Thursday, December 7, 2017

No, We did not give up.

Car work did not stop entirely, I believe we left you at taking scans of the undercarriage so we could make the rear battery box.

David Scanner System
 We did finish scanning, and found the results to be within  6mm of accurate.  Close enough that we were confident our battery box dimensions would fit in the car.  We think the system would have worked MUCH better if we had been able to put the car on a lift and get the camera several feet away from the undercarriage instead of 8 inches.  In the end it took almost two weeks to stitch all the images together but if the distance to the camera had been several feet the system would have likely stitched itself.

Fuel Tank Bay
Note all the stars we added to the bay to help the computer and use manually align the images.

Battery Box installed
We made the battery box and got it up into the bay.  SEE it fits with zero clearance, but no "adjustment" was needed either.

Battery Box installed
The 4x4's will be replaced by the original battery box rails off of the Nissan Leaf battery pack. Since our pack is distributed front and rear the load here will be significantly less, so structural failure is less of a concern.

Battery Box from above
OK, the box did not quite fit.  The two corners stick up through the floor about 20mm.  A modified rear seat pan will be put in and the rear seat will be fully functional when we are done.

We have spent quite a bit of time looking at how we want to pass the wires in and out of the battery box.  Originally we were going to install multiple bulkhead pin connections, after much discussion, and a visit to see a friends Mini project, we have decided to use flexible conduit and really long pigtails running all the way up to the front of the car.  This reduces the number of pin crimps and connections by over 200 and hopefully increases reliability of the rear pack substantially.

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?


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

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
  • Thursday, May 4, 2017

    Finding data on the pumps that need to be mounted to the I-beam [Steering Pump]

    Part number :BG91-3K514-AB
    From the DIYer site we have found some communications data:

    Raising the control line high seems to power up the unit and it takes about 200mA. Pump does not rotate at all ...... would seem to need the CAN bus to enable and command speed. The unit announces itself on the CAN bus at power up as id 04f

    BO_ 128 x80: 8 pas
    SG_ SteeringWheelAngle_pas: 7|16@0- (0.1,0) [-1000|1000] "degrees" Vector__XXX
    SG_ SteeringWheelRotSpeed_pas: 23|16@0- (0.1,0) [-3000|3000] "deg/sec" Vector__XXX
    SG_ VehicleSpeed_pas: 38|15@0- (0.1,0) [0|327.67] "km/k" Vector__XXX
    SG_ SensorInitialized: 53|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PumpEnable: 51|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SWARstatus: 49|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SteeringMessageNumber: 63|8@0+ (1,0) [0|255] "enum" Vector__XXX

    BO_ 662 x296: 8 pas
    SG_ VehicleSpeedCounter: 4|4@0+ (1,0) [0|15] "cnt" Vector__XXX
    SG_ VehicleSpeed: 23|16@0+ (0.01,0) [0|320] "km/h" Vector__XXX
    SG_ VehicleSpeedQF: 39|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ VehicleSpeedUB: 35|1@0+ (1,0) [0|2] "Boolean" Vector__XXX

    BO_ 644 x284: 8 pas
    SG_ PowerModeUB: 5|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PowerModeQF: 9|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ PowerMode: 38|5@0+ (1,0) [0|10] "enum" Vector__XXX
    SG_ CarMode: 45|4@0+ (1,0) [0|15] "enum" Vector__XXX

    BO_ 1195 x4AB: 8 pas
    SG_ PowerModeExt_D_actlUB: 32|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PowerModeExt_D_act: 47|5@0+ (1,0) [0|11] "enum" Vector__XXX

    BO_ 1024 x400: 8 pas
    SG_ VehConfParamHS8: 7|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS7: 15|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS6: 23|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS5: 31|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS4: 39|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS3: 47|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS2: 55|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS1: 63|8@0+ (1,0) [0|255] "u8" Vector__XXX

    BO_ 1029 x405: 8 pas
    SG_ VehInfoParamHS8: 7|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS7: 15|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS6: 23|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS5: 31|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS4: 39|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS3: 47|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS2: 55|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS1: 63|8@0+ (1,0) [0|255] "u8" Vector__XXX

    BO_ 320 x140: 8 pas
    SG_ EngineSpeedQF: 54|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ EngineSpeed: 52|13@0+ (1,0) [0|8191] "rpm" Vector__XXX

    BO_ 118 x76: 8 pas
    SG_ SteeringAngleSign: 6|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ SteeringAngleStatus: 5|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ SteeringAngleCounter: 3|4@0+ (1,0) [0|15] "cnt" Vector__XXX
    SG_ SteeringAngleCS: 15|8@0+ (1,0) [0|255] "enum" Vector__XXX
    SG_ SteeringAngleCRSign: 23|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ SteeringAngleCRShortFilt: 22|15@0+ (0.06104,0) [0|2000.09768] "deg/s" Vector__XXX
    SG_ SteeringAngleCR: 38|15@0+ (0.06104,0) [0|2000.09768] "deg/s" Vector__XXX
    SG_ SteeringAngle: 54|15@0+ (0.04395,0) [0|1440.10965] "deg" Vector__XXX

    BO_ 576 x240: 8 pas
    SG_ EpasFailed: 15|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ Ehpas_IDC_mode: 9|2@0+ (1,0) [0|2] "enum" Vector__XXX

    BO_ 79 x4F: 8 pas
    SG_ EngRun_D_ReqSte_UB: 63|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ EngRun_D_ReqSte: 62|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ EPSWarningEHPAS_UB: 57|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ EPSWarningEHPAS: 56|1@0+ (1,0) [0|1] "Boolean" Vector__XXX


