Francisco's Electric Pajero

Post up a thread for your EV. Progress pics, description and assorted alliteration
francisco.shi
Senior Member
Posts: 407
Joined: Mon, 17 Sep 2018, 16:30
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
Senior Member
Posts: 1151
Joined: Thu, 30 Sep 2010, 20:11
Real Name: Terry Covill
Location: Mannum SA

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
Senior Member
Posts: 407
Joined: Mon, 17 Sep 2018, 16:30
Real Name: Francisco
Location: Brisbane, Strathpine

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 76 times
New back flange and base of inverter cover
New back flange and base of inverter cover
20201019_172055.jpg (1.81 MiB) Viewed 76 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
Senior Member
Posts: 407
Joined: Mon, 17 Sep 2018, 16:30
Real Name: Francisco
Location: Brisbane, Strathpine

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 70 times
New flange inside view
New flange inside view
20201019_183611.jpg (1.55 MiB) Viewed 70 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
Senior Member
Posts: 407
Joined: Mon, 17 Sep 2018, 16:30
Real Name: Francisco
Location: Brisbane, Strathpine

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 29 times
Inverter logic board bolted to power stage.
Inverter logic board bolted to power stage.
20201025_113031.jpg (1.65 MiB) Viewed 29 times
All wires plugged in.
All wires plugged in.
20201025_113617.jpg (1.63 MiB) Viewed 29 times
I need to cut the wires to the right length.
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