Honda Insight Forum banner

61 - 80 of 102 Posts

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #61 (Edited)
Op amp and +50V setup etc now all working on the bench correctly over the full IMA operating voltage range.

Note to self!! I should have checked my BCM interceptor programming as it was modifying the battery voltage passing through!!! I just borrowed it from an older project IIRC the supercaps which had a fixed voltage system. Doh! It kept throwing IMA errors for no obvious reason even though the opamp circuit was working correctly until i realised what was happening. Oh well. Now we are inching forward again!


I think we now have the 48 Cell LTO setup voltage fooling as simple as it can be.

1) Non Inverting unity gain summing amplifier op amp circuit. $5 (Fitted inside MCM)

2) Isolated dc-dc converter (12V in and -24V - 0 - +24 V out (48V) ) $5 (Feeding standard BCM fooler)
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #62 (Edited)
Last video of the day. It's been a busy one.


48 Cell LTO Harness completed and OBDIIC&C talking happily to the 48 Cell pack and the bench car.

Resting voltage 118V. One block maybe needs slight charging.

OBDIIC&C setup for 48 Cell pack is maximum voltage limit of 125V.

Might have to change that when regen is active if it pushes the cells high or the buzzing will drive me mad!

Pause the video to look at the screens in more details if you wish. :)
 

·
Administrator
Joined
·
11,145 Posts

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #64 (Edited)
LTO Tails and switchboard install.


Note I also have access to the back of the switchboard bolts through the plastic sheet I installed.

See pics to follow shortly.

It's a bit fiddly but important IMHO to do a safe and secure job.
It's doable and once done that's it.

84732


Note I have used the same LTO terminal covers as others.

84733


The terminals are marked A,B,C,D.
The pack is split as OEM between B and C.
A & B connect to the front LTO block, C & D connect to the rear LTO block.

The four holes you can see also allow access to the back of the switchboard terminal bolts.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #66
Bench case full assembly and LTO mounting.

A few minor things I would do slightly differently next time.
But it's all good gaining experience and knowledge.

 

·
Super Moderator
Joined
·
7,755 Posts
Very nice packaging job. We all hope that the driving test prove successful.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #68 (Edited)
BCM Fooler with ignition switched +50V isolated dc-dc converter in series with main pack voltage.


Fooler in situ. Probably use double sided tape to stick it in position.

84781
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #69 (Edited)
Final bench tinkering....


In video1 above, I say 'BCM Interceptor', I mean 'BCM Fooler'.


Note.
In video 2 above I point out the wrong MCM connections!! Doh.
It should be the next connector to the left, A not B.
The wires shown in the video are connected in the wrong place!
I had to change that after the first incar test. :)

I'll post a full project summary and tweaked schematics later once all testing, fettling is completed.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #70
It's alive.....

IMA Start with static assist & regen working.
Road test to follow.

 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #71
I'm busy today but hopefully will have some time to work on the OBDIIC&C software.
It now needs major attention to get all the comms, control and display functions working smoothly.

1) It's talking slowly to the car on the serial K & H Lines to get the normal OBDIIC&C Stuff.
2) It's talking slowly to the IMAC&C P&P Joystick and Slave board in the MCM.
3) It's talking quickly to the LTO BMS boards via the CAN bus.
4) It's processing all this stuff then displaying it on the LCD etc

All that needs to happen as quickly as possible/practicable and in the right order etc.

I'm removing rarely used stuff from the software at the moment.
Once I have it restructured I will add features back in as space/time permits.

Still hoping for a test drive later if circs permit.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #72 (Edited)
Still working on software and a few mods before road testing.

Went to start today and immediate P1576. :eek:

This was caused by the 12v battery being low and the HV dc-dc converter voltage booster being down 10V.

40V instead of 50V, that immediately throws out the MCM and BCM cross checks and equals IMA fault.

As soon as I boosted my 12V to a higher voltage and the dc-dc output rose it was fine.

So as I suspected the dc-dc booster will have to be a 5V input type, and so will the little relay, both powered from the stable and accurate MCM internal 5V power as are all the other gadgets inside the MCM.

It does means we can put it all on one bespoke pcb in due course.

That little power socket on the back of the MCM will now output 5V not 12V..
Got to move those wires again. :rolleyes:


EDIT

Sorted the above now correct and stable voltage!

Test drive this morning.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #73 (Edited)
First 20 mile test drive report... No deal breaker issues or error codes. :)


Assist peaked at 108A+ at 115V so 11/12kw or so.
Regen peaked at an easy 75/80A

Further testing and system tweaking to do but appears to work quite well so far.
Assist very aggressive in lower gears...

