Francisco's Electric Pajero

Post up a thread for your EV. Progress pics, description and assorted alliteration
francisco.shi
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Real Name: Francisco
Location: Brisbane, Strathpine

Re: Francisco's Electric Pajero

Post by francisco.shi »

I had to put the diff upside down so it spins in the original direction. The bearings on the diff are designed to push rather than pull. So the plug that you see is actually the drain plug.
I was also concerned about the oil getting to the thrust bearings but the original diff for the Pajero had the input on the top instead of the bottom. So my assumption is that there is enough oil being thrown by the crown gear to get the oil to the thrust bearings.
The oil level is a little under the center line so the bottom crown gear is always immersed in oil.
I guess if it was always running very slow it could be a problem but I think you only need to do 20kph and there will be so much oil being thrown around that it won't be a problem.
The only issue is draining it and the breather port. I had to block the breather port off and will need to add a new breather port on top.
T1 Terry
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Re: Francisco's Electric Pajero

Post by T1 Terry »

With my set-up being a hypoid design, the pinion bearings and gear teeth were originally submerged in the oil as well as a oil catch port as part of the cast iron that collected the oil tow from the crown wheel and fed that through the pinion bearings as well, I guess to ensure there was oil flow through the bearings.
I'm now leaning towards the idea of rolling the diff centre back into its original position and drive from the original forward position with the electric motor, possibly through the 4 sp Alison auto that is already part of the rear engine drive set up .... maybe a mid mount ICE motor as well and then decide what to do with the rear engine compartment ..... I was always weary/ doubtful about the wisdom of turning a hypoid diff upside down ......

T1 Terry
Green but want to learn
francisco.shi
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Real Name: Francisco
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Re: Francisco's Electric Pajero

Post by francisco.shi »

I have been a bit busy working on other stuff.
I was having some trouble trying to get the CAN bus working. I didn't have a known working board that I could use for testing. Thanks to Andrew for lending me his boards.
After some troubleshooting I managed to get the CAN bus working on the SAME70 processor.

I also managed to make a comms protocol to send commands and settings to the inverter. Here is a video of it working under speed control.
Andrew's board reads the motor RPM via CAN reads the speed set point from the pot attached and calculates a torque command using a (badly tunned :oops: ) proportional controller running on Andrew's board. It then sends the torque command to the motor. None of the parameters are set correctly so it is a bit jerky.
I have finished drawing prototype board with the SAME70 processor and all the rest of the interface electronics. If I didn't make any mistakes it should all work.
I also came up with a way of getting the power cables and hoses out of the inverter. I just need to replace the flange on the back and make a case and the motor should be complete.
New back flange
New back flange
20201019_172025.jpg (1.68 MiB) Viewed 396 times
New back flange and base of inverter cover
New back flange and base of inverter cover
20201019_172055.jpg (1.81 MiB) Viewed 396 times
Now that I can use CAN to send the torque commands I should be able to run two motors. Cant wait to try it :twisted:
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

With the new flange installed.
New flange outside view
New flange outside view
20201019_183532.jpg (1.7 MiB) Viewed 390 times
New flange inside view
New flange inside view
20201019_183611.jpg (1.55 MiB) Viewed 390 times
I don't really like this solution. I wanted to keep the motor round all the way thru but I can't think of how to make a case for the back that can be easily removed, will be easy to make and will not have sealing issues where the cables and pipes go thru. The good thing about this solution is that I don't have to disconnect the power cables or the coolant hoses to remove the back cover.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

I got a prototype made with everything in. Still had a few mistakes but it should be good enough to test everything.
Inverter logic board
Inverter logic board
20201023_013741.jpg (1.58 MiB) Viewed 349 times
Inverter logic board bolted to power stage.
Inverter logic board bolted to power stage.
20201025_113031.jpg (1.65 MiB) Viewed 349 times
All wires plugged in.
All wires plugged in.
20201025_113617.jpg (1.63 MiB) Viewed 349 times
I need to cut the wires to the right length.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

Finished cleaning up the wires.
View of logic board.
View of logic board.
20201027_150039.jpg (1.73 MiB) Viewed 318 times
Added cable glands and thicker cable.
Side view
Side view
20201027_150229.jpg (1.63 MiB) Viewed 318 times
I still need to remake the bus bars so the cables come in straight into the busbars.
For now this will be good enough for testing.
motas
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Re: Francisco's Electric Pajero

