Hey Damien, THIS is exactly the video I need. I don't have an inverter or a prius or any plans on EV conversion as yet but it demystifies pretty much everything about the setup. Great stuff
Just successfully tuned a Gen 3 inverter and Gen 3 MG2 using this method. The video is a brilliant collaboration and thank you both very much. I was running v4.9FOC firmware which is newer than in this video and the “set pinswap 5” command didn’t work for me, however there is now a handy drop down menu item labelled pinswap which allows you to select PWMOutput23
Hi Damien! I suggest you look at the implementation of your developments on our channel. Thank you for your hard work and good luck in future projects.
FOC: Field Oriented Control. HV: High Voltage ~80-200V. IM: Induction Motor. OVERALL: discussion is about Toyota parts, but is generic for almost any permanent magnet motor which will need FOC software. TEST EQUIPMENT: It is assumed that only basic equipment is available such as light bulbs, switches and multi-meters. (12 V wires can be automotive grade, but HV cables MUST BE RATED FOR ~ 300 Volts). 0.51: Connections to VCU for Toyota Gen 2 Inverter. 4:27: Overall schematic of inverter and VCU Gen 2, 12V wiring including external items such as throttles and resolver connections 4:55: Discussion about VCU Gen 2 PCB components: purpose of; location of power supply ccts; pre-charge/charge circuitry etc. 6:21: location of solder jumpers for 'open collector' requirements with Asynchronous (IM) motors with encoder feedback. 6:37: VCU Gen 2 connections to inverter Gen 2 and trans-axle Gen 2. 7:08: Grey connector for throttle, brake, 12V power etc. 7:15: Black connector goes to Gen 2 inverter. 7:24: How to SAFELY apply 12V power to VCU Gen 2 for reducing damage from mistakes such as 12V to wrong pin... 9:46: 55W lamp, car battery, ideally fuse (10A?). 10:30: VCU energized: should be two LED s light steady, and third one flashing (shows STM IC executing software, :) ). 11:14: Initial hook up to Gen 2 inverter. Bypass inductor, Use 80-160 V DC supply initially. Use ~230V incandescent light bulb. 11:21: Signal harness has been connected at this point in time. 11:41: 2 pole connector is 12V supply to Gen 2 inverter. Watch polarity. 12:45: VCU Gen 2 AND Gen 2 inverter connected to 12V supply. Light bulb behavior slightly different to only supplying VCU Gen2. 13:00: Small glow of lamp due to quiescent steady state current consumption of Inverter Gen 2 electronics (Gate Driver board). 14:01: Bulb glowed as expected, can connect 12V supply directly, bypassing globe. Please use fuse in series with supply to protect wires. 15:04: Trans-axle Gen 2 temporarily wired to VCU Gen 2, HV battery, trans-axle resolver connected to VCU Gen 2. 15:42: Only MG2 of Gen 2 trans-axle connected to MG2 output of Gen 2 inverter 16:13: Trans-axle planet split device has been welded together and the trans-axle bolted back together. No oil in trans-axle. 16:27: MG2 and MG1 now spin at same speed all the time. See other videos for info on welding. 17:00: Stubs for trans-axle differential output were not available, so Damien put tape on the petrol connection for seeing rotation of the axle. 18:20: Discussing running trans-axle in open loop mode first, as part of FOC Tuning process. 18:43: HV battery connection to two bus-bars, (bypassing orange input cable port) to bypass buck/boost inductor. 19:04: Build up commissioning plan using the most simple steps conceivable. Can always add other steps later. 19:17: Bus bar closes to black capacitor square is HV positive, Bus bar closest to aluminum die-cast box is HV negative. 20:05: HV negative wire connect directly to HV battery pack (or equivalent) [Remember to use HV rated cable :)] 20:51: Recommendation: use HV battery rated 80-160V (150V?) good value... 21:17: Use ~20 Amp fuse HV rated and fuse holder HV rated, light bulb 230V rated 100W HV rated, bypass switch HV rated. 22:03: Fuse protect wires from shorts (does not protect electronics). Switch open for pre-charging inverter capacitors and seeing inrush current flow into inverter electronics and seeing how current flows into trans-axle during early commissioning phase. 23:03: If you don't understand pre-charging inverter capacitors, please pause watching this video and learn what this means first. 23:41: HV light bulb limits any fault currents that may flow during early commissioning phase. 24:08: HV light bulb protection for limiting fault current for wiring inverter incorrectly, inverter faulty, battery wired wrong polarity, any other unplanned conditions. (Please note, shorts on HV battery circuits can carry thousands of amps, with burning and UV flash-over) 25:36: Negative battery connection crocodile clip attached to HV battery (HV positive connection was already connected). Result, light bulb flashed for
