Francisco's Electric Pajero
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I thought about that but the problem is I can not control the down movement of the hoist accurately enough. The pack fits so tightly into the chassis of the car that I have to align it to the chassis as the battery goes in. Once it is in the right place then it is fine. To do that I need up/down accuracy of a few mm so that I can get things to align correctly.
If I was doing mass assembly it would be no problem as I could build something to keep everything in the right place.
If I was doing mass assembly it would be no problem as I could build something to keep everything in the right place.
- jonescg
- Senior Member
- Posts: 4721
- Joined: Thu, 21 Jan 2010, 23:05
- Real Name: Chris Jones
- Location: Perth, WA.
- Contact:
Re: Francisco's Electric Pajero
I did exactly that with my hoist. I guess being fairly new the control was pretty good.
AEVA National President, WA branch director.
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
There is only about 5mm clearance between the chassis and the battery box so I need align the box to the chassis very accurately. The hoist has a pull down leavers to lower it but it is a little difficult to move it down slowly. Also the leaver is on the side of the hoist so I would have to move down a little then get under the car and move the battery box then go back to the leavers and repeat. If I go down too much and the battery box is not aligned then the chassis puts pressure on the battery box and I can not move it then I have to go back out and lift the car a little. So I think it will be better to move the battery up using a manual jack that I can control accurately.
Re: Francisco's Electric Pajero
Hi Francisco,
By any chance can you share the motor model or where you brought the motor!
Regards,
By any chance can you share the motor model or where you brought the motor!
Regards,
-
- Noobie
- Posts: 2
- Joined: Wed, 01 Jan 2020, 20:43
Re: Francisco's Electric Pajero
Hi Francisco,
your DIY Battery with the LG E63 cells are very interesting.
-where did you buy the cells and how much do you pay?
-I`m looking for a 22S 60Ah - 75Ah battery for my new E-Trike
Regards
your DIY Battery with the LG E63 cells are very interesting.
-where did you buy the cells and how much do you pay?
-I`m looking for a 22S 60Ah - 75Ah battery for my new E-Trike
Regards
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
About the motor part number is TZ210XS45H-320.
I got it from some Chinese company but it is a bit difficult to buy from them. They do not want to sell to private buyers.
I got it from some Chinese company but it is a bit difficult to buy from them. They do not want to sell to private buyers.
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I did a group buy a while ago. I still have some left if you are interested. They are about A$65 per cell. Let me know if you want them.
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I have been a bit busy for a while and didn't really have time to work on the Pajero. I have managed to get back into it and I am now working on the inverter to drive the motor. I got the gate driver board made.
I will post some pictures of the motor when I get it assembled. I am hoping to have the motor turning in the next few days all going well.
Here is a picture of the power module.
It has two IGBT packs each with its own gate drive board all mounted on a water cooled block with 1000uF bus capacitor and input bus bar. It should be able to drive 800A @500 continuous. The motor terminals bolt directly to the IGBT output. I have separated the windings on the motor so half go to one pack and the other half goes to the other pack. This allows for good current sharing between the packs.I will post some pictures of the motor when I get it assembled. I am hoping to have the motor turning in the next few days all going well.
- jonescg
- Senior Member
- Posts: 4721
- Joined: Thu, 21 Jan 2010, 23:05
- Real Name: Chris Jones
- Location: Perth, WA.
- Contact:
Re: Francisco's Electric Pajero
Always respect for those who roll their own inverters. Looks great. What's the drivers board based off? I see the VESC boards are popular.
AEVA National President, WA branch director.
-
- Noobie
- Posts: 2
- Joined: Wed, 01 Jan 2020, 20:43
Re: Francisco's Electric Pajero
Hi,francisco.shi wrote: ↑Thu, 02 Jan 2020, 09:28 I did a group buy a while ago. I still have some left if you are interested. They are about A$65 per cell. Let me know if you want them.
thanks for the offer, I`m in EU so the postage is too high, I will offer maybe a EU group buy.
Is the LG E63B 63Ah cell still a strong cell in your eyes?
