The Nissan Leaf gearbox uses a single gear reduction and differential for transmitting power from the motor to the drive shafts. The gearbox also houses an electronic parking break mechanism which locks the input shaft from spinning via a solenoid operated lever. There is no oil pump and lubrication is provided by a splash lubrication system.
[[File:LeafGearbox.jpg|thumb|Leaf gearbox with newer style sealed bearings in place]]

The input splines are the same on both the EM61 and EM57 motors, but the bolt pattern is different. This means that you cannot use an EM61 motor with a EM57 gear box and vice versa. For more details on bolt patterns see [[Nissan leaf motor couplers and adapter plates]].

[[File:Inside gen2 gearbox.jpg|thumb|Gen2 gearbox with open bearings]]
A helical LSD is also available as an optional product for both Gen1 and Gen2 gearboxes from Nismo japan:

https://www.nismo.co.jp/products/nismo_parts/NEW_PARTS/index_2019.html#a2

== Gen1 with EM61 motor ==
gear ratios
[[File:Gen 2 gears.jpg|thumb|gen 2 gear box reductions gears and open diff]]
17:31 / 17:74

== Gen2 with EM57 motor ==
[[File:Leafgearbox.jpg|thumb|gen2 leaf gear box, em57 motor and inverter ]]
gear ratios

17:32 / 17:75

Input shaft bearings: 6207 and 62/32

Center shaft bearings: 6306

EM57 gearboxes have been found to feature open bearings (probably earlier variants) as well as rubber sealed bearings. There has been reports of open bearings failing prematurely especially with prolonged running in reverse direction which causes the splash lubrication not to function properly. Therefore it in advisable to pay attention to regular oil changes and use good quality oil with the gearbox.

Nissan's specs for oil volumes are 1.35 and 1.4L depending on the variant of the gearbox.

Nissan recommends Genuine Nissan Matic S ATF. However many people have found that replacing Nissan's with a better quality oil allows for more efficiency and reduces the noise of the gearbox. Therefore something like Redline D6 Fully Synthetic ATF is a [https://www.youtube.com/watch?v=xQda4531plQ better recommendation].

[[Category:Nissan]]

Mechanical design database

2023-07-18T11:50:56Z

Uppertown: /* A open data base for different mechanical hardware designs */

=== A open data base for different mechanical hardware designs ===

* adapter plates
* motor couplers
* drive shaft flanges
* covers, caps, shields,
* etc

zero ev CAD library https://zero-ev.co.uk/cad/?v=3e8d115eb4b3
{|
!motor
!source
!status
!gearbox
!source
!status
|-
|Nissan leaf gen 2+ (em57)
|https://github.com/bratindustries/adapter-plates/tree/main/nissan/leaf

https://bratindustries.net/product/em57-adapter-plate/
|fits!
|vintage VW
|
|
|-
|Nissan leaf gen 1 (em61)
|https://github.com/bratindustries/adapter-plates/tree/main/nissan/leaf
|untested
|Nissan 5 speed 71B
|https://github.com/bratindustries/adapter-plates/tree/main/nissan/5speed
|fits!
|-
|Mitsubishi outlander rear motor
|https://github.com/bratindustries/adapter-plates adapter plate with nema b-face pattern.

https://openinverter.org/forum/download/file.php?id=8468

https://openinverter.org/forum/viewtopic.php?p=25569&hilit=cad+file#p25569
|untested
|bmw
|https://github.com/bratindustries/adapter-plates
|untested
|-
|Toyota Prius transaxle
|
|
|
|
|
|-
|Lexus GS450h locking plate
|https://openinverter.org/forum/viewtopic.php?p=20934
|
|
|
|
|-
|
|
|
|
|
|
|-
|tesla model 3
|https://zero-ev.co.uk/TM3RDU.zip?v=3e8d115eb4b3
|
|
|
|
|}
{| class="wikitable"
|+3d printed parts
!parts for:
!function
!status
!source
!
|-
|molex memx cinch modice headers and encloser
|3d printable versions of the molex memx, used for many different vcu boards.
|
|https://github.com/bratindustries/molex-headers
|
|-
|toyota prius gen 3 inverter
|HV+LV conections
|fits!
|https://github.com/jamiejones85/Gen3PriusInverter3DParts
https://openinverter.org/forum/viewtopic.php?p=37156&hilit=3d+printed#p37156
|
|-
|toyota prius gen 2 inverter
|HV and MG adaptors/blanks
|
|https://github.com/Wonk6677/Prius-Gen-2-printed-parts
|
|-
|nissan leaf battery
|LV conector
|
|
|
|-
|nissan leaf gen 2 + inverter
|HV connection cover
|
|https://github.com/bratindustries/leaf-inverter-cover
|
|-
|gs450h inverter
|HV connections
|
|https://openinverter.org/forum/viewtopic.php?t=1694
|
|-
|mitsubishi outlander rear inverter
|HV connections
|
|https://openinverter.org/forum/download/file.php?id=13803
https://openinverter.org/forum/viewtopic.php?p=37192&hilit=3d+printed#p37192