38:26: The two high resistance pairs are the sine and cosine pairs of wires. They have almost identical resistance. 39:23: Which pair is the sine or cosine pair does not matter for the Openinverter forum FOC firmware. Therefore you don't need to lose time trying to work this out. There is a video by Johannes that describes the maths for this. 40:01: Need to make chart in the notebook for 4 possible permutations of connections for the sine and cosine pairs. Need to connect the same polarity of the sine and of the cosine coil to the ground return connection. 40:40: CRITICAL: Only 1 of these permutations will work your motor properly. The rest will only make your motor partially work. Even if you have a schematic from the manufacturer, you still need to go through this work. 41:44: Strongly recommend you bring out the resolver wires from the VCU and connect to some connector block with at least 6 tunnels in it. Put exciter coil wires to the right and the rest to the left. To facilitate changing sine and cosine coil polarities. 42:19: Wire the exciter coil of the trans-axle resolver to the exciter output of the VCU. Please note, polarity of exciter does not matter :). Because all you are doing is swapping polarity of BOTH sine and cosine coils, which does'nt matter. 44:32: Now we look at outside world connector of VCU. E.g.: Pin 1 is sin resolver connection. 47:40: With correct resolver connections of the system and tuning of the FOC firmware, end result commissioning is demonstrated by easily changing speed of the trans-axle axle by simply depressing the accelerator pedal. Have to stop now, more later.
48:35: Damien will post a parameter file on the Openinverter forum. Please post yours here too so we can build up data for everyone to use. 49:03: Page from notepad showing last configuration was the successful resolver feedback connections for correct sin/cos polarity. 49:34: Huebner web interface. >Load FOC firmware. > hwver>Prius. >Opmode = OFF. Must make sure resolver signals are being received by STM32 in VCU. Make sure HV completely turned off. Put vice grips onto shaft and turn manually for full revolution. Computer, Go to Commands . Put opmode into Manual / Run. angle L , R. Can graph from left or right.' Go to bottom of screen, hit Plot button, and see waveforn on screen. Plot 204 - 207 degrees. This plot includes jitter. We expect some, but not a lot. Jittering >5 degrees, would consider that a problem. For this, check wiring, screens of resolver cable. E.G. jumping over a hundred degrees, STOP problem in resolver wiring or something else, broken resolver winding etc. Restart Plot, rotate axle by a few turns look at waveform. Should get jumping wave forms that move from >0 to
@@johnspark740 Thank you so much for doing this breakdown. Normally I do this, but, a lot of this was a bit over my head, and it was a long video, so I struggled to write and summarize the context. I'd been slowly churning away at the first 30 minutes over the couple weeks since it was posted, and your summary is much better than mine was. Great job.
Hey Damien, THIS is exactly the video I need.
I don't have an inverter or a prius or any plans on EV conversion as yet but it demystifies pretty much everything about the setup.
Great stuff
Just successfully tuned a Gen 3 inverter and Gen 3 MG2 using this method. The video is a brilliant collaboration and thank you both very much. I was running v4.9FOC firmware which is newer than in this video and the “set pinswap 5” command didn’t work for me, however there is now a handy drop down menu item labelled pinswap which allows you to select PWMOutput23
Hi Damien! I suggest you look at the implementation of your developments on our channel. Thank you for your hard work and good luck in future projects.
