Vectrix VehicleMan - ESP32/LTE+GPS/CC-CP/triple CAN VCU/Tracker

[skr]

Hello community,

As a primer - Vectrix VX1 is a maxi scooter, designed some 20 years ago, the frame is basically a big battery box, motor is 22kW peak. Company went under multiple times, allegedly spending $ 250M+ to produce <2k units. Entire vehicle is CAN controlled, consists of ICM (controls, gauges, etc.), 1.5kW OBC (estimates range and SoC), MC (motor controller).

So, I recently acquired a Vectrix VX1 without a battery, whilst contemplating the time requirements for making one out of my battery stock I opted to make one out of VW HV repair center discarded 3x 12S MEB modules I got for pretty cheap - around 333€ a piece.

Next step was BMS - there are two options out there available from third parties, LTC6811 based BMS with CAN fault indication on the dash for 500€ and another which seems left over from Vectrix operations in Poland - 500€+, but also allows for removal of stock 1.5kW charger and replace it with a TC charger (kit of BMS + Charger is 1.5k+). Beeing a poor eastern european I opted to waste much more time and money building my own. Initially I drew designs based on BQ79612 slaves meant to be mounted at the end of each MEB module, TI doesn't want to give me docs (even as a corporate), so screw them. Then I switched to LTC6811 as it is well documented, but realized I don't want to reimplement everything already implemented in Flying ADC BMS, however I still need something to control the vehicle with.

Opting for can enabled esp32 board would definitely be enough, but if I am at it - why not create something much more useful, even moreso in a motorcycle, which is much easier to steal and harder to recover.

Here is a copy paste from the README:

Vectrix VX1 BMS manager + TC charger control + LTE connectivity + GPS tracker + Alarm + whatever else time can solve.

meant to be used together with Openinverter Flying ADC BMS

Includes:

• ESP32 + SD card
  Battery backup with charger for esp + LTE (1x18650)
  Footprint for GigaVESC HV (150-180V?)@2~3A(?) -> 12V DCDC
  LTE modem (SIM7070G with GNSS) + 1 SIM
  1x CAN TWAI transceiver
  2x CAN SPI transceiver (in case TC charger(s) are on the same address or say multiple R4850G2 are used)
  A few relays and mosfets for external loads
  Accelerometer/IMU for "alarm" functionality
  Moisture/temp sensor for condensation detection (?)
  RTC
  TYPE 2 charging CP PP control
  External antenna PCB for active GNSS + passive LTE should be here as well.

Here is the schematic: https://github.com/skrubis/vectrix-vehi ... eman-0.pdf
Here is the git: https://github.com/skrubis/vectrix-vehicleman/tree/main

Current status: Schematic

First few years of VX1 production has an always on 12V source, so I have placed all Battery backup related symbols as DNP. Models after 2008 or something have a charge pump on DCDC brick enable with ignition, so powering from a HV-DCDC module is there as well.

What am I looking for:
General feedback on the schematics. I plan on doing layout maybe over the weekend, so can still discard/fix something.
Pointers on either forking the Openinverter ESP32 web interface for FW or reimplementing everything myself.
I am not very well versed in Openinverter ecosystem yet, so I am sorry if I am reinventing the wheel.

Thank you in advance!

[modellfan]

I implemented the Open Inverter SDO for ESP32 and tested it against a standard Webinterface. I would be happy, when you jump on the train: https://github.com/Modellfan/esp32VCU/tree/main/src

[jetpax]

Hello community,

As a primer - Vectrix VX1 is a maxi scooter, designed some 20 years ago, the frame is basically a big battery box, motor is 22kW peak. Company went under multiple times, allegedly spending $ 250M+ to produce <2k units. Entire vehicle is CAN controlled, consists of ICM (controls, gauges, etc.), 1.5kW OBC (estimates range and SoC), MC (motor controller).

So, I recently acquired a Vectrix VX1 without a battery, whilst contemplating the time requirements for making one out of my battery stock I opted to make one out of VW HV repair center discarded 3x 12S MEB modules I got for pretty cheap - around 333€ a piece.