https://www.printables.com/@crasbe_360778/collections/563327
|
|-
|mitsubishi outlander rear inverter
|3D Scan
|
|https://grabcad.com/library/mitsubishi-outlander-phev-rear-inverter-1
|
|-
|mitusbishi charger
|conectors
|
|https://www.printables.com/@crasbe_360778/collections/563327
|
|-
|mitsubishi outlander rear Motor
|Resolver connector cable gland replacement
|
|https://github.com/Wonk6677/mitsubishi-outlander-rear-motor-3d-printed-parts
|
|-
|mitsubishi outlander rear Motor
|3D Scan
|
|https://grabcad.com/library/outlander-phev-rear-motor-1
|
|-
|mitsubishi outlander rear Gearbox
|3D Scan
|
|https://grabcad.com/library/outlander-phev-rear-gearbox-1
|
|-
|VW Golf GTE Battery
|3D printable Terminal cover
|Fits
|https://grabcad.com/library/1577279
|
|-
|Gs450H
|Inverter HV inlet blanking plate
|Fits
|https://grabcad.com/library/gs450-inverter-hv-inlet-blank-1
|
|-
|Gs450H
|Inverter side HV inlet
|
|https://grabcad.com/library/gs450h-side-port-1
|
|}
[[Category:Mechanical]] [[Category:Adapter]] [[Category:CAD]] [[Category:Nissan]] [[Category:Toyota]] [[Category:Mitsubishi]] [[Category:Lexus]] [[Category:VW]]

Mechanical design database

2023-05-31T14:50:30Z

Uppertown: /* A open data base for different mechanical hardware designs */

Uppertown:

'''<big>Now available for general sale [https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards here].</big>'''

'''Development continues''' and you can
[https://openinverter.org/forum/viewtopic.php?f=3&t=1277 follow and contribute along with the development here on the forum]

[https://openinverter.org/forum/viewtopic.php?f=3&t=1696 '''Support''' is available via a separate thread on the forum]

== Introduction ==
Rather than crack open inverters and swap components about to drive them, what if we simply send them the messages they're expecting? This has been the case with a couple of existing designs (Nissan leaf inverter and GS450H) and thanks to the SAM3X8E microcontroller no longer being stocked by JLCPCB this project looks to take it further.

So rather than driving an inverter powerstage this version sends CAN for the Leaf inverter or Sync serial for the GS450H and of course can be expanded to any number of others. This will be the default firmware for all vcu products from now on and future hardware will support future fun packed stuff like FLEXRAY!!!

It's basically an <s>rip off</s> homage and builds on other people's hard work in the shape of the following projects

* [https://github.com/jsphuebner/stm32-car STM32-CAR project]
* [https://github.com/jsphuebner/stm32-sine Openinverter]
* [https://github.com/Isaac96/SimpleISA ISA library]
* Leaf inverter driver by Celeron55

What we have as of now is the openinverter wrapper with things like :

* Throttle cal and mapping,
* Precharge and contactor control,
* Temp derating,
* BMS limits,
* for/rev/neutral control,
* Graphing and monitoring,
* Firmware updates via the web interface,
* Cruise control,
* Fuel gauge driver,
* etc

==Hardware==
So you've ordered your kit, first things first, watch the following video to assemble it.

Due to chip shortages (written summer 2021) the board isn't fully assembled so you will need to do some soldering, or take it to a local phone repair shop (or similar) who'll find soldering at this scale like playing with Duplo.