Great explanation , can’t wait to get started on my Highlander motors
Light bulbs as current limiters, LOVE IT!!! And yes, fuses protect WIRES, not components :D
Brilliant resource. Thank you for taking the time to do this.
FOC: Field Oriented Control. HV: High Voltage ~80-200V. IM: Induction Motor.
OVERALL: discussion is about Toyota parts, but is generic for almost any permanent magnet motor which will need FOC software.
TEST EQUIPMENT: It is assumed that only basic equipment is available such as light bulbs, switches and multi-meters. (12 V wires can be automotive grade, but HV cables MUST BE RATED FOR ~ 300 Volts).
0.51: Connections to VCU for Toyota Gen 2 Inverter.
4:27: Overall schematic of inverter and VCU Gen 2, 12V wiring including external items such as throttles and resolver connections
4:55: Discussion about VCU Gen 2 PCB components: purpose of; location of power supply ccts; pre-charge/charge circuitry etc.
6:21: location of solder jumpers for 'open collector' requirements with Asynchronous (IM) motors with encoder feedback.
6:37: VCU Gen 2 connections to inverter Gen 2 and trans-axle Gen 2.
7:08: Grey connector for throttle, brake, 12V power etc.
7:15: Black connector goes to Gen 2 inverter.
7:24: How to SAFELY apply 12V power to VCU Gen 2 for reducing damage from mistakes such as 12V to wrong pin...
9:46: 55W lamp, car battery, ideally fuse (10A?).
10:30: VCU energized: should be two LED s light steady, and third one flashing (shows STM IC executing software, :) ).
11:14: Initial hook up to Gen 2 inverter. Bypass inductor, Use 80-160 V DC supply initially. Use ~230V incandescent light bulb.
11:21: Signal harness has been connected at this point in time.
11:41: 2 pole connector is 12V supply to Gen 2 inverter. Watch polarity.
12:45: VCU Gen 2 AND Gen 2 inverter connected to 12V supply. Light bulb behavior slightly different to only supplying VCU Gen2.
13:00: Small glow of lamp due to quiescent steady state current consumption of Inverter Gen 2 electronics (Gate Driver board).
14:01: Bulb glowed as expected, can connect 12V supply directly, bypassing globe. Please use fuse in series with supply to protect wires.
15:04: Trans-axle Gen 2 temporarily wired to VCU Gen 2, HV battery, trans-axle resolver connected to VCU Gen 2.
15:42: Only MG2 of Gen 2 trans-axle connected to MG2 output of Gen 2 inverter
16:13: Trans-axle planet split device has been welded together and the trans-axle bolted back together. No oil in trans-axle.
16:27: MG2 and MG1 now spin at same speed all the time. See other videos for info on welding.
17:00: Stubs for trans-axle differential output were not available, so Damien put tape on the petrol connection for seeing rotation of the axle.
18:20: Discussing running trans-axle in open loop mode first, as part of FOC Tuning process.
18:43: HV battery connection to two bus-bars, (bypassing orange input cable port) to bypass buck/boost inductor.
19:04: Build up commissioning plan using the most simple steps conceivable. Can always add other steps later.
19:17: Bus bar closes to black capacitor square is HV positive, Bus bar closest to aluminum die-cast box is HV negative.
20:05: HV negative wire connect directly to HV battery pack (or equivalent) [Remember to use HV rated cable :)]
20:51: Recommendation: use HV battery rated 80-160V (150V?) good value...
21:17: Use ~20 Amp fuse HV rated and fuse holder HV rated, light bulb 230V rated 100W HV rated, bypass switch HV rated.
22:03: Fuse protect wires from shorts (does not protect electronics). Switch open for pre-charging inverter capacitors and seeing inrush current flow into inverter electronics and seeing how current flows into trans-axle during early commissioning phase.
23:03: If you don't understand pre-charging inverter capacitors, please pause watching this video and learn what this means first.