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I think they are very good cells. Having the tabs on opposite sides makes it easy to connect them together and reduces the amount of copper you need for busbars.
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
It is mostly my own design. The DC-DC converters (the 3 transformers with associated drivers oscillator and rectifier on the secondaries) is a pretty standard way of doing isolated psu for gate drives. I just used newer parts for the transistors that drive the primary. There are two transistors in one chip which makes it easy for the layout.
Then there are two infineon gate drive chips one is a boost ic which is just a single channel buffer. It can drive up to about 15A into the gate. The other chip (which is under the transformer so you can not see it) is a 2 channel isolated drive. It does the isolation and desaturation protection. It can only drive 2A so the need for the boost chip.
It is so much easier these days with all the custom chips that do everything.
In the past I had to do all of this stuff with discrete components. It made everything so much bigger and many of the parts ended up bigger than they needed to be just because of what they were designed for. Transistors are a very good example you can get very small transistors with very high peak current rating. In the past you had to use a bigger case just because they were designed to run continuously. So far I have tested it to 20khz but I think that is about the limit of what it can do before it starts overheating. The IGBTs have quite a large gate capacitance. The aim is to switch as slow as possible but fast enough that you can not hear the switching frequency under full load. My main concern are the switching losses at full current.
Then there are two infineon gate drive chips one is a boost ic which is just a single channel buffer. It can drive up to about 15A into the gate. The other chip (which is under the transformer so you can not see it) is a 2 channel isolated drive. It does the isolation and desaturation protection. It can only drive 2A so the need for the boost chip.
It is so much easier these days with all the custom chips that do everything.
In the past I had to do all of this stuff with discrete components. It made everything so much bigger and many of the parts ended up bigger than they needed to be just because of what they were designed for. Transistors are a very good example you can get very small transistors with very high peak current rating. In the past you had to use a bigger case just because they were designed to run continuously. So far I have tested it to 20khz but I think that is about the limit of what it can do before it starts overheating. The IGBTs have quite a large gate capacitance. The aim is to switch as slow as possible but fast enough that you can not hear the switching frequency under full load. My main concern are the switching losses at full current.
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I didn't know about the VESC project.
I think it is a good idea to use existing hardware.
Maybe we should start a similar project for EVs.
I think it is a good idea to use existing hardware.
Maybe we should start a similar project for EVs.
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I have been doing some further testing of the power stage. This time driving the motor. I put some wires between the motor and the power stage because I can't get to the components when it is mounted to the back of the motor.
I got a friend to lend me a board he has been using to learn about Field Oriented Control. Unfortunately the processor he is using is not fast enough to run the motor at full speed. The next thing I want to test is the rigidity of the mounting of the battery box.
The plan is to install the motor and put the car against a tree or something solid and drive the motor at full torque to see how much the battery box twists.
I hope I can do this in the next few days. I will post a video.
Here is a video if the motor spinning.
https://youtu.be/0ruQ-FQfgFA
[ Edited Coulomb: fixed tube tags; only the video ID must appear between tube tags. ]
I got a friend to lend me a board he has been using to learn about Field Oriented Control. Unfortunately the processor he is using is not fast enough to run the motor at full speed. The next thing I want to test is the rigidity of the mounting of the battery box.
The plan is to install the motor and put the car against a tree or something solid and drive the motor at full torque to see how much the battery box twists.
I hope I can do this in the next few days. I will post a video.
Here is a video if the motor spinning.
https://youtu.be/0ruQ-FQfgFA
[ Edited Coulomb: fixed tube tags; only the video ID must appear between tube tags. ]
Re: Francisco's Electric Pajero
Hi Francisco,
Good step, are you looking to do regen with FOC?
Good step, are you looking to do regen with FOC?
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
Yes. It already does regen.
The current processor is too slow to run the motor smoothly at full speed and it doesn't have enough pwm outputs to run the resolver and the 3ph bridge. So I will use a different processor on the final version. This setup is so that I can test the structural strength of the battery box and all the mechanical components. The plan is to put the test rolling chassis with a motor to drive the back wheels and drive it up to an immovable object (like a tree) and apply full torque to the motor and see that nothing bends. I will be doing the test with a 12v battery so it will not be able to move very fast. I do not expect it will be able to spin the wheels on a concrete surface.
