The ZombieVerter VCU Project

[Jack Bauer]

Many thanks Johannes:)

[Jack Bauer]

We have a schematic. Dropping into the pcb layout full time over the next few days.

[Bryson]

Looks good, thanks Damien.

On the digital inputs and brake input - those should all be 12v capable and I don’t see any zeners to clamp or anything to step them down. Is there something missing from the schematic there, or am I reading something wrong?

[celeron55]

There looks to be a 4k7/1k5 voltage divider in each digital input, which is combined with the clamping diodes in the stm32 and a capacitor for lowpass filtering. That should tolerate +-100V spikes and continuous 12V just fine, maybe even 24V.

[Jack Bauer]

Given the overwhelming positive feedback I must be some kind of genius so I'll just crack on with the pcb layout in between checking beach front property prices in Lanzarote.

[kiwifiat]

Looks good to me, only suggestion would be to substitute the pairs of clamping diodes 1N4148W-7-F for BAT54S-7-F. You get two diodes in a SOT23-3 package.

[Jack Bauer]

Components placed. All fits nicely on the board. Tracking starts tomorrow:)

[EV_Builder]

Given the overwhelming positive feedback I must be some kind of genius so I'll just crack on with the pcb layout in between checking beach front property prices in Lanzarote.

Whas it feasable to: implement switchable outputs/inputs?
and do we have a header for an extra top-mod board? Not everybody can draw and mod PCB's ehhh...

Another thought:
How beefy are the PWM outputs? Could they drive a HV contactor and form an economizer? (or should we use two outputs for that?) one turning on a relay and the second taking over with a PWM signal?

[EV_Builder]

We have a schematic. Dropping into the pcb layout full time over the next few days.

Ok i checked/reviewed the schematic. First of all i admire your work allot, but i do want to share with you my concerns.

My concerns are that this device is starting to become a one trick animal and if you ask me that's not the way to build a proper architecture, because you end up with a device to expensive because its to specific.

I see allot of 'project' dedicated stuff on there and IMHO we should really make that optional/configurable. (or even better send that over to a seperate slave device!), like remote IO device (see attached picture).

If we want to make this our general purpose EV controller we need to think in lanzarote terms. It should be a fit for all. Special external hardware may require an extra small mod board (internally) or external device. Atleast that's how i see the world. An VCU for all and a SLAVE (application specific) for some. So that means that the VCU should take care of the stuff that everybody needs tobe taken care off...

The tasks for this VCU in my world would be:
- Heating / cooling; (fans, heaters, pumps, temp sensors);
- managing the chargers;
- Gear communication to the inverters;
- CANBUS controlling the OEM Car.;
- Contactor control;
- AWD control if needed;
- DC/DC control;
- BMS communication;

Maybe a solution is to bring those header pins, MG1/MG2 temps, Toyota comms, Transmission feedback, via jumper pads to the corresponding IC's?

(IDEA: the gear feedback input circuitry configurable for general purpose input?? Can't they be 12Volts input anyway? - Which i can't find on the CPU in the schematic.... - This would give us 3 extra GP inputs...)

If needed we will jump wire then those inputs / outputs to the header.

I also came up with the idea to add arduino compatible headers. That would allow us access to a nice series of extension boards?

Architecture.png (9.9 KiB) Viewed 8126 times

If i can help let me know what needs tobe done / researched for this.

[Jack Bauer]

Alrighty, one day of tracking later... Reckon another day to finish tracking and another to clean up mistakes check fits with paper prints etc then we are good to go for prototypes.

So yeah, appreciate the feedback and assistance. There were a few omissions on the last schematic that I picked up on while tracking the board. Fixed in the attached. In terms of the design ethos used here I suppose its like a lot of things we color them in terms of our own experiences and requirements. Priorities for me invclude ease of use for end user (menu drop downs, simple params etc) and ability to control as much hardware as possibile in particular Toyota hybrid drive trains. We'll see where it ends up but I would see this as a good place to start

[EV_Builder]

Hey Damien that's good work! Thank u! Perhaps i was to oriented for lanzarote .

I sure want a simple install, that's why i seperate slaves on a seperate canbus and they won't need any maintenance at all! just a canbus interface to their in/outputs. Software will be only in the VCU select your slave! Add it to your config and it will be loaded on next boot .

But maybe you are right, lets first get this version going.

[Jack Bauer]

Layout done, drc passed and enclosure fit checked. Next up labeling, more checking then bom and placement file generation.

[JaniK]

That looks like all the space is used up quite well there

[Jack Bauer]

Pushed the latest schematic up to the repo if anyone cares to look. Found a few sillys, will be a few more I'm sure. I'm going to get this built by both JLC and PCBway just to see how they compare. Anyway, going to wrap this up and then jump over and finish the model 3 modboard and get them both ordered.

[steveknox]

Hi,
I know I'm late to the party, but has a Bluetooth receiver been considered? Even if there's no software for it now. I can imagine lots of uses. The obvious one is for displays, but we could conceivably have OTA updatea and other goodies with a Bluetooth connection.

Sorry if this is too late, but thought it worth at least mentioning.

Steve

[jon volk]

Hi,
I know I'm late to the party, but has a Bluetooth receiver been considered? Even if there's no software for it now. I can imagine lots of uses. The obvious one is for displays, but we could conceivably have OTA updatea and other goodies with a Bluetooth connection.

Sorry if this is too late, but thought it worth at least mentioning.

Steve

I made a plug and play HM10 module to replace the WiFi. It’s an EXTREME back burner project that intended to use a web-Bluetooth interface. I lost interest for the time being and have been honing my C usage and CAN bus “skills”

Would be happy to send one to anyone interested in pursuing this.

[Jack Bauer]

Wiring harness arrived from Aliexpress. Nice fit.

[steveknox]

I'm definitely game for looking at that, thanks. The radio silence i guess means that on-board Bluetooth isn't a consideration.

[steveknox]

Wiring harness arrived from Aliexpress. Nice fit.

That looks really good.

[johu]

I'm definitely game for looking at that, thanks. The radio silence i guess means that on-board Bluetooth isn't a consideration.

I'd say it's all covered by the wifi module already.

[Jack Bauer]

So quick update. First batch of 10 boards are now built and on their way from JLCPCB. Assuming they pass basic tests I will be making some available at a special discount to Patrons. General release subject to testing/validation and software development.

[steveknox]

So quick update. First batch of 10 boards are now built and on their way from JLCPCB. Assuming they pass basic tests I will be making some available at a special discount to Patrons. General release subject to testing/validation and software development.

Nice one. I'll take one off you and give feedback on here. I've got a range of inverters / motors to test with.

[Bryson]

Second that. My bench gs450h setup is live as of yesterday that I’m happy to use for testing.

[Jack Bauer]

Can also now announce sponsorship from PCBWAY who are covering the full cost of a prototype run:)
Anyone who intends purchasing a board will also need this kit of enclosure and header :
https://www.aliexpress.com/item/3285777 ... 4c4dWOmGPE

I will not be supplying these as getting them even in small volumes drives me into costly shipping,import charges,keeping stock etc. At the end of the day it will be cheaper and easier for customers to just buy one or two as needed via Aliexpress.

EDIT: a full kit of enclosure,header and pre wired harness is also available:
https://www.aliexpress.com/item/4001213 ... hBvGO&mp=1

[Jack Bauer]

Got a little delivery:)