Tesla Research

After purchasing the Tesla Model S Drive Unit from EV West, this is essentially a salvaged drive unit made into a kit with a controller from EV controls, it seems there is some work to make this "ready to run" unit working.

EV Controls user Guide

EVTV research

Inside | Hacking | Capturing CAN data | Unit delivered | update | update. | first shipment | 63 Impala | Drive Train | Inside | Hacking | HACKED | Hacked

EVBMW research

The Tesla Project : 15,000 RPM | IGBT Driver | Tesla Inverter Teardown | It Lives | Logic Board V2 | Rear Drive Unit Back Together | Just Crusin | Thermal Velocity

Others research

lightbulb test | Tesla motor hacked!

Wiring up the Harness

Controller





Inverter





Now showing CanBus signals coming from a working inverter


Motor Position Encoder

https://en.wikipedia.org/wiki/Incremental_encoder
1002722-00-B CRANKSHAFT POSITION SENSOR
1002722-00-C - SENSOR ENCODER

">



RPM shows a value when the shaft is spun by hand after connecting sensor showing it working


Accelerator Pedal (APP Sensor)





Now showing accelerator position after connecting to inverter

NOTE: This did not work as the supplied diagram is wrong

This one is correct for the supplied pedal:



Brake



Brake is showing as working (red dot on the right), and we can now select "D" drive (as well as other modes).


Delving in:

Driver board


Driver board connector




JST CPT connector

+

Driver and output datasheets

1ED020I12FA2 | IKW75N60T

Trinary control


Original gschem schematic

This is the 1.3Mhz trinary PWM (50/50) to inspect the transitions:
.equ LOW_IN   = 0x00
.equ HIGH_OUT = 0xFF
.equ DDRB     = 0x04
.equ PORTB    = 0x05


    ldi	r24, LOW_IN
    ldi	r25, HIGH_OUT

loop:

;   nop equivalent to jump
;   nop
    out	DDRB,  r24; OFF

    nop
    out	PORTB, r24
    out	DDRB,  r25; LOW

    nop
    nop
    out	DDRB,  r24; OFF

    nop
    out	PORTB, r25
    out	DDRB,  r25; HIGH

    rjmp loop


TIME:200nS/div, Blue:TP1(2vDC/div), Red:TP2(2vDC/div), Orange:TP3(2vDC/div), Green:TP4(2vDC/div).

This is showing fast transitions for high (Green) and low (Red) with the max wait 100nS and max switch 100nS.
Which means the total switching delay is 200nS well within the 1uS required.

Latest Tesla version of trinary.asm:


Hooking Up To Motor

Driver board only

TIME:200nS/div, Blue:TP1(2vDC/div), Red:TP2(2vDC/div), Orange:TP3(2vDC/div), Green:TP4(2vDC/div).


TIME:200nS/div, Blue:TP1(2vDC/div), Red:TP2(2vDC/div), Orange:TP3(2vDC/div), Green:TP4(2vDC/div).

Low power output



Output switching transition (~50nS):

TIME:50nS/div, Blue:TP1(2vDC/div), Green:V-phase(4vDC/div).

TIME:50nS/div, Blue:TP1(2vDC/div), Green:V-phase(4vDC/div).

Switching delay (2uS max)

TIME:500nS/div, Blue:TP1(2vDC/div), Green:V-phase(4vDC/div).

TIME:500nS/div, Blue:TP1(2vDC/div), Green:V-phase(4vDC/div).

Input vs output (~3.33kHz 50:50 PWM)

TIME:50uS/div, Blue:TP1(2vDC/div), Green:V-phase(4vDC/div).

Logic interface

To create the logic interface between the Arduino and the Tesla driver board a bit of stripboard needs to be laid out.