ElectricMotorcycleForum.com
Tech => Parts, Mods And Hacks => Topic started by: Doctorbass on April 04, 2017, 09:12:42 AM
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Hi guys,
let say you want to take a 2012 Xu and replace the controller to get better torque (but not power as battery is limiting factor)
I want to try installing a size 4 on a XU that has a stock size 2 to boost torque for a given low end torque until it reach max power that the battery can take
I want to take the original dcf and modify it to the size 4 parameters.
i tought i could just take the stock XU dcf and send it to the size 4 controller and then update the motor torque anc current to higher value but it generate alot of errors only by sending the Xu dcf to the size 4... any idea?
for fun i just compared the original S and SR dcf and isolated the parameters that have differences:
header Object ParameterName Scaling Parameter value decimal Parameter value decimal Unit diff in %
[6075] MOTOR_RATED_TORQUE Current limit 0,001 000668a0 420 000a1220 660 A(RMS) 157,1
[6076] MOTOR_RATED_TORQUE Peak torque 0,001 0001c2c8 115,4 0002bf20 180 Nm 156,0
[2920sub3] Traction baseline profile Maximum Torque applied when neutral braking 0,1 0046 7 001e 3 % 42,9
[2920sub4] Traction baseline profile Maximum Torque applied when footbraking 0,1 005a 9 0028 4 % 44,4
[2921sub1] Driveability Select 1 Profile Maximum Torque applied during drive 0,1 02bc 70 01e0 48 % 68,6
[2921sub3] Driveability Select 1 Profile Maximum Torque applied when neutral braking 0,1 0064 10 003c 6 % 60,0
[2921sub4] Driveability Select 1 Profile Maximum Torque applied when footbraking 0,1 0096 15 0064 100,00 % 666,7
[2922sub3] Driveability Select 2 Profile Maximum Torque applied when neutral braking 0,1 0064 10 003c 60,00 % 600,0
[2922sub4] Driveability Select 2 Profile Maximum Torque applied when footbraking 0,1 0096 15 0064 10,00 % 66,7
[4300sub7] Maximum Motor Current 1 1 0221 545 038d 909,00 A(RMS) 166,8
[4300subA] Minimum Motor Speed 1 ff51 175,00 ff3e 194,00 rpm 110,9
[4300subB] Maximum Motor Speed 1 17b6 6070,00 17b5 6069,00 rpm 100,0
[4301sub7] Maximum Motor Current 1 1 01eb 491,00 036a 874,00 A(RMS) 178,0
[4301subA] Minimum Motor Speed 1 ff56 170,00 ff48 184,00 rpm 108,2
[4301subB] Maximum Motor Speed 1 17b4 6068,00 17a2 6050,00 rpm 99,7
[4600sub7] Additional Motor Measurements Id (If) 0,0625 ffd4 4093,25 000d 0,81 A 0,0
[4600sub8] Additional Motor Measurements Iq (Ia) 0,0625 0018 1,50 0001 0,06 A 4,2
[4602sub2] Junction Temperature 1 (DWork.Tj[0]) 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub3] Junction Temperature 2 (DWork.Tj[1]) 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub4] Junction Temperature 3 (DWork.Tj[2]) 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub5] Junction Temperature 4 (DWork.Tj[3]) 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub6] Junction Temperature 5 (DWork.Tj[4]) 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub7] Junction Temperature 6 (DWork.Tj[5]) 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub9] Heatsink Temperature (U.DSP_Ts) 1 19 25,00 17 23,00 DegC 92,0
[4602subA] Overall DSP Maximum Motor Temperature (Y.Temp_max) 1 0055 85,00 0053 83,00 DegC 97,6
[4602subD] Maximum torque (DWork.Td_max) 0,0625 0735 115,31 0b3d 179,81 Nm 155,9
[4602subE] Maximum power limit torque (Y.T_power_limit) 0,0625 0735 115,31 0c30 195,00 Nm 169,1
[4602sub14] PCB Track Temperature Estimate 1 001b 27,00 0016 22,00 DegC 81,5
[4602sub15] Capacitor long term temperature estimate 1 0019 25,00 0017 23,00 DegC 92,0
[4602sub21] Maximum iq allowed 1 01a3 419,00 0293 659,00 A 157,3
[4623sub1] Maximum battery charge current 1 ffc9 -55,00 ff48 -184,00 A 334,5
[4623sub2] Maximum battery discharge current 1 022a 554,00 02b2 690,00 A 124,5
[4641sub2] AC Motor data Maximum Stator Current (Is_max) 1 01a4 420,00 0294 660,00 A(RMS) 157,1
[4641sub21] AC Motor data D-axis current controller proportional gain 0,00390625 0400 4,00 0300 3,00 75,0
[5100sub4] Heatsink Temperature 1 19 25,00 17 23,00 DegC 92,0
any help will be apprecaited
Doc
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Maybe something to do with different thermistor ranges or junction temps on the bigger controller? Are any of the errors temperature-related?
Ray
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Does the MY12 XU have an encoder like the MY13 S / DS?
Is the chart below the list of "errors" which occur when you try to direct install the MY12 dcf into the size4 controller? (if not could you list this as well)
Several things come to mind having modified my size 6 a bunch.
1) There are "addresses" (PDO's) carrying unique variables to be over written by the MMB at the sevcon level. If these are not present there could be an issue. If they are not addressed the same there could be an issue. You could simply address them correctly to match the size 2 and fill them with blank or "filler" data so they are ignored as well.
2) If it were me, and I have done this, I would take screen captures of every setting, every throttle curve setting, every addressed setting, etc and simply start from the base up on a clean size 4 dcf to make them identical. I would then "commission" the motor if it had an encoder to ensure this was correct. I did this several times when trying to set up a "clean" profile for my brake regen lever install which to back up to / from. This might mean re-addressing variables in your gen 4 if required to match the MY12 XU addresses. It takes a while but is worth the effort for sure.
3) Depending on errors you are getting the DCF might not have all required variables (would have to see the error log to verify) ... I had this a lot when I first used the DCF but later found out my database behind the version I had was not up to date and this was causing the issue. I am not sure if the gen4's you have, the size 2 / 4, have the same version firmware, but there is a chance it is expecting information your gen4 size 2 DCF save doesn't have.
And of course it could be none of these :D ... I haven't had a need to open my DVT in a while (since I last commissioned the current MY14 SR motor) so my memory is a bit foggy.
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This make sense Burton, The motor is ALSO using the SIN/COS encoder.. in fact this is like teh half version of the ME0913 of the 2012 and it only have a stator on one side of the rotor disk.
I have brick one of the size 4 trying to use it with the XU :( and now i'm trying the famous backdoor command to get it back to work like i already succeded in the past. Personally to make a base DCF file i use WINMERGE to compare multiple DCF and then isolate the differenced and keep the common program lines. what is difficult is to convert every wanted HEX value to DEC and also use the scaling value to calculate real value.. it take time but it worked for me when i made a DCF for the 2012 SR version and the 75-7 at 66V
btw do you have a link to the 2013 Zero schematic? i have to convert my 2012 powertrain to 2013 with a ZF11.4 and new MBB and DC-DC but the wiring and schematics are not available.
You can Pm me ;)
Doc