Zweiter Frühling für ION-Antrieb --- Sparta, Batavus, Koga ...

[dvjcodec]

Yes, two layers, no components and no VIA covering option enabled in JLCPCB (I forgot change previous calculation).
Basic version files on my Github.
PCB ordered

 

[gpu7990]

Hello comrades, i maked easy mosfet relay, based on cheap tlp190b and two or four(2p 2s) ap9970gp mosfets.
All you need it is replace vom1271 with tlp190b and add 1MOhm resistor between source and gate of transistors to swich them off. tested one week - works good.

I have some question about current setup
When I leave the bike on for a long time, it wakes up badly, I hear the display beeping, but it does not wake up, I need press buttons about 5-7sec to on it. And the second question, if the bike also stood for an hour or two, then it does not help until I de-energize the entire system. What can these two moments be connected with?
Also i found good bms code for esp32 with balancer, someone interested to integrate to all in one setup?
For cu2 display- i switch to cu3, because of these blinking issue.

 

[gpu7990]

As dc-dc i use xl7015, up to 80v input. Does not have enable pin, but not big deal to add mosfet switch.

 

[Mike747]

Hello comrades, i maked easy mosfet relay, based on cheap tlp190b and two or four(2p 2s) ap9970gp mosfets.
All you need it is replace vom1271 with tlp190b and add 1MOhm resistor between source and gate of transistors to swich them off. tested one week - works good.

Lots of progress!

When I leave the bike on for a long time, it wakes up badly, I hear the display beeping, but it does not wake up, I need press buttons about 5-7sec to on it. And the second question, if the bike also stood for an hour or two, then it does not help until I de-energize the entire system. What can these two moments be connected with?

Can it have to do with a standby-state of de esp32? Could a log give more insight? You can decode your own logs now!

 

[gpu7990]

Lots of progress!

Can it have to do with a standby-state of de esp32? Could a log give more insight? You can decode your own logs now!

this problem i have on all fw versions, and different motors. Esp works, i can change assist modes and see batt prc, but motor like in sleep, does not asssists. So it is only my setup problem?

 

[gpu7990]

I used to think it was ok, but now i think i found problem. For 10s 3kOhm pull up to bow bus is to low, need 4.5k, will try to test tommorow

 

[dvjcodec]

About motor power switch, why not switch GND? I think it doesn't matter positive or negative will be switch. Without GND motor will be permanent off too.

 

[Mike747]

About motor power switch, why not switch GND? I think it doesn't matter positive or negative will be switch. Without GND motor will be permanent off too.

Switching positive is like the original system. Bow-bus (to motor) will still function when power is down to motor.

 

[void-spark]

this problem i have on all fw versions, and different motors. Esp works, i can change assist modes and see batt prc, but motor like in sleep, does not asssists. So it is only my setup problem?

Sometimes after standing still a while on my own bicycle, I also get no support. Most of the time switching to no support, waiting a moment, then switching back to support 1/2/3 resolves it. Very sometimes it's stuck and I need to power cycle.
It probably gets stuck in a state somewhere
To see what happens I'll need some good logs though, when the weather stays better for a while that's more likely to happen

 

[Mike747]

The big display test
it might not even be relevant for the development, but I found it frustrating . When your XHP motor has 5 supportmodes, the CU3 display may not "start-up" the right way: when selecting first gear, it sets 3rd, 4th or 5th. I took 6 CU3 displays and connected them to a PMU3 (2 of them), PMU2 and PMU4 battery and 2 different XHP motors. And then also looked at 3 CU4 displays . All original and (somewhat) working batteries.

Findings:
* 3 out of 6 CU3 displays do set support right the first time, the others do not.
note: 2 of the displays that did not set support right the first time came from bikes that had the issue when I bought it.
* on PMU3, PMU2 and PMU4 the same CU3 displays behave the same way (nice).
note: 5 supportmodes should/could also work with PMU2 (NiMh).
* the CU3-V1 (first version with silver edges) display also displays 5 supportmodes AND does it the right way on start-up .
* it looks like the CU4 displays all start in gear 5 instead of 1. May have to look into it when I obtain or make a working PMU4+CU4 system.
note: 2 of these displays have a blue screen color, the other more green. The blue-ones (one KOGA, one Sparta) have the same product-number, the green one is different.

