[DRIVING] Renault Clio Electrique -97

[bexander]

Hi everyone!

A short introduction to my project car.
It started out as a stock Renault Clio Electrique from 1997. I bought the car in working condition but without the original NiCd batteries. First thing I did was to build a battery pack from used Headway 40152 LiFePO4 cells and fit them in the car. Ended up with a 42S5P pack with nominally 134V and 70Ah.
Then I built a BMS based on LTC6801 cell monitors and an Arduino Pro Mini.
Got the car past the anual car inspection in this condition.

Now the madness begun. Started removing some weight and also added some small aerodynamic improvements in hopes of improving the cars overall efficiency. One thing led to another and the attached pictures show what the car looks like today. Consuming less than 1kWh/10km @70km/h from the wall power outlet (including losses in the charger) and with a cerb weight of 810kg.

So why am I posting this here you might ask, this is not a conversion project.
Yes, well, the time has come to replace the stock motor and motor controller with something more efficient and more lightweight so my plan is to use a Lexus MGR and a Toyota Yaris Inverter.

The stock motor is a SepEx DC motor with a stated efficiency of 84% and a weight of 75kg. The stock motor controller weight is 15kg and the stock gearbox is estimated to 30kg.
I'm hopeing that the MGR will have an efficiency above 92% and with a total weight reduction of 60kg I think that the cars total overall efficiency will be increased by around 10%. Time will tell!

As of now I'm gathering the parts I need.
I appreciate any thoughts and ideas on how to further improve the cars efficiency!

[konstantin8818]

Nice little car! I'll watch this project with interest as my current aim is to make the MGR spin as well.

[jap]

Very impressive consumption numbers! I like your approach towards efficiency and maximising utility from a small batterypack. Can't wait to see it powered by MGR

[Kevin Sharpe]

cool project

[bexander]

Have started the job of fitting the MGR to the car. First up is to adapt drive shafts / half axles.

My idea is to use VW drive shafts as these have bolted inner CV-joints and are available in many different lengths.

VW_drive_shaft_length.pdf

(26.82 KiB) Downloaded 456 times

To fit VW shafts in the outer end I will use Clio uprights with Clio wheel bearing and VW Lupo hubs. The diameters fits but needed some adjustment in the lathe on the inside length to allow the splined axel of the CV to slide in 1mm further. Also fitted with VW Lupo brake disc.
Should now fit with Clio calipers. Job done!

Next job is to make an adapter to fit them on the MGR output flanges.

[bexander]

Adapters between MGR output flanges and VW driveshaft ends done!

[RetroZero]

Very cool. Nice bit of machinery.

[bexander]

Recived the inverter logic board for the Yaris inverter yesterday.
Solder it together and started testing.
I have MGR spinning with sine and calibrated current and voltage measurements.
At the moment I'm having some problem getting the resolver to do what I want . Will keep trying tomorrow.
Then next step is FOC.

[bexander]

Got the MGR to spin smoothly in both forward and reverse direction using the latest FOC FW.
Also tested sending throttle pot and io signals over CAN.
My parameters so far, if anyone interested.

Yaris_MGR_FW4_87FOC_2020_08_16.json

(1.3 KiB) Downloaded 375 times

[bexander]

Have started to disassemble the car.
Out with the old...

I have also replaced the uprights to the ones with the VW hubs.

Next up is to start fitting the MGR.

[bexander]

In with the new...

Next, fitting the inverter.

[bexander]

Some progress today. Yes, it temporary.

[Bratitude]

In with the new...
IMG_1395_scale.JPG
IMG_1396_scale.JPG

Next, fitting the inverter.

Looks awesome. Good choice with the vw shafts. so many different parts and combinations available. do you mind sharing the drawings/ cad(if there is one) files for your adapters?

[bexander]

I have a dxf file for the flanges but I'm not able to add it as an attachment?

[bexander]

I made a pdf from the dfx in scale 1:1.

Drive_flange_adapter.pdf

(127.3 KiB) Downloaded 467 times

I might need to add some measurements for this to make sense as a pdf...

[bexander]

I adjusted the flanges thickness today down to 13mm (was 18,5mm) so I have updated the drawing accordingly and added some measurements.

Drive_flange_adapter_2.pdf

(148.22 KiB) Downloaded 521 times

[bexander]

A basic cooling system and some wires.

And some HV contactor/precharge wiring.

[bexander]

Temporary wiring in place.

Have tuned syncofs and adjusted some other parameters with full pack voltage.

Yaris_MGR_FW4_90FOC_2020_09_27.json

(1.3 KiB) Downloaded 468 times

Next I need to regrease the half shafts and then it is time for a test drive.

[bexander]

Took the car out for a short testdrive today. It runs but not so good. It is not running smoothly and is a bit jerky so maybe I messed up syncofs or any other tuning. Will start over and recheck everything.

[Bratitude]

Looking good. When I have time I’ll put links to your half shaft adapters in the wiki.

Interested in seeing how the mgr runs! I think your the first to move a vehicle with it!?

[bexander]

Looking good. When I have time I’ll put links to your half shaft adapters in the wiki.

Interested in seeing how the mgr runs! I think your the first to move a vehicle with it!?

Thanks! I'm very interested as well to see how it runs.

My temporary wiring is messing with my resolver signals. When looking at the angle signal when motor is stationary it jumps up to 40 degrees. No wounder the motor is not running smooth... Founde a lose wire. Fixed now and the angle now jumps 4 degrees but I still have som random spikes so will need to fix this first and then redo syncofs tuning. I also have a very long signal cable at around 4m as per original in the Lexus. Might have to shorten this as well to improve signal quality.

[Bratitude]

Looking good. When I have time I’ll put links to your half shaft adapters in the wiki.

Interested in seeing how the mgr runs! I think your the first to move a vehicle with it!?

Thanks! I'm very interested as well to see how it runs.

My temporary wiring is messing with my resolver signals. When looking at the angle signal when motor is stationary it jumps up to 40 degrees. No wounder the motor is not running smooth... Founde a lose wire. Fixed now and the angle now jumps 4 degrees but I still have som random spikes so will need to fix this first and then redo syncofs tuning. I also have a very long signal cable at around 4m as per original in the Lexus. Might have to shorten this as well to improve signal quality.

Is there any shielding? depending on how it was run in the original car, might have been insulated.

[bexander]

Looking good. When I have time I’ll put links to your half shaft adapters in the wiki.

Interested in seeing how the mgr runs! I think your the first to move a vehicle with it!?

Thanks! I'm very interested as well to see how it runs.

My temporary wiring is messing with my resolver signals. When looking at the angle signal when motor is stationary it jumps up to 40 degrees. No wounder the motor is not running smooth... Founde a lose wire. Fixed now and the angle now jumps 4 degrees but I still have som random spikes so will need to fix this first and then redo syncofs tuning. I also have a very long signal cable at around 4m as per original in the Lexus. Might have to shorten this as well to improve signal quality.

Is there any shielding? depending on how it was run in the original car, might have been insulated.

Yes, the resolver cable is shielded and shield is connected to ground in one end.

[wwojciech]

How about max speed? clio have much smaller wheels then lexus

[bexander]

How about max speed? clio have much smaller wheels then lexus

I have not tested this yet. Don't know if I ever will. Can I make the car go 90km/h I'm statisfied.
I have a lower battery voltage than in the Lexus as well as smaller wheels. Time will tell...