Porsche 924S EV Conversion - Part 8 - Thunderstruck/Leaf bench test setup and walkthrough

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Күн бұрын

Some of our previous videos featured the benchtop test setup we are using to try and get components working before mounting them in the car. This video walks through that test setup along with our motivations for why/how we did things. Hopefully it is helpful to someone else.
Full project playlist: • Porsche 924S EV Conver...

Пікірлер: 21

@user-ms7lx5ew7k Жыл бұрын

Very good

@iamdaveface Жыл бұрын

Fantastic Video Frank! I’m planning a thunderstruck for my 924 build so great to see it in action! Looking forward to learning more from you on battery and mounting options. Keep up the great work.

@iamdaveface Жыл бұрын

I wanted to ask what throttle pedal did you go for? The 80V batteries are a great idea for the test rig. I think I’ll copy this for my build 😎

@FrankGraffagnino Жыл бұрын

Hey thanks. We would love to follow other builds so please let us know if you publish anything. For the pedal, right now we are using the one that comes with the thunderstruck VCU kit

@steveclunn8165 Ай бұрын

I've been trying to figure out the wires coming out of the motor and which ones go where I couldn't tell from your video though nice job of wiring everything up really clean and neat

@FrankGraffagnino Ай бұрын

Let me know if you need help tracking down some information for this motor

@steveclunn8165 Ай бұрын

@@FrankGraffagninothe problem turned out to be the low voltage cutoff was programmed higher then the battery pack. Had to use a computer to get in and change the settings. Looks like there's two grounds 2 12 volt positive and a key on. I did a 924 years ago back in the days of blood acid batteries. It performed very well I think you'll be happy..

@alexandervdr4764 6 ай бұрын

Hi Frank, great stuff and very inspiring to see this father/son tandem at work! Question: I will use a compact bench battery system too based on RC heli/aircraft battery packs in series (that is my other hobby...). What is the current you draw with your configuration from the 250V pack? And what is the capacity of these greenworks modules?

@FrankGraffagnino 6 ай бұрын

I'm not sure if the exact current unfortunately. It depends on the load from the motor / inverter and your commands to it. But I can assure you that when you use fuses you need to make sure you use high voltage fuses and not traditional auto fuses - the current may be sufficient, but if it has high voltage it will jump the gap of a broken fuse. Lesson learned!

@alibro7512 Жыл бұрын

Great setup and lots of good advice, thanks for sharing, just wondering are you planning to use a second contactor for the HV Battery negative? I understood it was normal to do so and I plan to use two contactors and a fuse in my rear battery pack as well as in the HV junction box. When sourcing your HV Battery consider the physical size and shape of the modules and how they will fit into your car and how they are linked together. I bought an eGolf battery pack and the modules are less power dense than those from a 40kwH Leaf pack, heavier and less easy to link together. They are probably easier to fit in a space where height is a restriction though. It would be good if you can work out the shape your battery boxes will be before buying the battery modules so you can buy modules suitable.

@FrankGraffagnino Жыл бұрын

this is great advice. and yes, we've learned that you really need two contactors instead of one so we plan to do that. It looks like we will be going with the chevy volt battery and it has two contactors inside a module at the front of the pack... i'm hopeful we can reuse those. But if not, we will just add a second one to the one that we have that came with the thunderstruck kit. Thanks for the comment!

@alibro7512 Жыл бұрын

@@FrankGraffagnino I got contactors with the eGolf battery pack but they do not have economisers so will draw too much current if driven constantly from 14V and will have a shortened life. I'm planning to use a buck converter to reduce the voltage to 10V where they seem happy to switch but draw much less current. Originally I was going to have 4 or 5 battery boxes but when I realised how difficult it would be to make them safe I've now changed the layout. The thought of live cables running the length of the car with no easy way to kill the power from them did not appeal so I'll be losing boot space but gaining some safety. Have you seen Damien Maguires video where he was working with Volt batteries? The look to be very tall.

@FrankGraffagnino Жыл бұрын

@@alibro7512 that's interesting... i'll have to keep an eye out for how much current they draw. I haven't seen the video you are referring to, although I've watched a number of other teardown videos. The batteries are a bit tall so they won't fit in our Porsche the same way they went into the volt, so that means we will need to position each module in the front of the car and (hopefully) not have to put some of them in the rear. But, we'll see.

@pierrec1590 Ай бұрын

Would it not be possible to use a $10 bridge rectifier and cap on 240Vac to get 340Vdc? How about a voltage doubler on 120Vac?

@FrankGraffagnino Ай бұрын

Theoretically possible and Benjamin Nelson did that on his KZfaq channel so you might go check that out.

@gjsxnobody7534 Жыл бұрын

So, which batteries or BMS did you end up using? DIYBMS? SIMPBMS? ORION? THUNDERSTRUCK? EMVEV? We are putting together our own packs..

@FrankGraffagnino Жыл бұрын

We are using a Chevy volt battery and the thunderstruck MCU

@gjsxnobody7534 Жыл бұрын

@@FrankGraffagnino how did you get them talking on the CANBUS? And how would I get my home grown BMS to talk on the CANBUS? What is the tool called that does that? I’m not afraid of coding. Just don’t know which direction to connect to different devices on the CANBUS

@FrankGraffagnino Жыл бұрын

@@gjsxnobody7534 I'm not sure I fully understand your question. Basically if you just hook up the two wires they will start talking. If other devices are listening the msg IDs that are on the bus they will pick them up. Having a computer also hooked up to listen in on the communication can be helpful for debugging or generating CAN messages. Lots of great software for PCs to talk on a CAN bus.

@gjsxnobody7534 Жыл бұрын

@@FrankGraffagnino Yes, understood that the messages will flow on wires when connected (properly of course). but if I buy an accesory that has msd ID = 123, how does the corresponding item know what msd ID = 123 means? for example, you have a accelerator pedal, and I want to use a hand throttle instead. how does the VCU, or Motor controller know if my throttle accesory is sending a msg ID that is something other than "123".. or are all throttle/accelerator standard world wide?

@FrankGraffagnino Жыл бұрын

@@gjsxnobody7534 so some of the items that come from vehicles will have all of their messages hard coded in them. There are files called "DBC" files which are sort of a description file that explain which bits for each message can be translated to a real number. I would suggest as a first step to just get a CAN data logger set up which can let you log all the data and then eventually parse the data out of the messages. This page has a decent CAN overview: www.autopi.io/blog/can-bus-explained/