Next step was BMS - there are two options out there available from third parties, LTC6811 based BMS with CAN fault indication on the dash for 500€ and another which seems left over from Vectrix operations in Poland - 500€+, but also allows for removal of stock 1.5kW charger and replace it with a TC charger (kit of BMS + Charger is 1.5k+). Beeing a poor eastern european I opted to waste much more time and money building my own. Initially I drew designs based on BQ79612 slaves meant to be mounted at the end of each MEB module, TI doesn't want to give me docs (even as a corporate), so screw them. Then I switched to LTC6811 as it is well documented, but realized I don't want to reimplement everything already implemented in Flying ADC BMS, however I still need something to control the vehicle with.

Opting for can enabled esp32 board would definitely be enough, but if I am at it - why not create something much more useful, even moreso in a motorcycle, which is much easier to steal and harder to recover.

Here is a copy paste from the README:

Vectrix VX1 BMS manager + TC charger control + LTE connectivity + GPS tracker + Alarm + whatever else time can solve.

meant to be used together with Openinverter Flying ADC BMS

Includes:

• ESP32 + SD card
  Battery backup with charger for esp + LTE (1x18650)
  Footprint for GigaVESC HV (150-180V?)@2~3A(?) -> 12V DCDC
  LTE modem (SIM7070G with GNSS) + 1 SIM
  1x CAN TWAI transceiver
  2x CAN SPI transceiver (in case TC charger(s) are on the same address or say multiple R4850G2 are used)
  A few relays and mosfets for external loads
  Accelerometer/IMU for "alarm" functionality
  Moisture/temp sensor for condensation detection (?)
  RTC
  TYPE 2 charging CP PP control
  External antenna PCB for active GNSS + passive LTE should be here as well.

Here is the schematic: https://github.com/skrubis/vectrix-vehi ... eman-0.pdf
Here is the git: https://github.com/skrubis/vectrix-vehicleman/tree/main

Current status: Schematic

First few years of VX1 production has an always on 12V source, so I have placed all Battery backup related symbols as DNP. Models after 2008 or something have a charge pump on DCDC brick enable with ignition, so powering from a HV-DCDC module is there as well.

What am I looking for:
General feedback on the schematics. I plan on doing layout maybe over the weekend, so can still discard/fix something.
Pointers on either forking the Openinverter ESP32 web interface for FW or reimplementing everything myself.
I am not very well versed in Openinverter ecosystem yet, so I am sorry if I am reinventing the wheel.

Thank you in advance!

You might want to consider using an esp32s3 which allows you to connect the modem on USB, which saves a lot of pins and complexity.

[skr]

I initially drew the schematic with S3, but opted to go vanilla ESP32 as a way to avoid any previous codebase breakages. S3 is eons ahead in terms of debugging, but my experience has been hit or miss in terms of reusing code others have written. I would like to not spend months writing code for this. Current schematic has no pins left over, but I have no clue what else I may need to add, so no biggie.

[skr]

Finished laying out the components, now routing and ordering. Various fixes in the sch.

The more I look at the power tree the more mentally challenged it starts to look, but should work, hopefully.
Form factor is dictated by 3x Johannes Flying ADC BMS side by side, on standoffs.

I have never tested the HV DCDC design, but the author spent many months on this



no clue on how noisy it is or what is the Iq.
Given that I will not be using it - it is reserved for others to find out if anyone ever replicates this board.

[skr]

Finished routing and ordered. Routing is a mess, but hopefully at least parts of it will work alright.
Git pushed. Sadly 4Layers due to laziness + RF antennas

[skr]

Talking about reinventing the wheel - only now found out about headless zombie project ( viewtopic.php?t=5947 ) and OVMS. Looking at the OVMS schematics it seems like I have done something not very far from that project. Nice to know that there is plethora of shoulders of giants to stand on, while reinventing the wheel.

[skr]

Just an update - assembled first prototypes + flying ADC BMSes, now forking the web ui fw for vehicle comms,

Lots of small mistakes in the board schematic, hopefully will update the git with fixes. Biggest one so far is probably forgetting to attach type 2 cc mode pins anywhere. Cells seem to be balancing, reading correctly, now only need to figure out everything else before I put it all in to the bike.
I had some unexplained mishaps with the bms, so a bit stressful putting them on MEB modules, as in if anything goes wrong with bms- it means angle grinding the module open, changing the fuse and then welding it back up, which is about a full day of work per module.

[johu]

Like it was meant for it I mean dimension - wise