I feel your pain. There is nothing worse than the 'crap its gone again' feeling.

You're right they look very familiar. Good Lord makes my version of how to control the motor look pedestrian.


Actually, its just JBs simple circuit on page 3 and 4 that's controlling the motor. The rest of it is IO, sense checking and a micro to run the Prius DC to DC convertor and provide CAN ...

Hi, sorry for not replying sooner. A few distractions here!

I've not posted the files on GitHub as I've found a few problems which I was going to sort out before doing so.

If you want to have a look, I've posted the schematic in the following repo: https://github.com/andymartell/Prius-DC-Motor ...

Here's a screen grab of what we have so far. The boards are on their way from China after Chinese New Year.

Hey Jack,

A bit slow I'm afraid. Working outside so sometimes the weather gets the better of me. Trying to get things together to do a road test. Just putting the battery pack together. I was thinking today that an estate would be better than a coupe!

Hey Johannes,
No need for KiCAD for 3D, Eagle and Fusion360 can do it. Some of the parts need models, but quite a lot is already there:

Great work Johannes. Have you got anything to share yet?

I realised there was a mistake on the Huebner BMS wiring diagram I made. The connections on the 1st isolator module connector JP2 were reversed. Also I swapped the position of JP2 and JP3 on the diagram to match the actual PCB:

Huebner BMS Wiring Diagram.jpg

I've updated the version earlier in ...

I had the same thought myself. I'll take a look.

That's great news. In the meantime, I think there was a plan for a high level linux computer (RPi, beagle board) front end. Is there something available to try out?

Also been working on some enclosures for the various modules that can be 3d printed. Here's one for the battery measurement module:

Fusion BatMeas.png

3d print BatMeas full.png 3d print BatMeas inside.png

There's a few tweaks then I'll put the stl files somewhere in case anyone wants to make ...

For anyone building their own version of the Huebner BMS, I've just corrected a couple of errors in the Isolator BoM (RS485 Version). The crystal should be 11.0592MHz and the processor should be an ATMEGA88P.

Hi arber,

The part number on my inverter is G9200-47190. The control PCB was F1759-47070/05. The 05 is in a white square and looks like the revision number. It came from an Auris according to the breaker.

I've created this wiring diagram for Johannes' BMS and added it to the Wiki as well.

Huebner BMS Wiring Diagram.jpg

This diagram has been edited. The connections on the 1st isolator module connector JP2 were reversed. Also swapped the position of JP2 and JP3 on the diagram to match the actual ...

Hey arber,

Looks like an interesting project! I've made a DC motor drive board from Damiens Prius design (not yet published as there are a couple of mistakes I want to correct beforehand). There were a few things I discovered which may be useful to you.

When my inverter arrived, the board was not ...

Inspiration for the power steering came from Damien's Red Arrow video:

https://youtu.be/GD5K6TmF5PY

Parts I used as follows:


Zafira B or Astra H TRW Power Steering Pump
Pressure port: M16x1.5 to 1/4" BSP male adaptor, 16mm Dowty Seal (sealing surface not particularly flat), 90 degree female ...

There are some days when you suddenly feel like you're making some progress and I have a couple of those this weekend!

Got the front motor mount sorted. Zafira PAS pump installed and running. No leaks!

And made a mounting frame for the inverter:

IMG_0626.jpeg

Decided to put all the batteries ...

Hi Peter, only just seen this as I’m away at the moment. Looks like you’re sorted though. What’s your total pack voltage by the way?

At that sort of price, the blue pill might be a candidate for the CAN version of Johannes' BMS Isolator board.

Ah, yes good point. I got all excited that it was actually working!

I think the next thing is to build up the HV Junction Box and where to fit it. Had to resort to a bit of CAD:

E46 engine bay.png

The slightly opaque parts represent the engine bay components.

Time to order some bits and hope ...

Another couple of steps forward over the past few days.

Started putting the firmware together for the controller. Can signals up and running and contractor control working.

Just done the first low voltage test run using a 12V battery and starter motor. It works!

Hi Barry
I am also new in forum did you know that logic bord Gerber file
ground is 2 layers and +5v is 3 layer is it correct ?
If you have logic bord components i can buy
Thanks
Sri

Hi Sri,

Damien's logic board is 4 layer. The two internal layers are +5V and Gnd. The exact order of the ...

I am at the testing stage of the controller and i have a small issue with the throttle potientomer. I have got a poteniometer from a golf cart that seems to work fine. When i check the output of the PWM it only works in a small range of the potienimeter . Do ineed to change the resistor in the ...

Been a little while since my last update, but made a bit of progress.

Added some conduit under the car for the rear battery cables:

IMG_0314.jpeg

Got it back on 4 wheels and ran the E46 on a 12V battery and achieved 'First Roll'!

https://youtu.be/PogbvR57uZo

Meanwhile the PCBs turned up for ...

Yep saw it. I've currently got a 'garage floor' test rig setup with the relay box from my leaf battery in it. The contractors are connected to switches so I can manually bring them in, including the pre-charge relay.