Thanks for the response on the contactors.
If the contactors chattered under high load currents that would be worst for contactors allowing heat and possible melting and fusing. But with SF6 Gas in the KiloVACs the arcing would be suppressed and minimal.
And the battery circuit should not be confused (by me) with the higher inductive path of the motor.
So I can understand that the 720V pack will release less current for same power and with such an accumulated gap of 11 (x2 per Kilovac) contacts the voltage would have hard time jumping those hurdles.
Glad to read the wear is minimal. And chance of having to replace 11 contactors is minor.
So also you have implemented motor power shutdown when "Crash" blocks the pilot relay of the engaging of the battery packs.
I wondered if the connections at the CRASH output may have allowed feedback but not power to the pilot Relay. I've seen some dodgy daisy chained 6.2mm Quick Connects linked up for wire interconects. Sorry "Gage" was meant to be "CAGE CLAMP" style terminals with spring pressure... like in the solar panel thread. But you wrote they are 2mm male/female spade style. So there seems to be two wires twisted and joined into the female crimp terminal side. I wondered if there were two connections.
Also makes me wonder if further protection of the contactors and pre-charge circuit would be a valuable investment with further monitoring of the actual voltage supply to the contactors.
But you have Bus Voltage monitoring by Wavesculpter Controller on Can-Bus and IMU measuring battery half segments and the CMU's adding up to full Cell Voltage.
Monitoring and Alarms can sometimes blow out and cost more than the core functionality. So suggesting even more is worrying.. [:{]
Sometimes just relying on rugged construction is all that is warranted.
Interesting energy consumption rates.
176Wh/km * 85km/hr = 14.96 kW (Mexy down )
220Wh/km * 85km/hr = 18.70 kW (Mexy up )
110Wh/km * 85km/hr = 9.35 kW (ImEIV Up hill )
What else contributes..........
"Any other ideas, anyone"
Charger - (Charger and Cell efficiency is important but not included in the above numbers, so "wall to wheel" would be another comparison to consider"
Battery - Does the Battery segment above the motor get warmer than the others?
Wiring/Contactors -
Heating/AirConPump/Lights/etc - Cosy warm toes are need some times in cool convertible cruising...
Inverter - Water cooled so how do you know if losses are significant. In/Out coolant temps?
Wiring3Phase - When low speed and high torque pushes high currents.
Motor - (100°C may push alot of heatsink power out such a large connected metal area. But clutch may be source nearby missleading thermal status)
Clutch - (There maybe more slip/heat than expected in MeXY)
Gear Box - (not sure of how many shafts are between motor and diff in iMIEV)
Diff/90Spur - Mexy is 90° and iMIEV is //
Wheels -
Brake - Drag ... are they hot?
Cornering/Camber/Toe-In - Handling can prioritize over straight line efficiency for 'fun'
Mass - Up Hill (M.G.H) and Kinetic(M.V²/2) and contribution for Regen
Aero -
Regen -
( Wheels/Diff/GearBox/Clutch/Motor/Inverter/Wiring/Battery)
( These can each have different factors when power flow is in the other direction)
Long list....
Would be interesting to know what the motor draws when on a dyno.
- So when speed is 85km/hr and Motor and Battery currents are as per driving on flat ground the torque can be measured by dyno and mechanical losses determined.
I hope the worn Diff and Clutch (and tyres) are big contributors to the Consumption Figures and can be eliminated with new replacements. For an "easy" fix.
Then you could line up against these three moded MX5's, I wonder what there fuel consumption is ???
http://www.youtube.com/watch?v=lt39DhYBaA0#t=379
Makes me think of Bullets Dyno Setup.
Shown in the Youtube clip is bolts to the wheel axles not to the rubber via flywheel.
7C