Saturday, July 15, 2017

Vacuum sensor

We got our vacuum sensor today.  The MAP sensor from a 1.8T VW can output analog for both pressure and vacuum.  This one came off the top of an intercooler.  Voltage output seems to go from 0.33 to 4.5V.  0.33-1.94V is vacuum.  We will read this into the DMOC controller and hopefully it can output a CAN code to the dashboard for an idiot light.

Friday, July 14, 2017

Charger cables

I have the Brusa NLG513 charger, but the charging cable that came with it has the wrong connector on it.

I have the J1772 to the charger.

I need the upper connector with the male pins.

This is the cable that came with the charger, but it obviously has the wrong end on it.  Anyone have the right cable for sale or willing to swap?

Thursday, July 13, 2017

Rear battery box out for review

We have stumbled on the design of the rear battery box for almost a year now.  The configuration has not changed much in that time, just overall size nudges.




The plan is to slide the 6 modules into place and place threaded rods through the pack to hold them in place clamped.  The bus bars can then be installed on them with two wire leads protruding for connection to the 20 pack or the main output relay.  The two 10 packs are on the original Leaf plates and will have the bus bars applied to them again with a couple of leads extending.  The two packs will then be lowered into the box, secured with threaded rods, and the wiring connections completed.  A 5/8" plexiglass plate will be secured and sealed to the opening above the 20 pack.  The entire pack will be flipped upside down with the threaded rods now protruding from the top it will be lifted/the car may be lowered onto it with the rods passing through the floor pan for securing to the pack to the frame.  An independent skid plate will then be installed under the pack for debris protection.

We could use a little help figuring out the best wiring pattern.  I have tried to upload both an excel worksheet we have been using to visualize the wiring in both xlsx and csv format.  They are plain sheets there should be no macros in them.  Anyone know how to upload them here?

This is the rear battery pack for the golf.  There are 26 modules in the pack, 4 stacks of 5, and 3 stacks of 2 as shown in the 3D images.  Note that the shorter stack is inline with the lowest rows in the 5 stacks.  Physical arrangement is FINAL, no moving modules...Each of the 3 boxes represents a connection on each battery module.  The middle connection is for sensing and may not be used for a power connection.  The outer connections represent + and -.  The entire set of 26 must be connected in series, + - + - +-......  Due to space constraints the outer gray set of connections should not be end points for the entire pack or transition to the 6 pack, but should route up or down in the rows of the 20 pack using flat bus bars as shown in the front box pictures.



Suggestions please.

The winning suggestion
This pattern looks like the best option.  It will allow the sections deeper in the box to be pre-connected leaving only one connection to make near the top of the box between the 6 pack and the left 10 pack.  This arrangement requires 13 long bus bar connections.  The original leaf pack only had 10.  So we are short 3.  It is simple enough to make the bus bars, but we would also like to reuse the Leaf orange safety housings like we did on the front boxes.  Anyone in the U.S. have some spare leaf protective covers we may use?

UPDATED:

Requires fewer long bus bars, and therefore we have enough parts.





Tuesday, July 4, 2017

Rear battery box scans and progress up front.

It took 3 days to for the scanning computer to crunch numbers.  It did not come anywhere close.  We did figure out that the save all scans button hand scrolled off screen, and we were able to save the 88 scans.  After almost two weeks of stitching scans together by hand, this is what we have.


You can see that we were able to get three larger sections completed in the scanner tool software.  The software loaded everything to memory, our 32 GB of memory was right at the edge and the system could not handle all three sections at once.  All the group scans were "fused" and then exported to .obj files that ProE could import.  Alignment in ProE is very difficult.  I am not convinced this effort will yield any usable results as we note many misaligned edges that appear to be out of place by 6 -10 mm.

In the mean time we also worked on the front batteries.  First thing, install a hoist...  We were given a free sling track usually used to hoist patients from a chair into a bath.  Rated at more than 500# and with 5' of travel this took an extra day to install, but we did not need to lift the completed pack.





Reaching up to install the bolts that tie the pack down to the frame.
This pack slid back to the other and was also bolted in.  The original Leaf wiring and bus bars were used.  The large orange loom at the right goes to the Leaf BMS.  The short orange is for the heaters one at the front of the packs and one at the rear.  The black loom is for the temp sensors.


Tuesday, June 20, 2017

Bus bars for front battery box and still working on the rear box

Front battery box bus bars and BMS monitoring harness.
We were able to reuse the bus bars and connectors from the Leaf pack.  These connectors came from the front Leaf packs so there is an intermediate harness between these and the BMS.  By moving only ONE pin in the intermediate harness and ONE wire in these harness we were able to duplicate the LEAF BMS connection Pattern.  YEAH!

Since our pack has 22 modules in the front and 26 in the rear we will need to splice ~4 wires with a connector from the rear harness into the front intermediate harness.  MUCH cleaner than we had hoped.  YEAH!

Starting work on the rear battery box again.  It will be a tight fit and a friend had access to a DAVID scanner.  This system works by projecting a series of known patterns onto a surface and using the camera to image the pattern the computer can figure out the shapes... we'll see.



So far today we have taken ~100 scans of the undercarriage.  That is to say 50, what the... @#$%$#

Well plug the computer back in... and 50 more... The computer has been working on stitching it together for several hours now.