Conclusion:
It could be a software issue between components or a software-update in the display.

 

[void-spark]

The big display test
it might not even be relevant for the development, but I found it frustrating . When your XHP motor has 5 supportmodes, the CU3 display may not "start-up" the right way: when selecting first gear, it sets 3rd, 4th or 5th. I took 6 CU3 displays and connected them to a PMU3 (2 of them), PMU2 and PMU4 battery and 2 different XHP motors. And then also looked at 3 CU4 displays . All original and (somewhat) working batteries.
Anhang anzeigen 499734
Findings:
* 3 out of 6 CU3 displays do set support right the first time, the others do not.
note: 2 of the displays that did not set support right the first time came from bikes that had the issue when I bought it.
* on PMU3, PMU2 and PMU4 the same CU3 displays behave the same way (nice).
note: 5 supportmodes should/could also work with PMU2 (NiMh).
* the CU3-V1 (first version with silver edges) display also displays 5 supportmodes AND does it the right way on start-up .
* it looks like the CU4 displays all start in gear 5 instead of 1. May have to look into it when I obtain or make a working PMU4+CU4 system.
note: 2 of these displays have a blue screen color, the other more green. The blue-ones (one KOGA, one Sparta) have the same product-number, the green one is different.

Conclusion:
It could be a software issue between components or a software-update in the display.

Well, some logs most certainly should give a hint here, as it shows what the display is doing

 

[gpu7990]

Sometimes after standing still a while on my own bicycle, I also get no support. Most of the time switching to no support, waiting a moment, then switching back to support 1/2/3 resolves it. Very sometimes it's stuck and I need to power cycle.
It probably gets stuck in a state somewhere
To see what happens I'll need some good logs though, when the weather stays better for a while that's more likely to happen

Yes, that's exactly what I'm talking about. Maybe a temporary solution is to make the esp reboot timer every 30-60 minutes? In order not to climb the fuse.

 

[gpu7990]

I have many different versions of displays and maybe all variants of ion motors/ With Parking and Revers modes, all Nm variants. So i can test something if you need.
Also have ION DT with front motor that have separate controller - it works with current firmware with throttle stick, but currently i not tested this with torque sensor- it is placed outside of wheel shaft. See on photo, as i figured out it is have own logic to send commands to bow bus.

 

[dvjcodec]

Yesterday I did a 3D printing battery pack for Batavus SR6. 10S4P battery pack + BMS + controller

 

[gpu7990]

Can someone tell me why round cu2 displays may not turn on, the small square one on the right in the photo turns on and works without problems, and the round- zero reaction, or one 1sec of 20prc bettery and shuts down, although it is working.
Power supply 5 volts, pull-up resistor tried 3-4.5k

 

[Mike747]

Can someone tell me why round cu2 displays may not turn on

Can it be the holder? I think the rond ones, CU2, do not fit in "newer" holders desinged for the square ones, CU2v2, (you can not turn them all the way to make good contact).

 

[gpu7990]

Works fine on original battery.
on orig batt bow bus 24v
on esp32 bow same 24v
Vcc 5V on orig and 5v on esp32
Used latest firmware version.

 

[gpu7990]

Also intresting fact, works good from 10Ah old battery, but not work from 11Ah new variant, so it is software side.

 

[Mike747]

Also intresting fact, works good from 10Ah old battery, but not work from 11Ah new variant, so it is software side

Could the 11Ah have software for CU3 instead of CU2?

 

[gpu7990]

CU3 instead

Yes, that is right)
And what is the problem then, I use software specifically for cu2.
Also small square cu2 works good.
Do you tested old round displays?