1971 GMCe Lexus GS450H BMW 530e Tesla Model S Electruck [Upgrade]

[Gregski]

same concept here, just a bit less arcane USB cable

[Gregski]

and just like that we were back to where we left off, but with a different CAN Bus analyzer tool, hopefully a more better one (at least this one has a manual)

CAN-Bus-Analyzer-Users-Guide-DS50001848C.pdf

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[PacEmaker]

So with the Microchip CAN Bus Analyzer, you're winning now?

It's just I want to get something to analyse can bus coms but not sure I want to spend $200AUD on one, but if it's superior and easier to use than other options then maybe I'll get one.

[Gregski]

So with the Microchip CAN Bus Analyzer, you're winning now?

It's just I want to get something to analyse can bus coms but not sure I want to spend $200AUD on one, but if it's superior and easier to use than other options then maybe I'll get one.

no sir, please check out that thread here: I think I CAN, I think I CAN...

I even tried it with both, each analyzer responsible for sending only one message, and still no dice

[Gregski]

LESSONS LEARNED

In the spirit of full disclosure thinking I would go out and buy a complete OEM Chevy Volt first gen J1772 charge port and wall charger, seemed like a good idea at the time, but i soon discovered it just complicates things, actually makes it impossible to control the charger, as the silly charge port or wall charger needs to be controlled itself do to the Pilot and Proximity connections

[Gregski]

some_time_later.png (174.2 KiB) Viewed 3924 times

[Gregski]

oh no he didn't....

[Gregski]

and we got ourselves a dime a dozen regular US 120 volt (pronounced: "one ten") 15 amp power cord, perfect for some troubleshootin'

[Gregski]

it's time for...




[ wait for it ]

LaunchScreen.png (92.73 KiB) Viewed 3875 times

[Gregski]

[Gregski]

and literally in the 11th hour I got it working but only by enabling both the low voltage and the high voltage chargers using the 0x03 bit and when I do so I can see amps on the high voltage orange wire going into the battery, it reads 3.5 amps which is approximately half of what I have it set to ie 8 amps, but that's because I am on only 120 volts AC

[Gregski]

Oh my goodness, it all works, I figured it out, and you will not believe what was the problem!!!

I was trying to charge an AGM deep cycle battery and not a "real" car battery. Who knew that won't work?

Mighty Max.jpg (24.94 KiB) Viewed 3873 times

[Gregski]

I learned a lot over the weekend, and today I had to rest my brain and do something with my hands....

Commence Operation Porcupine

[Gregski]

the idea is a modular design that will put crane operators out of business


first we load up the bottom three cell modules (each weighing in at just under 30 lbs)

once those three are individually loaded and bolted up, we simply flip that batch over - right side up

and now we are ready for the top batch

and there we have it, "The Stack" configuration (genius I tell yah, genius!)

[Gregski]

now every battery pack has it's pros and cons, be it a Tesla pack, a Nissan Leaf, or this BMW 530e, and this one is no different, one of the downsides of it is these unobtanium proprietary high voltage cables, it is a real challenge to reconfigure the standard pack layout whilst utilizing only the stock high voltage cables

some like this one joins two cell modules very smartly.... (we like, we approve)

[Gregski]

here is one BMW 530e battery pack (Embedded Fun Fact: which consists of six cell modules, unlike the 330e which only has five) reconfigured in The Stack Formation, unfortunately we are unable to complete this arrangement because we are one cable short, technically we have the cable but it is just too short to join Cell Module #2 to Cell Module #3

[Gregski]

I'm a Simple Man, I see a gap... and I fill it!

yes we did run out of gas... (no literally)

but we recovered, and one side's done

[Gregski]

and onto the other side, having the frame rails level now is a total game changer

man I love a clean canvas

[Gregski]

alright, let's load 'em up proper

[Gregski]

now I currently only have one pack installed here, but hopefully you'll get the idea how this design is meant to hold two of them, six cell modules on top and anther six upside down

[TheSilverBuick]

Nice job on the Volt charger.

You're looking at 20-24 kwh of battery under the hood? Any plans for more capacity? Or did I under rate the batteries you have? I like the layout.

[Gregski]

Nice job on the Volt charger.

thanks have you seen this write up I did on it: I think I CAN, I think I CAN...

You're looking at 20-24 kwh of battery under the hood? Any plans for more capacity? Or did I under rate the batteries you have? I like the layout.

only 18.2 kWh as these packs are only 9.1 each, by my guestimate 18.2 kWh times 3.5 miles per kW will give me roughly a 63.7 mile range, and my goal is 100 miles, so one more of these packs under the bed and I'm golden

[Gregski]

so time to make a List for Phase I as I plan on doing or should I say NOT doing some stuff in this Phase that may be a bit controversial

PHASE I PROGRESS REPORT as inspired by our very own bobby_come_lately's The Plan!

[ this list is clickable so feel free to poke around please ]

1. Mount Lexus transmotor - ✔
2. Install modified Lexus drive shaft - ✔
3. Mount transmission fluid pump controller
4. Mount Lexus inverter - ✔
5. Mount Honda CRV brake booster - ✔
6. Install Toyota Prius power steering column - not happy with this install (my job, not the part)
7. Install first BMW 530e battery pack - ✔
8. Lay down on the floor the Damien Maguire VCU
9. Install modified BMW 530e pre charge circuit aka "Safety Box"
10. Install Chevy Volt first gen DC-DC converter
11. Install BMW E46 throttle pedal
12. Install B&M transmission floor shifter
13. Install Tesla Model S water pump

Not happening in Phase I

1. Lock GS450h input shaft in the Lexus transmotor*
2. Install Chevy Volt gen 1 onboard battery charger**
3. Install Battery Management System aka BMS***
4. Install customized digital gauges
5. Install second BMW 530e battery pack

the Controversial Section (we can thumb wrestle over these items if you like - by appointment only, ha ha)

* Input Shaft, I want to dyno test the truck with only MG2 powering the rear wheels to see how much horse power it actually puts out in real life, before adding MG1 to assist with traction power

** no Charger, this is the first of the radical ideas, why do we need a battery charger mounted on board permanently, isn't that the equivalent of driving around with your very own gasoline/petrol pump, can you imagine pulling up to SHELL or Chevron with your own pump mounted in the back of your truck?

*** no BMS, eventually I plan on getting SimpBMS but it is just so expensive here in the States, I think they want $650 for the hardware

[Gregski]

another day another mock up

[Gregski]

as much as I love this BMW 530e hybrid battery pack, it's Achille's heel has got to be the proprietary high voltage terminals, which call for the unobtanium plugs and wires, here I am trying to figure out how to use only the stock amount of high voltage cables to rewire it flat instead of two cell modules stacked on top like in the original implementation