Prius Gen2 adapter board development thread

[johu]

thats what we want Will draft a new release soon, just want to do a quick Polo ACIM test prior.

[RetroZero]

Thanks so much for the testing. Away for 10 days recharging the batteries and following from the side lines. Operation 'Gen 2 transaxle' real life test on its way!

[LRBen]

I'm planning to get back to my inverter next week, BMS on my quad died so that stopped my 48v HV testing.

Going to start from scratch with the setup given it's been a couple months since I touched it and it looks like there has been some updates.

Thank you Johu and Damien for your continued testing on this.

[imwoody36]

im looking for confirmation the new firmware works before i get back to work..what is a polo acim test johu? and does it affect the FOC firmware?

[Jack Bauer]

the new firmware works. I have a 1 hour 40 min full tutorial video ready on youtube just waiting for Johannes to review before it goes public. I would ask everyone to wait for this please.

[johu]

im looking for confirmation the new firmware works before i get back to work..what is a polo acim test johu? and does it affect the FOC firmware?

The Polo ACIM test is the test for the sine firmware. The FOC firmware is tested on Touran. Whenever I release a firmware I test on these two vehicles first to make sure it at least drives fine.

[RetroZero]

Looks like it will be no TV for me, as I have a nice video to watch. Thanks Damien and Johannes. I'll update wiki once I got my head around everything.
One Gen2 Transaxle to be re-assembled tomorrow

[Jack Bauer]

[ZooKeeper]

JB & JH, THANK YOU for this!

Two questions;
1) seems like the dc current draw was fairly low (<20A), is that accurate?
2) What odd behavior is expected when the resolver wiring is incorrect?

[johu]

1) it should be
2) It behaves odd
Either you get no spin at all or just jerking

[Jack Bauer]

This happens when you get one of the three wrong resolver connections :

[ZooKeeper]

GREAT! I was hoping the wrong settings did not result in something subtle

Thanks!

[tom3141]

Thanks Damien and Johannes.

The explanation of syncofs was excellent. I’d managed to get a fairly decent tune on mine following the wiki procedure but didn’t fully understand what I was trying to do with syncofs. The video completely clears it up.

[MattsAwesomeStuff]

Just in case anyone's presuming I won't do timestamps and summaries as usual... I am, I'm just slow to get to it this time. I'm about 1/3 done (the easy 1/3, before it gets technical). I'll be coming in a couple days probably.

[RetroZero]

Thanks for pushing through . I'm going through it slowly checking where I went wrong with my setup.

[hugow93]

Thanks Johu and JB, this video is a great resource.

I was working slowly through it this morning:

1. Using the car headlight bulb and 12v supply, VCU behaves as expected.
2. When connecting the I9, the VCU behaves as expected, but the car headlight bulb doesn't light at any point.

I reassembled the circuit from scratch several times to account for any wiring mistakes with no difference, and presume this means that the inverter has been damaged.

At this point I see my options as:

a) Getting another inverter
b) Dismantling this inverter to find the damaged components.

Before I go further, does anybody see something I'm missing from this?

Thanks for the help!

[ZooKeeper]

1. Using the car headlight bulb and 12v supply, VCU behaves as expected.
2. When connecting the I9, the VCU behaves as expected, but the car headlight bulb doesn't light at any point.

I presume that the VCU and I-9 are connected as per the video from about minute 12? This means the 12v and ground are shared and all the connections from the VCU to inverter board are wired?

Try powering only the I-9 thru the lamp, it should draw about 1.5A (Prius Gen2) and light most 12v lamps at least dimly if the connections are good.

It is very possible that the logic connection(s) inside the inverter are not fully seated, especially if it has been apart, which could cause a partial or complete open circuit to the I-9 connector.

[hugow93]

1. Using the car headlight bulb and 12v supply, VCU behaves as expected.
2. When connecting the I9, the VCU behaves as expected, but the car headlight bulb doesn't light at any point.

I presume that the VCU and I-9 are connected as per the video from about minute 12? This means the 12v and ground are shared and all the connections from the VCU to inverter board are wired?

Try powering only the I-9 thru the lamp, it should draw about 1.5A (Prius Gen2) and light most 12v lamps at least dimly if the connections are good.

It is very possible that the logic connection(s) inside the inverter are not fully seated, especially if it has been apart, which could cause a partial or complete open circuit to the I-9 connector.

Thanks ZooKeeper,

Yes, setup was as per video (I-9 in parallel with VCU).

I connected the I-9 to lamp and 12v separately as well, with the same result unfortunately.

I'll source a replacement inverter for now, and go back to find out what's wrong with this one at a later stage.

[ZooKeeper]

Yet another potentially stupid question, or two..

I noticed that "numimp" was 256 in the video and searches have not provided any real answers, so the questions are: how was that determined and what if any, influence does it have on proper system function?

[kiwifiat]

Yet another potentially stupid question, or two..

I noticed that "numimp" was 256 in the video and searches have not provided any real answers, so the questions are: how was that determined and what if any, influence does it have on proper system function?

numimp relates to the number of pulses generated per turn of an encoder. In this case it is probably the default value but in reality can vary vastly. Since the Prius has a resolver it is irrelevant and should probably be automatically hidden when resolver is selected.

[ZooKeeper]

Perfect, thanks. That explains why changing had no obvious effect.

[ZooKeeper]

Here are my latest Parameters, will also post them in my project thread.

2005 Prius Gen2 Inverter + 2007 Highlander MGR (Q211) + Huebner VCU 4.90.R.foc

Throttle is good in both directions, but manual mode seems "smoother" than on the pedal somehow.

[Jack Bauer]

Much appreciated.

[Jack Bauer]

Got sent a link to this video. Web interface in Russian:)

[konstantin8818]

Got sent a link to this video. Web interface in Russian:)

Which is translated with Yandex translate (some sort of Google translate in Russia) and is very funny to read
I'm in touch with this guy, so gave him some translation hints...