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title2023/11/14 Vehicle Fault States - Non Battery

Vehicle Fault States - Non Battery

Pedal

Fault

Condition

Action

Stuck Pedal

No way to detect it

N/A

Lose communication in pedal node

No pedal data

Set throttle to 0 upon missed transmission

MCI

Fault

Condition

Action

CAN Fault

Error status from WS22

Error indication on console, immediately auto-clear

Maybe limit torque for overcurrent

Steering

  • No detectible errors

Power Distribution

Fault

Condition

Action

Output over current

Isc reading at full scale

  • Disable load switch

If BMS fault

  • BPS Fault

Else

  • Display error code if possible (if not CC fault), pull over if needed

Aux Fault

AUX Valid GPIO low

  • Error code, pull over

DCDC Fault

DCDC Valid GPIO low PA15 or PB5

  • Error code pull over, leave everything on

    • Not allowed to drive on AUX

Aux low

AUX ADC voltage low PB3 or PB4

  • Indicator light turns on

    • Might need to add

  • Make determination on where to stop

AUX/DCDC Overcurrent

Current greater than x value (can be 8A for now)

  • Indicate, pull over/manually turn off car

AUX/DCDC Overtemp

Temp greater than 60C (can change)

  • Indicate, pull over/manually turn off car

AUX not valid on startup

AUX Valid GPIO low on startup

  • Will never get detected, car won’t turn on

DCDC Fault signal

Signal high from DCDC PA6

  • Nothing, display warning light

Solar Sense

Fault

Condition

Action

No current

No current in one or more strings when relay closed

  • Display error code

Dead

No response over CAN

  • Display error code

Expand
titleMeeting Minutes 2023/11/07

Timelining

Complete

Pending

Optional

Controller Board

MSXV PD

  • Dec 2

Solar

  • Jan

Center Console

Pedal

  • Nov 11

MCI

Carrier

  • Nov 25

MSXIV PD

Current Sense

  • Nov 25

Steering

MSXIV AFEs + LTC6820

Mockup creation: Feb - Mar/Apr

Functional Testing: Apr - May

Vehicle Fault States

Battery

Parameter

Source

Condition

Action

Cell Voltage

BMS AFE - LTC6811

One cell group falls under: 2.5V

  • BPS Fault Minor

One cell group rises above: 4.25V

  • BPS Fault Major

One cell group is imbalanced by greater than 0.5V

  • BPS Fault Major

Pack Current

BMS Current Sense - MAX17261

Pack current rises above 58.2A

  • BPS Fault Minor

Pack current falls below -27.08A

  • BPS Fault Minor

Cell Temperature

BMS AFE - LTC6811 (cell + ambient)

BMS Current Sense - MAX17261 (cell)

Ambient temperature rises above xxC

  • BPS Fault Major

Cell temperature rises above xxC

  • BPS Fault Major

Pre-charge time

BMS Carrier CB

Pre-charge takes too long

  • Failure to complete state transition, err code on display

Lose BMS

Power Distribution

BMS hard fault

  • 30 second timer, Shut down BMS AUX power to cut relays, keep BMS DCDC power on for fans

Lose AFE

BMS Carrier CB

AFE does not respond

  • BPS Fault Minor

Lose current sense

BMS Carrier CB

Current sense does not respond

  • BPS Fault Minor

BPS Fault:

  • Relays open (one IO per relay):

    • Main relay pos

    • Main relay neg

    • Pre-charge relay

    • Solar relay

  • BPS Strobe External

  • BPS Indicator Center Console

  • Cut MCI

    • Send message to PD to disable MCI LS, in the event that regen was commanded to prevent it from keeping the HV bus energized

  • Display error code on centre console

Expand
titleMeeting Minutes 2023/09/20

PVDR Battery Test Plan Review

Solar Testing

...

Expand
titleMeeting Minutes 2023/08/02

PD validation update + lessons learned @jenna k

  • Power rails were up at first, encounter smoke

  • Observed current spike on display of pwr supply, board started smoking

    • Intermittent issue, happened 3rd time immediatly but not first 2

    • Zener diode was shorted between pwr/gnd

    • Something else was smoking but it still works

  • 3v3 from CB was at 1.8V

    • 12V*0.042A = 0.5W

    • Replaced CB connector which fixed the issue

  • 5v outputs 5v5, should be 5v2 based on FB

  • In the future to set low current limit when powering boards

Update from ASC @Jonathan Xie

  • Basically okay, small brained some things but we good?

  • Stated only issue was can’t power steering and drive

LV Power Distribution

  • Quiescent draw of AFEs from main pack

Current sense architecture @Soumav Maiti @Mitchell Ostler

  • Pass relay power through for cutoff

MCI/transition to drive state @Forest Zhou @Mitchell Ostler

Press button to drive, what happens?

  • Enable HSD to MCI

  • MCI triggers precharge start

  • Precharge closes motor contactor once complete

  • MCI reads precharge complete

  • Drive mode indicator comes on in CC

Expand
titleBattery Box

Pack Design

  • Went with module design since we did it for msxiv

  • Device on number of modules first → drives number of series/parallel cells

  • 2x4+1 config

Expand
titleMeeting Minutes 2023/07/19

Solar Testing

  • Solar panel connected to MPPT

    • 7x4 stack, 1 mppt, connected to dc load

    • Panel lying flat with protective film

    • dc load set to 25V, 60W as measured at load with no clouds

    • Dropped to 45W with clouds

  • Compared with protective film vs without 100W vs 125W without

    • 56 cells (200W max → 63%)

    • Voc -> 19v

    • Isc → recorded

    • Both MPPTs connected series

  • Alastair Correya (Unlicensed) to update confluence tmrw

  • Tested with batteries as well, similar power to eload

  • Spoke with Elmar, set output pot so that they are proportional to stack sizes

Battery Box Board Mounting

...