Ah big thanks,
so I will probably leave modmax be for now.

in theory I could increase vlimmargin for later field weakening. but it would also come in quicker. will probably leave it as is till I have exhausted other options.

good to know id should be negative. that would explain it slowing down ...

So I have been doing some digging. anything that might help get a bigger picture of the HSG motor.

It seems that when running a bus voltage of 160v the critical speed is around 2500 mechanical RPM.

I am currently running 98V so roughly I should expect 1520RPM to be my critical speed.

Converting ...

Update.

https://youtube.com/shorts/ulGTgARPWI8?si=xjO8VyO4ETL8escs

Thing does things.

I do need some support now tho.

Still doing the field weakening runaway thing.
Also seems to have it's speed artificially capped. If I crank the throttle the speed jumps up then tapers back down.

The ...

That's really good to hear, I haven't experimented with exporting different formats from Altium. only importing of various types when we adopted Altium a while ago.

Will try and do a test export when I get a free moment. longer term test I would be looking at a possible revision of the mini ...

Not much progress this weekend as I was pit crew for a relative at brands hatch.

Have had some questions come in around the adapter board I did so figured I would post here to make it easily accessible.

The below images are of the V1 version that I had made. there are some changes I will make if I ...

Hi, Mini update.

Chain drive is sorted. nut still has about 6mm of thread engagement not great but not terrible, as the loads will be lower then went running a micro Vbelt.
PXL_20250906_153939731.jpg
PXL_20250906_211907680.jpg
PXL_20250906_211915064.jpg

Need to sort driveshaft. it seems a ...

Also a bit late to this one.

Happy to contribute towards wiki stuff. I have already made small contributions, page edits ect. had some thoughts around a current status / newest versions / recommended hw usage page, but I don't know how to make new pages, so you are safe for now.

I am fairly new to ...

Thanks. Starting to stray into build territory now :D

Sla printer is absolutely accurate enough to print splines. Just I'm kinda lazy.

Gearing isn't so bad. The axel sprocket is designed to be quick switch so won't have to swap the motor side one.

Rotax max kart engines rev to 14,500. The HSG ...

Bit more progress.

Got the pully off of the HSG. Man that was a fight. was a recall issued for the nuts coming loose. I think the fix was emptied a bottle of mystery goo into the threads. I was bending a 1 inch breaker bar.

PXL_20250828_221939228.jpg

PXL_20250828_221942472.jpg

PXL_20250828 ...

Got garage a bit clear and got the test mule down off the wall.

PXL_20250825_211459323.jpg


PXL_20250825_215255255.jpg

It's an EX rental kart. The whole thing is 3mm steel so not going to be blisteringly fast. But probably better being sturdy given I will be mounting 2x 24s VW Passat modules ...

No that's definitely dodgy. Which version software?


Thanks for the reply.
I am on 5.35.R FOC master release, not tried the double sync advance park Clark editied one yet.
hubner inverter picture 3.PNG

Attached is the current peramiters.

Not touched it since last tuning session as haven't ...

So some findings from tonight's tuning session.

sync off tuned by running current through phase A confirmed 59450 as about bang on.
PXL_20250821_195220811.jpg
range of motion at pole was pretty big so marked the extremes and picked the midpoint.

Confirmed angle plot increases when turned in ...

I agree shorted phases will be hard.
for most load testing brakes are fine, but for doing my proposed method for syncoffs tuning the load needs to be identical between tests. friction based setups are hard to do with any repeatability.

I think easiest would be some form of squirrel cage fan. just ...

Ah thanks I hadnt thought of doing it that way, will give it a go.
Looking at your linked post was helpful.
Annoyingly I got several scope shots of spinning the motor by drill, but never saved them

I had another idea.
mount a fan or some other form of load that increases with rpm to the motor ...

So, time to continue fighting the tuning, I have been coming up with what I think might be a bad way to validate Syncoff.

In one of Pete9008s post he says : If you are coasting (no throttle or regen, torque request of zero) then iq and id will be zero. If syncofs and syncadv are correct then vd ...

Hi Thanks for the reply.

I have tried tuning the motor both forwards and backwards by swapping resolver and motor phases. seems pretty consistent. but I am lucky in that my application rotation direction is the same as the OEM one (counter clockwise)

Yeah plan is to open source the files once I ...

Thanks,
Based on that I think 700hz is the final value I will use but will slowly work up to it.
(motor is 3 pole pairs and rated to 14000 RPM).

I have been looking at motor tuning in a bit more depth. I left Kp and Ki at the default 32 however for my motor inductance and voltage it looking like ...

Thanks, I am used to SPM and BLDC motors where field weakening is just a nice little extra rpm at the end not a core operating principle.

I pushed the frequency limit up from the default 200hz to 300hz and it got stuck at max rpm so is clearly still something going on.

Out of interest the speed ...

So I have some progress.
Running on 100v now I got brave and set manual id of 150A. I got no motion from the motor with sync offset values from 58500 to 60500 so still a very large range. and I only get moments of runtime at 150A on the motor (haven't hooked up cooling yet, it really needs it ...

Ah ok no worries,

I was mounting a 3 position switch for forward - neutral - reverse within driver reach so that works, will verify kicking it into neutral stops operation then I will remove estop.

Oh shiet. Estop triggers hardware PWM stop. But... During the chip crisis the 3-channel nand became unavailable so I disconnected estop and used a 2 channel one. Then never reverted the change...

Have been thinking about this, looking at the schematic. Did you just change the part or did you ...

Thanks, I figured it was sync offset field weakening related as it was a fixed rpm it took off at. I hadn't considered just turning field weakening off. It's a good suggestion, I will try later.

I have 2 other VW Passat modules on charge so can try throwing some more voltage at it during manual ...

Yeah deffo sync offset needs better tuning. swapped 2 resolver wires. then had to swap 2 motor phase wires, strange notchy mechanical feeling now in opposite direction. motor turns the other way in forward and sync offset re-tuned to be approximately 32000 more, so reversed as expected.

not sure ...

Ah thanks, I did think it was a tad strange.
How's the holiday going?

Has a new maintainer been found? or is that still in the works?

I have noticed a few other oddities, motor feels like mechanical grinding in reverse when inverter is enabled, both moving it by hand or with throttle command. but ...

Vary busy Saturday.
Got inverter working.
Bricked software update going to foc so had to get the st link out.
But resolver connections were right first time so win some lose some.

Very rough syncoff tune didn't have any inverter cooling so didn't push it past 60A

Runs on the throttle pedal but ...