Resting battery voltage might be a tad high so might tweak that down ten volts to see what effect it has.
So i will add some adjusters to fiddle with the voltages.

LTO Pack cell deviation was about 30mv before and after drive.
Pack 120V at start about 115V at end.

Loads of work to do on the OBDIIC&C/CAN/IMAC&CP&P software.
Still a mess at the minute. :coffee::coffee::coffee::oops:

Car has to go for it's annual inspection tomorrow as well.

EDIT While I work on the OBDIIC&C software for now I will run two OBDIIC&C devices.

1) I will use an LTO dedicated CAN OBDIIC&C with all the normal car stuff removed.

2) The original OBDIIC&C can concentrate on normal stuff and the IMAC&C P&P.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #75 (Edited)
Time to start thinking about phase 2. The community/I now need your input or help.

If you have been following this thread you will know the car is now on the road working.

There are still tweaks to make and software to write, but basically we know it can work and have established the general principles and basic mods required.

90% of the mod can be done inside the MCM in an hour or so by a competent solderer.
It would be fairly simple to provide an exchange MCM/BCM service or a pcb/kit for home installation into the MCM/BCM.

Inside the MCM we have.

1) VPIN OP amp mod. (Required) $5 self build
2) MCM HV INPUT dc-dc +40/50V Voltage booster (Required) $10 self build

3) +40% Current hack. Requires uprated 125A minimum IMA fuse. (Optional) $45
4) BCM Interceptor for fixed 75% soc, fake temp, pack over/under voltage and temp protection. (Optional)
5) IMAC&C P&P Slave pcb for IMA manual control and electric cruise. (Optional)

Inside the BCM we have.

6) +40% Current hack resistor. Requires uprated 125A minimum IMA fuse. (Optional) $1

Outside the BCM/MCM modules we have.

7) BCM Fooler 10k matrix in a box attached to the harness, battery +/- & the MCM. (Required)
8) LTO BMS CAN connectors and CAN upgraded OBDIIC&C for cell monitoring (Optional)
9) OBDIIC&C/IMAC&C P&P to control and monitor system. (Optional)

LTO Block Mounting and case mods.

You have seen how I did my LTO pack physical assembly.
Anyone competent with basic tools could repeat and improve on what I did to actually mount the blocks.
My material choices/sizes etc were dictated with what I had at hand etc to build the prototype.

So my thoughts are now these.

1) It's time to start designing an all in one schematic/pcb for the MCM mods to combine items 1-5 above into one more reliable and simpler to fit and mount assembly.

2) Does a US Insight enthusiast/batterybuilder/supplier/engineer/mechanic/electronics guru etc want to work with me on this to develop a commercial kit or conversion service?

Anyway food for thought. Keep safe during the CV19 thing.
At least it is giving me hours of free time for this and many other G1 Projects! :)
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #76
Planned work over next week or so, not necessarily in order.

1) Make up another MCM with the minimum mods required. (This is nearly done already, just awaiting parts.)
So that's VPIN opamp and dc-dc voltage booster only.
No BCM Interceptor, No current hack, No IMAC&C P&P.

2) Make another pack V2 with my two other LTO blocks.
Change things slightly due to stuff learnt on V1.

3) Keep working on OBDIIC&C LTO CAN IMAC&C P&P software combo.

4) Tidy and sort out workshop/garage!

5) Car test an unmodified BCM and the minimum modified MCM combo.
Many people might be happy with just that without all the bells and whistles.
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #77 (Edited)
Just passed UK vehicle inspection today with 48 Cell LTO fitted ;)

We call it the MOT over here. Ministry of transport test.

It's a yearly comprehensive test for vehicles over three years old.
Emissions/mechanical/error lights etc.

 

·
Registered
Joined
·
19 Posts
You plan to integrate the IMAC&C into the the proposed AIO board!? How is the BCM interceptor optional?

Just would like to offer my service if i could be of any help for the conversions. I am good with a soldering iron and following schematics.
 

·
Premium Member
Joined
·
652 Posts
4 days ago you showed the picture of the two lto packs in the original NiMH case. Does this impinge on the air flow tube from the DC- DC exit out of the car?
 

·
Administrator
Joined
·
11,145 Posts
Discussion Starter #80
4 days ago you showed the picture of the two lto packs in the original NiMH case. Does this impinge on the air flow tube from the DC- DC exit out of the car?
That was removed in my project car and has been for ages since I first did Lithium.
The answers is it probably does/would impinge on it but might be able to be modified in some way.

I want heat in the battery compartment so that vent loss has never bothered me.
 
61 - 80 of 102 Posts
Top