GS450H gearbox with Camry inverter G9200-33171 [SOLVED]

[jrbe]

I wasn't aware of your local fabrication limitations. Do you order from JLCPCB? They do CNC machining pretty affordably. If you get both sides correct, pump and transmission i could use those and make you a step file or 2.

An esc is about speed. A vesc can be programmed for torque, speed, or have a script run it.
I think the official 4.x VESC hardware can run down to 8 volts. The Toyota pump should run fast enough on 12v to make all the pressure you need. You should not have to use field weakening. Basically I think it will be much more controllable with a VESC. The need for a position sensor in an oil pump is silly.

[PetersonOctavius]

have you used VESC?
i wasnt able to find a seller of those so i could try it out.

[jrbe]

VESC is similar to open inverter but for small motors. People use them on skateboards, scooters, and some have been converted to run cars. It's open source and requires anyone selling one to not use the vesc name which makes them challenging to find.

I've used 2x "FLIPSKY 75100 Pro V2.0 75V 100A with Aluminum PCB" so far on projects. USB has worked well, Bluetooth has been challenging but I'm also using scripts. These drop out around 12v I think so probably not ideal. They claim 4s at the low end. I can test mine to check the min voltage if you want. But a low battery will also mean no drive if you use one of these.

[PetersonOctavius]

hi, its been a while, after all my oil pump issues, i ended up buying another oil pump from Gregski.
been running fine ever since, on 40%
after a couple of moths of driving, i was cruising at around 60-70kmh, i had a torque loss, mg2 spun freely. i had to restart the car and it worked fine....for 2-3weeks, it happened again. even before those torque losses happened i ordered lock rings for the gs450h, and they arrived. so i decided to put them in the gs450h to test and see what are the cons, the pro's we already know.

so today i managed the install the lock rings, so now, my gs450h is mechanically locked in high gear.
in theory the oil pump will only need to circulate oil for lubrication and cooling.
tomorrow i will put it back in the car to see how it will perform.

many thanks to the user @konstantin8818 for the .dxf file,

viewtopic.php?p=33459#p33459

i was able to upload his file on sendcutcend.com , i choose steel, with a thickness of 0.313" or 8mm, i ordered 4 of them but i ended up using 3, because the clucth plates are 30mm, and 4x8 is 32mm.
more info on the video below.

[Jacobsmess]

Glad to see the steel toe cap flip flops in action. What are the pros of this arrangement?

[PetersonOctavius]

In theory getting rid of the external oil pump all together if possible.
The oil pump provide pressure for the clutch plates, you can choose high or low gear. But the oil pump is known to fail. No oil pump means no driving
Locking the gs in high gear means no oil pump yes driving
But no changing from low to high, always in high
I m hoping that the gears will splash the oil around by themselves and i hope that running whithout pump will not affect cooling

[PetersonOctavius]

sooo, after mechanically locking the gs450h in HIGH gear and installing it back in the car, it wouldnt spin.... i got scared, but it was due to lose contact in the resolver wiring. after fixing that, the car drove fine.

i let it charge up and the next morning i drove it to work, oil pump completely turn off, before i used to have it on 40%.
the only thing i did was monitor my mg2 temp, it behaved just like before. so i can say i successfully ran the gs without oil pump.

so far the pros are :
- quieter car
- when the car i on, idling, it used to pull around 1.3Amps from the HV batt, now its idles at around 0.8 Amps. you can say the oil pump at 40% duty was pulling 0.5 amp, constantly. thats roughly 150-200watt. going to work and back is like 1 hour driving. soo around 200Wh of energy is being saved. not a lot, but its something.

also, i can drive without expecting loss of torque due to oil pressure

[Bigpie]

Now just to see how it holds up over the miles. It would be good the junk the oil pump

[PetersonOctavius]

so far so good, nothing weird happened.
as exprected Mg2 temp is running slightly higher
normally MG2 gets to around 48-50 degree C when driving, today its was sitting more around 51-52 degree C
way to go

[PetersonOctavius]

DAY 2, running the GS450h, oil pump off.
still running fine, no unexpected behaviors, no unexpected noises.

today on my way to work, mg2 temp climbed steadily till 53 degrees C, AC on, oil pump off.
as soon as i turned on the oil pump, 40% duty, mg2 temp drops the 51 degrees C.
i drive a couple of minutes, 51degrees solid. then i turn off the oil pump, it stays at 51 for quite a while, then 52 for quite a while...and finally it stabilizes at 53 degrees C. with AC on, the condenser heat flows to the radiator.
with AC off, the whole system runs at 2 degrees cooler, so 49 to 51 degrees.

this kinda confirms my assumption of higher temperatures if the gearbox relies only on oil splashing and no oil pump.
i was expecting higher temps difference, but it seems to only be 2degrees difference.

so far, so good
stay tuned