
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My revised wiring schematic, now that I am back to one controller and a series wound motor:
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Old 10-03-2013, 04:18 AM   #236 (permalink)
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First commute of the fall

Today was D-day. I finally decided to put insurance on the car after a week of soggy motorcycling to work.

It was rather uneventful. No breakdowns and not much excitement.

The new motor definitely has more torque but runs out of steam at a lower RPM. Math would obviously dictate this as the HP output is nearly identical because of the limitations of my controller, and HP = (FT-LB)(RPM)/5252. Actually it might now have slightly less power because I am now missing a field controller that was putting another 2500W into the motor as well. But it sure didn't feel less powerful once I realized that I needed to shift at a lower RPM.

I am still getting used to the new power curve. An example of this is on the way home, going up the mile long hill with the 4-way stop in the middle. After the stop (still going up hill), it topped out at 53 km/h in second gear at 4100 RPM. The old motor would top out at 60 km/h in the same spot. All I had to do was shift into third (2700 RPM) and it then accelerated to over 65 in no time.

The throttle response is now much much nicer. Throttle angle seems to be more proportional to torque output, where before it was proportional to motor RPM, almost sort of like a farm tractor throttle. And the oscillation caused by two controllers fighting over who is boss is now gone (because I fired one of them ).

When I got home, where the old motor would be about 150F on the body thanks to the climb up the hill, the new motor wasn't even warm to touch! Either this motor is more efficient or its increased mass is acting like a giant heat sink.

Today I fixed the vacuum pump relay chatter problem. You can hear this chatter in the previous video I posted. All I did was plumb the vacuum switch directly into my new vacuum reservoir instead of into a tee between the reservoir, pump and brake booster. Problem 100% solved. The reservoir dampens any pulses before they get to the switch.

Here is the vacuum reservoir I made out of a piece of ABS pipe and some end caps:


And here you can see how it now resides in a nook in the fender:


Of course with my new vacuum switch fix, it now has another small line running into it that the picture doesn't show.

Last edited by mechman600; 10-03-2013 at 04:29 AM..
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Old 10-03-2013, 08:56 AM   #237 (permalink)
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Congrats on the first successful day. Glad the motor worked well for you - and I can confirm mine barely gets warm in my normal use too.
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Ecodriving test: Manual vs. automatic transmission MPG showdown



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Old 10-03-2013, 12:45 PM   #238 (permalink)
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*sigh* I want an EV...
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Old 10-03-2013, 01:33 PM   #239 (permalink)
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Quote:
Originally Posted by Daox View Post
*sigh* I want an EV...
Your Paseo would make a perfect one!
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Old 10-03-2013, 11:35 PM   #240 (permalink)
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Looking really good. glad to hear you are having success. An uneventful drive is the best kind of drive. Now that you know the motor works well, you should have the potential to raise the system voltage for more speed, if you decide to. Have you checked out the top speed yet to see how it compares with the old one?
I still wonder if your first motor may have worked just fine in a lighter car.

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