BMW i3 Inverter: Difference between revisions

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https://openinverter.org/shop/index.php?route=product/product&product_id=72
https://openinverter.org/shop/index.php?route=product/product&product_id=72
'''<big>Overview</big>'''
There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.
There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.
Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v
'''<big>Openinverter Drop-in Board</big>'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.


{| class="wikitable"
{| class="wikitable"
Line 32: Line 48:
| 9|| 5V (OUT) ||  
| 9|| 5V (OUT) ||  
|-
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Low
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
|-
| 11|| GND ||  
| 11|| GND ||  
|-
|-
| 12|| RESOLVER_S1 || Sin Hi
| 12|| RESOLVER_S1 || Sin Lo
|-
|-
| 13|| THROTTLE1 ||  
| 13|| THROTTLE1 ||  
Line 42: Line 58:
| 14|| THROTTLE2 ||  
| 14|| THROTTLE2 ||  
|-
|-
| 15|| RESOLVER_R1 || Excitation Hi
| 15|| RESOLVER_R1 || Ex Hi
|-
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
|-
| 17|| MTEMP+ ||  
| 17|| MTEMP+ ||
|-
|-
| 18|| MTEMP- ||  
| 18|| MTEMP- ||
|-
|-
| 19|| RESOLVER_S4 || Cos Low
| 19|| RESOLVER_S4 || Cos Lo
|-
|-
| 20|| EMCYSTOP_IN ||  
| 20|| EMCYSTOP_IN ||  
Line 56: Line 72:
| 21 || GND ||  
| 21 || GND ||  
|-
|-
| 22|| RESOLVER_R2 || Excitation Low
| 22|| RESOLVER_R2 || Ex Lo
|-
|-
| 23|| START_IN ||  
| 23|| START_IN ||  
|-
| || ||
|-
| || ||
|}
|}


There are 2 variants of the i3. one with the REX and one with out.
the REX variant has a additional 25kw inverter to run the onboard generator.
Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v
{| class="wikitable"
{| class="wikitable"
|+Gate Driver Board Pin out
|+Pinout for Gate Driver Board
!Pin No
!Pin No
!I/O
!I/O
Line 229: Line 236:
|35
|35
|I
|I
|IGBT PSU 12V on
|IGBT PSU on (5V or 12V)
|
|
|-
|-
Line 283: Line 290:
|}
|}


[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]
Note: Pin 35 is connected to a [https://openinverter.org/forum/viewtopic.php?p=69712#p69712 mosfet gate on the gate driver board] and has been tested with both 5V and 12V.
 
 
 
'''<big>Motor Resolver & Temperature Sensors</big>'''
 
12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920
 
Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.
 
The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}
 
[[File:Mod 1. - Close SJ3.jpg|thumb|Mod 1. Close SJ3]]
 
 
 
'''<big>Modifications required to drop-in boards</big>'''
 
Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.
 
 
'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''
 
This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. [[Mini Mainboard|Additional explanation here]].
 
 
'''Mod''' '''2. Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:Ampseal board.png|thumb|300x300px|Mod 2. - Ampseal adapter board]]
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|Mod 2. - ERNI Microbridge adapter board]]
A [https://openinverter.org/forum/viewtopic.php?p=63903#p63903 pair of adaptor boards] (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.
 
 
'''Mod''' '''3.''' '''Code Update for Gate Driver Board - SPI Commication'''
 
The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.
 
On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.
 
To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);
 
 
</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>
 
[[File:Mod 5. - Gate driver PSU.jpg|thumb|Mod 5. - Gate driver PSU power pin]]
 
 
'''Mod 4.''' '''Check solder connections on the drop-in board'''
 
The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.
 
 
'''Mod 5.''' '''Gate driver PSU power pin'''
 
Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 100 Ohm resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply. Some earlier notes in the i3 hacking thread suggest it may also have been tested with 12V.
 
 
'''Mod 6. CAN slew rate pin'''
 
This pin is floating but needs to be [https://openinverter.org/forum/viewtopic.php?p=41110#p41110 tied to ground with a resistor] if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.
 
 
 
'''<big>Openinverter Parameters</big>'''
 
[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.
 