Post by motas »

Hey mate, awesome project! Not sure if I missed it but any chance of a link/source for that motor? 100kW continuous is perfect for my Jeep conversion. Cheers!
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

To get 100kw continuous you have to rewind it and not sure if there is an inverter you can get off the shelf that will run it.
When are you planning to do your conversion?
motas
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Re: Francisco's Electric Pajero

Post by motas »

I doubt I'd need 100kw continuous, would ideally like about 125-150kW peak though. It's only got about 75kW peak stock!

Not in any huge rush, would be happy to wait for the right solution.
Jeep CJ10 - in pieces awaiting conversion
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

It has 100kw peak and 50kw continuous without rewinding and I have a spare motor. I could see if I can get you the original inverter.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

My plan is once I got everything finished I was going to see if I could get enough people together to buy say 10 and get them rewound from the factory and I would make sets with a built in inverter.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

I had the chance to play with a Nissan Leaf motor yesterday. I was curious as to the back EMF so here are some pictures.
Voltage measurement
Voltage measurement
20201101_201034.jpg (1.26 MiB) Viewed 220 times
Voltage measurement
Voltage measurement
20201101_201034.jpg (1.26 MiB) Viewed 220 times
19.2v @ 13.3hz.
That is 1.44v/Hz. Compared to my motor before rewinding of 1.55v/Hz.
I don't know how many poles the motor is. I had no way to check as I couldn't measure the rpm.
The back EMF is a nice sine wave as expected.
Attachments
Speed measurement.
Speed measurement.
20201101_201005.jpg (1.45 MiB) Viewed 220 times
francisco.shi
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Location: Brisbane, Strathpine

Re: Francisco's Electric Pajero

Post by francisco.shi »

I got the inverter cooling hoses connected. I was a bit worried it was going to be difficult to get a preformed hose to fit. Luckily good old Holden Commodore happens to have one that fits almost perfectly.
View of coolant hoses.
View of coolant hoses.
20201102_171035.jpg (1.62 MiB) Viewed 206 times
View from front of motor.
View from front of motor.
20201102_171054.jpg (1.64 MiB) Viewed 206 times
Now I have to get one of the hoses to connect to the motor coolant inlet and that should be pretty much it.
The next joint.
The next joint.
20201102_171538.jpg (1.6 MiB) Viewed 206 times
This is going to be a messy part to make.
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jonescg
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Re: Francisco's Electric Pajero

Post by jonescg »

I struggled to find the exact hoses I needed for the Prelude heater loop, and while I made something work, it ain't pretty.
You did well to find those ones and make them work.
AEVA National Secretary, WA branch chair.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

I took 2 pieces of wire. Bent them in the shape I needed the hose to be.
Then went to super cheap and went thru all their hoses until I found two that fit.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

I took the motor out of the test chassis so I could install the new inverter hardware. Now I have two motors on the bench.
Two motors on the bench.
Two motors on the bench.
20201114_182326.jpg (1.43 MiB) Viewed 78 times
I should get the new inverter boards sometime next week. Then I can start testing the coms with two motors. I don't expect any problems. After that I will install two motors and test them together. Should have good acceleration.
I also finished making the connector for the coolant between the inverter and the motor.
Coolant connection for motor.
Coolant connection for motor.
20201114_182023.jpg (1.78 MiB) Viewed 78 times
Now that the motors are almost ready it is time to start working on finishing the battery pack.
Today I started making the parts for the battery pack.
First I need to cut the material for the cooling plates.
Precut sheets.
Precut sheets.
20201114_170108.jpg (1.68 MiB) Viewed 78 times
Then fold them.
Folded cooling plates.
Folded cooling plates.
20201114_183141.jpg (1.77 MiB) Viewed 78 times
That is it for today.
francisco.shi
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Re: Francisco's Electric Pajero

Post by francisco.shi »

Some small progress today.
I made some parts for the battery.
Cell clamps.
Cell clamps.
20201121_190943.jpg (1.5 MiB) Viewed 31 times
.
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