Scanning Lessons:
A. During a scan the save button is not available. Therefore if you do not finish a scan sequence successfully all scans of that session are lost.
B. It puts it ALL in RAM therefore stuff the machine with RAM or you will thrash the disk.
C. It is not meant to take scans of large objects in close proximity. The depth of field generated by the projector blurs within inches at close distance. This would have worked much better if we were able to place the car on a lift at 5 ft. from the projector so the variation in depth of the pan by 6 inches would be small compared to the distance, but we are 13" from the pan varying by 6" and therefore significantly pushing the limit of the projection resolution.
D. Markers with slight depth are better than stickers.
E. When it is done scanning it should beep or have the projector flash so you know when to move to the next location if you cannot see the screen.
F. Power interrupted = lose everything. See [A] and [B]
Scans to be posted in a couple of days.
Day 2 still crunching

Tuesday, May 30, 2017

Productive weekend

SIDE NOTE: We installed a 10000+ Lumen 100 watt LED light in the family room.  It has 4 CREE LED in it.  It is wired to two wall switches so we can run, 1,2, or 4 LED.  I learned that GFCI circuits do not like to share a common neutral as the circuit does not maintain current flow equilibrium.  A honey do project complete!


Like all things in this house, not available in stores, highly Lopified, very functional, beauty in in the eye of the beholder.  A twin to this light is in the garage as it was replaced due to a mfg. flickering issue.  I noted the drivers update 20 some versions between the units.  

Made the charger port connection.















Hopefully installed the Z-bars for the last time.  Sprayed some WD-40  into it to prevent rust.  Beveled and capped the ends.

You can see that the gearshift has been reinstalled and the vacuum pump has been mounted under the center of the I-beam.  Joshua has given us a vacuum reservoir from a VW Scirocco that will likely go in the drivers side wheel well.  And the control plan for the vacuum pump is to find a CAN based MAP sensor that will be used to control the pump relay and to throw a dash light if the vacuum fails.

Made a plate to cover the starter port on the transmission.
Removed an ear from the transmission as well next to the starter port for clearance to the I-beam.
You can see the vacuum pump clamped to the I-beam, it has rubber pads above and below the I-beam to isolate it from the frame.

Stuffed the first battery box.
11 Modules laid out for test and installation
It has been 1.5 years since these were charged.
They seem to be holding very evenly.
Perfect fit!
The heater and thermocouple wires are visible.
Just a wee overweight.  Original estimate was 100lbs,
A heavier gage metal was used to make the box,
and the cells with the brackets weigh more too...
The studs will be connected with rails to prevent movement near the bus bars.  The bottom of each studded module is bolted to the bottom of the box.  There are also 4 rods through the modules to transfer load from the non-studded modules to the studded modules.

Task list. This will be updated regularly.

Front Relay box

  • Will be mounted
  • Need to:


  • Create circuit diagram 
  • Create the BMS circuit connections diagram
  • Bus bars need to be reconfigured to fit. 

  • Plexiglas need to be cut to make box.

  • Rear Battery boxes

  • Will be mounted to the frame
  • Need to:


  • Create circuit diagram 
  • Create the BMS circuit connections diagram
  • Bus bars need to be reconfigured to fit. 

  • Lower battery frame needs to be cut to fit the box width.

  • Front Battery boxes

  • Will be mounted to the Z-bar
  • Need to:


  • Create circuit diagram 
  • Create the BMS circuit connections diagram
  • Bus bars have been reconfigured to fit. 

  • Top rails need to be cut and bolted down.

  • Water cooling pump


  • Will be mounted to the bottom of the I-beam
  • Need to:



  • Create circuit diagram 
  • Create hydraulic diagram
  • Create control program


  • Need to order:


  • Square U-bolts
  • Mounting plate 
  • Mounting bolts 
  • ΓΈ25mm id hose to/from pump 
  • Regulator switch 
  • Relay (check supply)
  • Reservoir tank (have) 

  • Vacuum Pump
  • Will be mounted to the front of the I-beam
  • Need to:


  • Create circuit diagram
  • Create Pneumatic diagram 
  • Create control program


  • Need to order:


  • Square U-bolts
  • Mounting plate 
  • Mounting bolts 
  • 3/8 hose from pump, what to booster check valve?
  • Regulator switch, Looking for MAP sensor with CAN output
  • Relay (check supply)
  • Reservoir tank (check supply) 
  • Check valve (check car)

  • Steering pump
  • Will be mounted at a much later date after the car is operational.
  • Will be mounted to the top of the I-beam on the passenger side between the windshield wiper fluid reservoir and the DMOC.
  • CAN codes have been found and are on a page specific to the pump.
  • Will require new hoses and fitting to be made.
  • Reservoir is built in and part of the return loop. 
  • Need to:


  • Create circuit diagram 
  • Create hydraulic diagram
  • Create control program

  • A/C compressor


  • Will be mounted at a much later date after the car is operational.
  • Will be mounted under the I-Beam on the drivers side.
  • Will require new hoses and fitting to be made.
  • Will require finding the CAN codes
  • Need to:


  • Create circuit diagram 
  • Create hydraulic diagram
  • Create control program