 
 
'''<big>Future Development</big>'''
 
List of tasks to be completed to enable full use of these motors:
 
# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github
[[Category:BMW]] [[Category:Inverter]]

Latest revision as of 16:34, 20 December 2024

BMW I3 inverter

BMW I3 inverter

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72


Overview

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: Infineon FS800R07 IGBTs rated for 800amps 650v


Openinverter Drop-in Board

Openinverter i3 drop-in board

The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.

Pinout for Ampseal Plug
Pin No Assigniment Description
1 12V
2 BRAKE_IN
3 PRECHARGE_OUT
4 CANL
5 CANH
6 DCSW_OUT
7 FORWARD_IN
8 REVERSE_IN
9 5V (OUT)
10 RESOLVER_S2/ENCODER_A Sin Hi
11 GND
12 RESOLVER_S1 Sin Lo
13 THROTTLE1
14 THROTTLE2
15 RESOLVER_R1 Ex Hi
16 RESOLVER_S3/ENCODER_B Cos Hi
17 MTEMP+
18 MTEMP-
19 RESOLVER_S4 Cos Lo
20 EMCYSTOP_IN
21 GND
22 RESOLVER_R2 Ex Lo
23 START_IN
Pinout for Gate Driver Board
Pin No I/O Description Notes Pin No I/O Description Notes
1 21 GND Switching Mosfets ?
2 I 32V in 22 GND Switching Mosfets ?
3 I 32V in 23
4 I IGBT A HI 24
5 I IGBT A LOW 25
6 I CS (ADC) 26 GND IGBT Driver ground
7 I SDI 27 GND IGBT Driver ground
8 I SDO 28 GND IGBT Driver ground
9 I SCK 29 GND IGBT Driver ground
10 I IGBT B HI 30 GND IGBT Driver ground
11 I IGBT B LOW 31 GND IGBT Driver ground
12 I IGBT C HI 32 GND IGBT Driver ground
13 I IGBT C LOW 33 5V IGBT Driver Power
14 34 5V IGBT Driver Power
15 35 I IGBT PSU on (5V or 12V)
16 O IGBT DRIVER UVW Upper Ready 36 O IGBT Driver Fault
17 O IGBT DRIVER UVW Lower Ready 37 I 5V LEM Current sensor Power
18 O Current Sense C Signal 38 GND Current sensor Ground
19 O Current Sense B Signal 39 GND Current sensor Ground
20 O Current Sense A Signal 40 GND Current sensor Ground

Note: Pin 35 is connected to a mosfet gate on the gate driver board and has been tested with both 5V and 12V.


Motor Resolver & Temperature Sensors

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test.

ERNI Minibridge Connector. Dots indicate pin 1.
Pinout for ERNI Microbridge
Pin No Colour Description Notes
1 Brown Sin Hi Twisted pair. 22.4 - 33.6 Ω.
2 Blue Sin Lo
3 Yellow Ex Hi Twisted pair. 22.4 - 33.6 Ω
4 Green Ex Lo
5 Red Cos Hi Twisted pair. 13.6 - 20.4 Ω
6 White Cos Lo
7 Blue Temperature

Sensor

From BMW Service Technical Training Manual - I01 High-voltage Components:

There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.

8 Grey
9 Red Temperature

Sensor

10 Grey
11 - Unused These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
12 - Unused
Mod 1. Close SJ3


Modifications required to drop-in boards

Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.


Mod 1. Close SJ3 on the openinverter board with solder

This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. Additional explanation here.


Mod 2. Motor Resolver & Temperature Sensor Adaptor Boards

Mod 2. - Ampseal adapter board
Mod 2. - ERNI Microbridge adapter board

A pair of adaptor boards (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.


Mod 3. Code Update for Gate Driver Board - SPI Commication

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:

//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

and insert these lines of code below it, to disable the Error Output:

//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
Mod 5. - Gate driver PSU power pin


Mod 4. Check solder connections on the drop-in board

The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.


Mod 5. Gate driver PSU power pin

Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with 5V to this pin via a 100 Ohm resistor from the adjacent pin 34, which receives power from the openinverter's 5V supply. Some earlier notes in the i3 hacking thread suggest it may also have been tested with 12V.


Mod 6. CAN slew rate pin

This pin is floating but needs to be tied to ground with a resistor if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.


Openinverter Parameters

This initial set of parameters have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.


Future Development

List of tasks to be completed to enable full use of these motors:

  1. Motor temperature sensor to be mapped and added to code
  2. Design files for adaptor boards posted to github
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