I thought I should start a project thread, to describe my project and open up for some discussions regarding the strategy and components.
The final goal is a 4wd car, very light weight since it will be a space frame chassis with fiberglass body.
Car: Porsche 356 coupe replica, space frame chassis utilizing Corvette C7 suspension front and rear. So basically it will be a scaled down C7 (length and width) with 4wd performance on par with a Polestar 2.
Inverter: Chevrolet Volt with dual motor control
Motors: 2x Leaf MY11 motors with gearbox (one will be flipped over, due to short wheel base, oil gallery will need modification.
Battery: I have a complete Tesla model 3 long range battery, unfortunately its to long for my wheelbase, so if someone (in europe) has a standard range battery and is interested in a trade - I'm interested.
Inverter plans:
Reason for this choice: Good value dual motor inverter, very compact design.
The basic goal is as stated 4wd concept, but the route isn't fully determined, and thats why I'm very open for discussions. I've seen the Chevy-pcb here, but I take it that its just one stage + parallelisation option, so not dual motor.
My initial idea was to utilize two rev 3 boards on an "adaptor" board for the motor controllers, and having an extra controller that handles the demand values to each controller. So for instance, if going full acceleration the main controller would send eg 70% to the rear and 30% to the front, and when going to regen, it sets front to 60% regen and 40% regen in the back, this would make the car behave a little more predictive in slippery surfaces. Also having the controller "externally" would allow for the inverter to be "finalized" quite early on, and then do adjustments and car adaptions in something like a BCM that controlls the behavior and load share.
Motor plans:
Reason for this choice: Good value, readingly available
Since wheelbase is very small, I need to flip one motor over. One other option would be to run it in reverse, but that would make the load in the gears different from the intended design and it would still require modifications to the oil gallery for proper lubrication. So as of now the idea is to flip it over and modify the oil gallery to get proper lubrication.
Battery plans:
Reason for Tesla battery: Was available within my closest friends..
As mentioned I already have a Model 3 Long range battery pack, unfortunately its about 30-40cm too long for my wheelbase to be able to utilize the dual wishbone suspension used for this build. So I will be starting to look for a standard range battery pack, where the modules are way shorter (I would guess about 2/3 of the length of the 75kW pack).
Also ideally I'd like to keep the BMS controller, I only started looking into that yesterday, and found https://ingenext.ca/products/tesla-mode ... controller that seems to be doing what I'd like, however very expensive, but I haven't seen any other options right now that works?
As said, any input is appriciated, specially on the inverter and Battery plans
Who am I?
I'm an engineer in the automotive industry, working with automation systems and HW testing like gearboxes, motors, engines, batteries, etc. My main quality in the industry is complete designs of testbeds - so I'd like to call myself a testbed architect, focusing on finding all components that will fullfil the intended tasks. I'm not the best programmer, but usually I have a quite good idea of how things need to be controlled for the intended application
I'm also using the TM3 standard range batteries and have some reference 3D models on the forum here if you need to do any checks...they're still bulkier then we'd like. Did a lot of looking at BMS options and finally had to settle on the Orion 2