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Author Topic: 2012 XU to sevcon size 4  (Read 145 times)

Doctorbass

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2012 XU to sevcon size 4
« on: April 04, 2017, 09:12:42 AM »

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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rayivers

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Re: 2012 XU to sevcon size 4
« Reply #1 on: April 18, 2017, 07:25:43 AM »

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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Burton

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Re: 2012 XU to sevcon size 4
« Reply #2 on: May 07, 2017, 08:16:01 AM »

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.
« Last Edit: May 10, 2017, 05:09:04 AM by Burton »
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Doctorbass

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Re: 2012 XU to sevcon size 4
« Reply #3 on: May 10, 2017, 08:33:19 PM »

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
« Last Edit: May 10, 2017, 08:40:46 PM by Doctorbass »
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