23:41: HV light bulb limits any fault currents that may flow during early commissioning phase.
24:08: HV light bulb protection for limiting fault current for wiring inverter incorrectly, inverter faulty, battery wired wrong polarity, any other unplanned conditions. (Please note, shorts on HV battery circuits can carry thousands of amps, with burning and UV flash-over)
25:36: Negative battery connection crocodile clip attached to HV battery (HV positive connection was already connected). Result, light bulb flashed for
38:26: The two high resistance pairs are the sine and cosine pairs of wires. They have almost identical resistance.
39:23: Which pair is the sine or cosine pair does not matter for the Openinverter forum FOC firmware. Therefore you don't need to lose time trying to work this out. There is a video by Johannes that describes the maths for this.
40:01: Need to make chart in the notebook for 4 possible permutations of connections for the sine and cosine pairs. Need to connect the same polarity of the sine and of the cosine coil to the ground return connection.
40:40: CRITICAL: Only 1 of these permutations will work your motor properly. The rest will only make your motor partially work. Even if you have a schematic from the manufacturer, you still need to go through this work.
41:44: Strongly recommend you bring out the resolver wires from the VCU and connect to some connector block with at least 6 tunnels in it. Put exciter coil wires to the right and the rest to the left. To facilitate changing sine and cosine coil polarities.
42:19: Wire the exciter coil of the trans-axle resolver to the exciter output of the VCU. Please note, polarity of exciter does not matter :). Because all you are doing is swapping polarity of BOTH sine and cosine coils, which does'nt matter.
44:32: Now we look at outside world connector of VCU. E.g.: Pin 1 is sin resolver connection.
47:40: With correct resolver connections of the system and tuning of the FOC firmware, end result commissioning is demonstrated by easily changing speed of the trans-axle axle by simply depressing the accelerator pedal.
Have to stop now, more later.
48:35: Damien will post a parameter file on the Openinverter forum. Please post yours here too so we can build up data for everyone to use.
49:03: Page from notepad showing last configuration was the successful resolver feedback connections for correct sin/cos polarity.
49:34: Huebner web interface. >Load FOC firmware. > hwver>Prius. >Opmode = OFF.
Must make sure resolver signals are being received by STM32 in VCU.
Make sure HV completely turned off.
Put vice grips onto shaft and turn manually for full revolution.
Computer, Go to Commands . Put opmode into Manual / Run.
angle L , R. Can graph from left or right.'
Go to bottom of screen, hit Plot button, and see waveforn on screen. Plot 204 - 207 degrees. This plot includes jitter. We expect some, but not a lot. Jittering >5 degrees, would consider that a problem. For this, check wiring, screens of resolver cable. E.G. jumping over a hundred degrees, STOP problem in resolver wiring or something else, broken resolver winding etc.
Restart Plot, rotate axle by a few turns look at waveform. Should get jumping wave forms that move from >0 to
@@johnspark740 Thank you so much for doing this breakdown. Normally I do this, but, a lot of this was a bit over my head, and it was a long video, so I struggled to write and summarize the context. I'd been slowly churning away at the first 30 minutes over the couple weeks since it was posted, and your summary is much better than mine was. Great job.
@@MattsAwesomeStuff Love your kind words MattsAwesomeStuff. I actually followed your method of documenting the steps, so kudos to you too :)
You, Sir, are a LEGEND.
Hi Damien, Do you plan to do any videos on the registration process and requirements of the car after the conversion?
soooo, I was thinking that I'm stupid, but all it was is a software bug.... =) it doesn't however changes the fact that I'm stupid =D
No stupid =S for SMART because you are doing an EV conversion :)
I found a Software Bug. Trouble was, it was the software that runs me.
Great !!!!
Thank You Sir.
Thanks for the info..👍👍
thanks Damien!!!!!!!!
(After the first seconds of watching this video: ) Damien! What happened to your accent? What happened to your coupe? ... oh wait .... :-)
Я тоже так думал... :-)))