Hybrid setup
Posted: Mon May 10, 2021 5:11 pm
Hello everybody,
My name is Rob and I’m a complete newbie in this space. It is great to see how much knowledge is here and I’m stunned by the projects some of you pull off. I already read a lot and watched a lot of youtube to learn as fast as I can, but it is a lot…..
I have this plan in mind that has got me completely hooked, and I wonder if your knowledge can help me out
It’s a plug in hybrid setup for a campervan. Fully electric is an issue because of weight limitations (battery pack) on the vehicle and the size the thing of it makes the range to smal.
I have a Audi q7 quatro Hybrid gearbox that has a 308Volts 98Kw 3 phase motor
The gearbox Itself wil be controlled with a HTG gearbox controller that can be hooked up to the engine management of the combustion engine via canbus. This controller is open source and has a lot of parameters to fiddle with.
The exact working principle of the electric motor coupled to the rest I’m still studying on, but what I can see from the technical drawing and exploded views is that it consists of a servo actuated dry clutch that can switch between Full electric, full combustion and combo. How that wil work in the end is not clear yet. If it involves some manual intervention, than that is fine as long as it is safe.
The thing for me is powering the electric motor. This is what I had in mind:
HV Battery Pack preferably Tesla model 3 60 KW 350V because they fit like a glove in the chassis
It is not yet clear to me how to the cooling heating of the tesla packs work.
Pre-Charge Contactor and Resistor Nissan Leaf
Negative Contactor Nissan Leaf
Positive Contactor Nissan Leaf
Nissan Leaf Inverter gen 3 120KW 350V WITH FAST CHARGE OPTION
Precharge unit (Tesla or Nissan?)
Open Source Logic Board (open inverter)
Fast charge plug Nissan leaf
Leaf cooling system for cooling motor and inverter system
Resolver or encoder is on the motor on the audi gearbox but no info on which exactly yet.
The engine ECU is GM and has these signals:
GMLAN High Speed (-)
MIL
Engine Speed
Vehicle Speed - Out
MAP Signal
GMLAN Low Speed (+)
Oil pressure signal
Throttle Pos #2 (0.5v - 4.5v)
Ignition "OnPower
The combustion engine and gearbox are a fixed plan, with or without hybrid (I have the same gearbox non hybrid) The rest is to be designed as simple and solid as possible, IF possible. Better ideas are very welcome.
Couple of questions:
Most important; Do’s and don’s,?? Ive seen a lot of trial and error here so the best advice is how NOT to do it.
Is the leaf the route to go or Tesla or something else?
Is the recuperating brake switched on by brake light signal? Because of the mass of the van I think that having this properly engaged is a big power generator
Is the accelerator signal from the GM ecu useable for the leaf inverter?
Is there somebody that has a list of parts with part numbers from the leaf that I would need for this?
Looking forward to you ideas and questions te learn from!
My name is Rob and I’m a complete newbie in this space. It is great to see how much knowledge is here and I’m stunned by the projects some of you pull off. I already read a lot and watched a lot of youtube to learn as fast as I can, but it is a lot…..
I have this plan in mind that has got me completely hooked, and I wonder if your knowledge can help me out
It’s a plug in hybrid setup for a campervan. Fully electric is an issue because of weight limitations (battery pack) on the vehicle and the size the thing of it makes the range to smal.
I have a Audi q7 quatro Hybrid gearbox that has a 308Volts 98Kw 3 phase motor
The gearbox Itself wil be controlled with a HTG gearbox controller that can be hooked up to the engine management of the combustion engine via canbus. This controller is open source and has a lot of parameters to fiddle with.
The exact working principle of the electric motor coupled to the rest I’m still studying on, but what I can see from the technical drawing and exploded views is that it consists of a servo actuated dry clutch that can switch between Full electric, full combustion and combo. How that wil work in the end is not clear yet. If it involves some manual intervention, than that is fine as long as it is safe.
The thing for me is powering the electric motor. This is what I had in mind:
HV Battery Pack preferably Tesla model 3 60 KW 350V because they fit like a glove in the chassis
It is not yet clear to me how to the cooling heating of the tesla packs work.
Pre-Charge Contactor and Resistor Nissan Leaf
Negative Contactor Nissan Leaf
Positive Contactor Nissan Leaf
Nissan Leaf Inverter gen 3 120KW 350V WITH FAST CHARGE OPTION
Precharge unit (Tesla or Nissan?)
Open Source Logic Board (open inverter)
Fast charge plug Nissan leaf
Leaf cooling system for cooling motor and inverter system
Resolver or encoder is on the motor on the audi gearbox but no info on which exactly yet.
The engine ECU is GM and has these signals:
GMLAN High Speed (-)
MIL
Engine Speed
Vehicle Speed - Out
MAP Signal
GMLAN Low Speed (+)
Oil pressure signal
Throttle Pos #2 (0.5v - 4.5v)
Ignition "OnPower
The combustion engine and gearbox are a fixed plan, with or without hybrid (I have the same gearbox non hybrid) The rest is to be designed as simple and solid as possible, IF possible. Better ideas are very welcome.
Couple of questions:
Most important; Do’s and don’s,?? Ive seen a lot of trial and error here so the best advice is how NOT to do it.
Is the leaf the route to go or Tesla or something else?
Is the recuperating brake switched on by brake light signal? Because of the mass of the van I think that having this properly engaged is a big power generator
Is the accelerator signal from the GM ecu useable for the leaf inverter?
Is there somebody that has a list of parts with part numbers from the leaf that I would need for this?
Looking forward to you ideas and questions te learn from!