The current processor is too slow to run the motor smoothly at full speed and it doesn't have enough pwm outputs to run the resolver and the 3ph bridge. So I will use a different processor on the final version. This setup is so that I can test the structural strength of the battery box and all the mechanical components. The plan is to put the test rolling chassis with a motor to drive the back wheels and drive it up to an immovable object (like a tree) and apply full torque to the motor and see that nothing bends. I will be doing the test with a 12v battery so it will not be able to move very fast. I do not expect it will be able to spin the wheels on a concrete surface.
-
- Groupie
- Posts: 320
- Joined: Mon, 09 Jun 2014, 16:45
- Real Name: Rusdy
- Location: Australia
- Contact:
Re: Francisco's Electric Pajero
Hmmm... I can see tug war test YouTube channel coming up with your Pajero. Maybe try with a Hilux first?francisco.shi wrote: ↑Tue, 14 Jan 2020, 07:43 ... and apply full torque to the motor and see that nothing bends...
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I am not expecting it to be able to spin the wheels. That means that a highlux on low range and 1000kg on the back will pull the Pajero.
As much as it looks impressive for a Tesla to drag a Ute it is all about grip. Any old Ute with enough weight on the back and in low range will drag any Tesla any day with little effort.
As much as it looks impressive for a Tesla to drag a Ute it is all about grip. Any old Ute with enough weight on the back and in low range will drag any Tesla any day with little effort.
- JD Solar and EV
- Noobie
- Posts: 25
- Joined: Thu, 21 Mar 2019, 18:20
- Real Name: Jon
Re: Francisco's Electric Pajero
Wow, there are people posting in here.
Well there you go.....
Well there you go.....
Current AEVA QLD Chairman
Check out my EV videos at JD Solar and EV YouTube Channel
https://www.youtube.com/channel/UCNMxXc ... bUTfpHU5LQ
Check out my EV videos at JD Solar and EV YouTube Channel
https://www.youtube.com/channel/UCNMxXc ... bUTfpHU5LQ
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
A bit of a test drive.
Just testing the mechanics and the gate drive. So far only running one motor at 30% of peak torque.
Just testing the mechanics and the gate drive. So far only running one motor at 30% of peak torque.
-
- Senior Member
- Posts: 1952
- Joined: Thu, 30 Sep 2010, 20:11
- Real Name: Terry Covill
- Location: Mannum SA
Re: Francisco's Electric Pajero
It that a smashed windscreen? Part of the engine & Transmission removal or prior to the job?
T1 Terry
T1 Terry
Green but want to learn
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I bought a rolling chassis from the wreckers so I could do the testing and measurements without having to pull apart the one I am using. Once I get everything right I will pull apart the real one and transfer everything across. Because the motors and battery are all one unit I expect it will take longer to get the petrol engine, transmission and associated ICE stuff than to install the electric conversion.
The smashed windscreen was from the wreckers taking the engine out.
The smashed windscreen was from the wreckers taking the engine out.
-
- Senior Member
- Posts: 1952
- Joined: Thu, 30 Sep 2010, 20:11
- Real Name: Terry Covill
- Location: Mannum SA
Re: Francisco's Electric Pajero
Clever move, maybe you can find someone who wants the rolling chassis EV powered to run around their property or as a number plate swap unit for one they had written off.
T1 Terry
T1 Terry
Green but want to learn
-
- Senior Member
- Posts: 826
- Joined: Mon, 17 Sep 2018, 16:30
- Real Name: Francisco
- Location: Brisbane, Strathpine
Re: Francisco's Electric Pajero
I think it is too bad. It has no brakes. Only regen braking It is good enough to hold it on a slope.
Re: Francisco's Electric Pajero
Nice, this is impressive. Moving a 2 tons SUV silently with ease.francisco.shi wrote: ↑Mon, 03 Feb 2020, 17:14 A bit of a test drive.
Just testing the mechanics and the gate drive. So far only running one motor at 30% of peak torque.