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Tuesday December 12th 2017
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‘Mini-EV’ Archives

Azure Dynamics (Solectria) 445TF UMOC Controller Testing

Azure Dynamics (Solectria) 445TF UMOC Controller Testing

My older son acquired an Azure Dynamics (Solectria) 445TF UMOC Controller and loaned it to me to test in the Mini. Constructed an interface circuit to convert the Ford Siemens Motor's single ended encoder output to bipolar differential drive required by the controller.   Fabricated connections out of some removable DB-25 [...]

Current Waveform Investigation

Current Waveform Investigation

I measure all three phase currents today to see if there might be visible phasing issues.  I only have a two channel scope so Phase 3 was not measured at the same time as Phase 2. The Phase 3 current is also being measured with a different current sensor.  With the scope settings it has a slightly different gain. The waveforms are noisy and [...]

Shutter/Jerking Current Waveform

Shutter/Jerking Current Waveform

Attached is a picture of the filtered Phase 1 PWM signal (green) and its resulting Phase 1 motor current (yellow) in open loop control mode. Expanded view shows the current variation (yellow) which results in the shutter/jerking.  It smooth before and after this section.  The higher current peaks are about 400 amps.  Not sure what [...]

Prius Inverter Evaluation

Prius Inverter Evaluation

Have been evaluating the possible use of a Prius Inverter driven with a Microchip controller over the past several months.   Removed the link capacitor to see the driver circuit and replaced it with a  smaller cap (blue) and hooked 36 volts across it.  Using the setup below,  hooked 12 volts between connector labels IGCT and GINV to [...]

Lessons Learned Using Industrial VFD for Motor Controller

Lessons Learned Using Industrial VFD for Motor Controller

This post contains a breif overview of what we learned trying to use an Industrial VFD as the Motor Controller. We purchased two used Industrial Variable Frequency Drives on eBay. The first one was a 30 HP 460 AC Benshaw Sensorless Vector Drive RSi030SX4B which turned out not have enough current output to get the car rolling consistently from a [...]

Making the Transmission Adapter Plate

Making the Transmission Adapter Plate

These are the steps used to create the adapter plate to attach and center properly the motor to the transmission. We started with a  3/4" 6061 aluminum plate and made an acrylic template that showed the bolt holes from both transmission and motor as well as the outlines. This kept us on track and helped make decisions. The next step was [...]

Making the Coupler

Making the Coupler

The following shows the basic steps used to fabricate the Motor to Transmisson Coupler.   This coupler used concepts shown by Tischer.     Bought extra stock for future and incase we messed up: Cut a Plug to center the B-Loc to the Coupler: Testing fit of B-lock: Not shown here but we clamped on the B-Lock and [...]

Drivetrain Picture Summary

Drivetrain Picture Summary

Drivetrain Mini Cooper S Transmission bought on eBay: Sizing up 3/4 inch Aluminum Transmission Adapter Plate with locating pin and marked acrylic sheet: Marking drill holes on Transmission Adapter Plate with Transmission placed with locating pin: Our Mini-EV version of  a Tischer style [...]

Transmission Pictures

Transmission Pictures

Mini Cooper S Transmission bought on eBay:

Motor Picture and Power Curves

Motor Picture and Power Curves

Motor: Ford F8Y8-14B280-AC (Siemens PV5133-4WS20 W11)

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