Help FOC tuning Prius gen 3 & Outlander PHEV rear needed

[FFMan]

I had my setup working ok on the bench but now it's in the car i can't it to work. On the bench i went through the FOC and video and arrived at what i thought was an initial but working set of parameters and wiring.

In transferring it to the car two things happened, there is like 5% chance the resolver wiring is wrong as my notes weren't as clear as they could have been. Also, during the winter whilst sorting out the mechanicals the V1C board got a bit corroded and furry, suspect it wasn't sealed. i clean that up carefully with contact cleaner, a razor blade and a brush and sealed it. It looks a little dull but ok i think. Everything else is the same as working on the bench i.e. using my test rig, not the throttle pedal in the car yet etc,. Using a test set of lIPOS about 120V

So where i am now.

With sine f/w motor turns ok

With foc f/w, i can plot the resolver return, it swings from 0-360 and jitter is around 1 degree, which all appears to be correct.

As there was doubt about resolver wiring and i went back and started the pair id process again, set syncofs to zero, but i find in any combination, with the bulb in series, as soon as i start the inverter the bulb lights, with manualid & iq set to zero. If i enter a value for manualid of say 3, the bulb gets brighter. The motor doesn't turn. The light tays on until i stop the inverter. I don't recall this behaviour before, what does this indicate ?

For comparison I have polepairs and respolepairs set to 5, and pinswap to 8.
I note the polepairs & respolepairs differs from a known good set of params for the phev front motor, but i guess they're different motors so could ?

any help much appreciated. Getting close but wheel turnage eludes me !

[Bigpie]

The bulb staying on, what version of the firmware is that with? If it's with 5.24 it might be expected due to the current not being directly tied to the throttle position. 4.94 was the version I used for getting things setup.
Don't you have a gen 3 inverter?
Give me a Skype if you want to just talk through it, might make something obvious jump out.

[FFMan]

yep - you're right gen3 inverter - don't think i can edit the post heading now can I

in terms of versions. I think my bench run was 4.94, but when i load the parameters i exported back then, some of them say invalid when loading, is that normal or does that suggest i had the bench test running on earlier version still ?

it's currently on 5.24

Are you free 2pm for a skype - i could 4.94 test before then.

[Bigpie]

I've updated the thread title.

I'll be around on the laptop at 2 no problem.

[FFMan]

To keep the thread updated.

Thanks to Bigpie for troubleshooting with me, the main issue i had was that during the install from bench to car i had flipped the motor phases. There was additional muppetry on my part during the diagnostic process which led down some blind alleys, but as things stand i have decent motor control on 150v with my test rig.

So next steps on Mon/Tue are to install the proper ampseal connections and hard wire to car and test.

thanks to bigpie and pete008 for their valuable assistance.

[Mhs]

Great to hear you got it running again!
I have the exact same setup (planning 200v battery though) would love to see the parameters that worked for you.

[FFMan]

I’ll post up the params as I go. No doubt some tuning will come once it’s on the road.