    BO_ 128 x80: 8 pas
    ID in decimal xin hex: number of bytes in packet Subsystem (Power Assist Steering, pas)
    SG_ SteeringWheelAngle_pas: 7|16@0- (0.1,0) [-1000|1000] "degrees" Vector__XXX
    signal name: startbit l number of bits @sign (resolution, offset) [min value l max value] "units"

    SG_ SteeringWheelRotSpeed_pas: 23|16@0- (0.1,0) [-3000|3000] "deg/sec" Vector__XXX
    SG_ VehicleSpeed_pas: 38|15@0- (0.1,0) [0|327.67] "km/k" Vector__XXX
    SG_ SensorInitialized: 53|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PumpEnable: 51|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SWARstatus: 49|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SteeringMessageNumber: 63|8@0+ (1,0) [0|255] "enum" Vector__XXX

    This pump will be mounted between the windshield washer fluid reservoir, and the DMOC.  The required orientation and height prevent it from being mounted under the I-beam as originally intended.  A plate will be made that will mount to the top of the I-beam and the side of the pump.

    Finding data on the pumps that need to be mounted to the I-beam [Vacuum Pump]

    Vacuum pump

    This pump was for the Ford Transit Connect electric vehicles. Ford part # A426C.

    Voltage: 12V
    Full Load Current: 12 Amps
    Continuous Current: 8 Amps
    Vacuum: 25+ in of hg
    Vacuum Port Size: 3/8 Inch Hose Barb
    Weight: 2.7 kg

    Data I am still looking for:

    Which way is up? Does this pump have a preference as to which way it is mounted in the car? Does anyone have installation instructions, or maintenance requirements? It is oiled?

    I will mount it with the motor up and the breather down.  Thus as it sucks wet air through it any condensate will hopefully migrate out rather than into the motor.

    This pump will be placed in front of the I-beam near the center.  It will be hard mounted to a plate, the plate will sit on a rubber pad on the I-beam for vibration isolation.  The plate will be held in place by a pair of square u-bolts sandwiching the I-beam.

    Wednesday, April 19, 2017

    Friends of the project

    I know it is not proper etiquette to go back and change pages in the blog at later dates, but the number of people stepping forward to help on the project is important to us.  We will only list a little about each person to recognize them for their support until they say they want more information about them or their business added.  Come back and visit this page to see who else is helping.

    Top listing has no choice, THANK YOU to my lady for letting me play in not an inexpensive way on a project that had/has a lot of risk.  Oh, yeah, and to my boys for humoring me, but I know they want to drive it!

    The final inspiration, he knew I was interested and provided a connection to tip the scale and get us going: Wolf

    Project design overview soundboards :
    Dad, despite this being a really dumb idea that takes time away from more important things... he can still be goated into a theoretical discussion. :)

    Automotive Knowledge:
    Beaumont Alignment (These are the only guys that I have trusted to work on my cars (when I haven't done it myself) for over 30 years!)
    Mike @ Advance Automotive Danville

    Pre-Pack Machining

    Electronics and computers:




    Mike and Joshua
    Advance Auto Parts : Thank You Kevin for letting me stare at the back room shelves.

    UIUC students that have put in hours of labor an internet time learning.

    The I-Beam is in.

    The main new load bearing member is in the car permanently.  From a Civil Engineers perspective, "This is so cute," as the beam is 2.33"W x 3"T.  I have no idea why they make one so small, but it works for us! 
    Positioning the I-Beam into the frame for welding.

    You can see at the top end of the I-Beam that we added a plate.  The plate allowed us to do the difficult welds out of the car, and better match the thickness of the car sheetmetal to ease the welding in the car.  The in-car weld goes around all 4 sides of the plate.  Thank you to Keith for the insight in making the engineered system more manufacturable.

    James welding in the I-beam
    We caught James Brownfield in action and had a bit of fun with him.  No matter how many times we told him that the welding helmet would darken automatically he obviously has been using the traditional welder mask all his life and would twitch his head to flip the helmet up and down for each weld.  Constantly expanding his horizons, I learned during this visit that in addition to being a precision instrument maker, that he also does real estate brokering.
    As opposed to my plan for some coarse and messy good old fashioned stick welding, James preferred TIG and they are much prettier than I could ever do.

    Z-Bar battery frame with doubler plates tacked in position.
     I was not convinced the welds on the Z-Bar would hold as predicted and James had the suggestion of adding doubler plates to the sides spanning the welds.  We welded the joints, ground them flat, and then TIG welded the doubler plates all-around.  The image also shows the addition of the spanner angle iron.  These angle parts serve two functions, they significantly stiffen the Z-bars for side loading and they provide the lower attachment points for for the battery boxes.

    Z-bar doubler plates
    I-beam in, front battery boxes in place.
    In the above image you can see the water pump and vacuum pump resting on the I-beam.  We are now int he process of determining the exact placement of the pumps.  They will hang from the underside of the I-beam,  Above the beam will be the DMOC controller and the 12V battery.

    Friday, April 7, 2017

    Battery frame progress

    The I-Beam front support member of the battery frame was fitted last night.  Hopefully it warms up enough today to put some paint on it so we can weld it in fully along with the rest of the frame soon.

    A donation to the cause a friend has shared a cut-off saw.  A little maintenance, fresh wires, oil, and a fresh blade made it cut like butter!  Manufactured in 1941! We found the thread standards in 1941 must not quite have matched today's standards when replacing some of the frame bolts.

    I-beam test fit.  It will be welded at both ends to the main car frame.  It will have the battery frame set on top of it and the DMOC.  The A/C compressor, water pumps, vacuum pump, and steering pump will be hung from it.
    Battery box with side holes for the battery compression rods.

    Battery box with lower holes for battery and battery frame attachment.