The current list of parts to be fitted:<syntaxhighlight>
CONN1
IC10 = MCP25625T
IC14 = TJA1020 OR MCP2004
IC19 = NCV7356
IC20 = TJA1055T
IC21, 22 = AD5160
IC27, 28, 29 = FAN3122
</syntaxhighlight>And the positions on the V1 board.
[[File:Zombv1boardb.jpg|none|thumb]]

'''The enclosure kit links:'''

Enclosure Kit with Header, connector and pins :

https://www.aliexpress.com/item/32857771975.html?spm=a2g0s.9042311.0.0.39f24c4dWOmGPE

Prewired connector with 3M leads :

https://www.aliexpress.com/item/4001213569338.html?spm=a2g0o.cart.0.0.366c3c00qhBvGO&mp=1

'''Note that in addition to the VCU, the inverter and transmission, you will require a specific CANBUS connected shunt''': [[Isabellenhütte Heusler]]

<youtube>https://www.youtube.com/watch?v=geZuIbGHh30</youtube>

<youtube>https://youtu.be/MUhs9j9R9Mg</youtube>

== Installation ==
'''Pin Out Diagram'''[[File:ZombieVerter VCU V1 cable side pinout.jpg|thumb|alt=|VCU pinout diagram |none]]
[[File:Zomb-con-et.png|none|thumb|List of connections to system components (GS450 application)]]

Further information for a GS450 system can be found here: [[Lexus GS450h Inverter]]

'''Note''': In the software port 0 = EXT2 and port 1 = EXT

== Software==

https://github.com/damienmaguire/Stm32-vcu/tree/LIM_ST107

NOTE. Early boards fitted with the GD chip require different firmware to the St board.

The VCU is configured by connecting to its wifi access point. For existing units this is something like SSID: ESP-03xxxx, no password. For future units (shipped after 20/10/21) this will be SSID: inverter PASSWORD: inverter123

Then navigate to 192.168.4.1 to see the huebner inverter dashboard.

=== Initial start-up and testing (Instructions for GS450H application) ===
Get familiar with the interface and check that all of the parameters make sense. If in doubt, make sure the default value is set. At each stage the current state of the system and any error can be seen on the interface, for example '''opmode''' and '''lasterr'''. Press refresh at the top of the screen to update the values.

You will need the HV supply connected, which can be a lower voltage (50-100V), current limited power supply for test purposes. Set '''udcmin''' to some value below that (e.g. 50V for a 100V supply) and '''udcsw''' to 10V lower than the supply.

* Apply the '''Ignition T15 in''' 12V signal. The relay supplying 12V to the inverter should now be on.

* Check the accelerator by applying it gradually and watching / refreshing the interface. You should see values at '''pot''' change as the pedal is pressed. '''potmin''' should be set just above where your off-throttle position is, and '''potmax''' just below the value seen at maximum travel. Same for '''pot2min''' and '''pot2max''', if they are electrically connected. The resulting value as a 0-100 value can be seen at '''potnom'''.

''If it does not show up, check for errors and check that throtmax is not set to zero!''

* Apply the '''Start''' 12V signal for a short time. The pre-charge relay should turn on, and the voltage available at the inverter and the U1 input of the ISA shunt should quickly rise. If the '''udc''' reading goes above '''udcsw''' within 5 seconds then the main contactor(s) should close. If all is well, '''invstat''' should now be "on", '''opmode''' should be "run".

''If you do not see a good value at udc, it may be that your external shunt is not connected properly or is not initialised.''

''If you do not see a good value at Invudc, it may be that the inverter is not powered, or the communication signals are not correctly wired.''

* Once the contactors are on, select forwards direction. For example if '''dirmode''' is set to "Switch" then a 12V signal applied to the Forward input will work.

* Carefully apply the accelerator and the motor should begin to turn. Do not spin the motor up to any speed if you are using a test power supply.

== Software update ==

As supplied, both the ESP32 (the wifi plug-in board) and the STM32 (main MPU) are pre-loaded.

The "UART Update" field on the GUI can be given a '''stm32_vcu.bin''' file to update the firmware. Note that at this time, loading via Windows 10 is suspect and may lock you out of the board. Ubuntu works best.

By using the ST-Link V2 in-circuit loader, '''.hex''' files can be sent to the board to initialize a fresh STM32 MCU, or if it can't be loaded via the bootloader.

The connections needed to use the ST-Link loader are shown below:
[[File:0B35D4F9-BA64-46E7-A570-A0CE1D619D63.jpg|none|thumb]]

==Supported OEM Hardware==

*Nissan Leaf Gen1/2/3 Inverter/ motor
*nissan leaf gen 2 drive stack (inverter, dcdc, charger) gen 3 coming soon

*[[Lexus GS450h Inverter|Lexus GS450H inverter / gearbox via sync serial]]
* Toyota Prius/Yaris/Auris Gen 3 inverters via sync serial
* chevy volt HV water heater
*BMW E46 CAN support
*BMW E39 CAN support
*BMW E65 CAN Support
*CCS DC Fast Charge via BMW i3 LIM