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Participants

Goals

  • Validate the new driver controls and motor interface to make sure we can send reliable drive commands to our motors 
  • Make sure our car drives before Karl leaves Waterloo 

Boards Tested

  • Driver Controls - Steering Rev 3
  • Driver Controls - Pedal Rev 3
  • Driver Controls - Center Console Rev 3
  • Pre-Charge/Motor Interface Rev 4

What went well? 

  • New CAN based driver controls seems to be working as expected. No brake lights flickering or throttle cutting out as seen in ASC 2018
  • New Pre-Charge significantly reduced the pre-charge time to < 5 seconds. 
  • New Motor Interface based on the MCP2515 forwarded all messages without any issues for extended periods of time
  • Installed T-connectors on Motor bus to make sniffing the Motor CAN bus and running PhasorSense easier
  • Debugging with a DBC and new PCAN-USB dongles was a breeze
  • We were able to remove the wheel after hammering for a long time

What didn't work well? 

General

  • ADC driver seems to be broken when LTO is disabled, or when Continuous mode is enabled. Currently there's a workaround in firmware, but we should look at the binaries and figure out what's going on here.
  • SPI drivers had been broken on master

Power Distribution

  • The car seems to turn off whenever the lights are turned on. There's no BPS fault or any other abnormal activity on CAN. Could this be a DC-DC overcurrent/under voltage? 
  • The aux battery even when charged cannot close contactors for more than a few times. Look into either replacing power distribution or the battery. 
  • The power pins seem to behave weirdly for the spare and motor controller (PA7, PB1)

Motor

  • The left/driver side motor that we used ASC 2018 stopped working. Consider re-harnessing the motor. We swapped in the back-up motor to the left-side. 
  • We hit the SWOvercurrentLimit on the WS20s (mainly right motor, sometimes left motor) when accelerating quickly. This limit is currently set to 67 Arms (Actual limit = 67 * sqrt(2) * 15% overcurrent = 108.965A). We don't seem to hit this if we press the accelerator pedal slowly, so this may not be that serious of an issue. 

BMS

  • Kill switch did not work. This should be solved when we swap in the new BMS Carrier Rev 4 once validation is complete.  
  • Current sense didn't seem to be working. Investigate this further


Things to Do

Mechanical

  • One of the battery box rails came off on the driver side. We also took off the spring/sleds for ease of removal.
  • Missing mounting screws for WaveSculptor 20s
  • Verify replaced motor is installed/torqued correctly 
  • Create PCB mount for Pre-Charge/Motor Interface
  • Create PCB mount for Pedal board
  • Create PCB mount for steering interface board
  • Create PCB mount for new BMS Carrier Board 
  • Windshield is pretty scratched/dirty. We should consider polishing or replacing this for visibility. Also it's missing a few screws. 
  • The driver seat is not installed properly and will tilt back when you lean on the back.
  • Secure the mount for the brake potentiometer 
  • Look into a better way to remove wheels
  • Fix the sketchy array prop rod ends, which are falling apart
  • Steering wheel/column is not mounted properly
  • Seems like there might be air in the brake lines? Pedal goes to the bottom pretty easily. 
  • There’s a clicking noise on the right front tire. Investigate this further.

Electrical

  • Clean up harnessing in the front of the car after the boards are mounted. Add wiring loom to all exposed wires.
  • Driver side DRL doesn't seem to be working. Check harness and front lights board
  • Finish validation for BMS Carrier board and swap that in for the master battery box - Liam Hawkins, Aashmika Mali
  • Finish bring-up for new AFEs and make sure everything still works 
  • Wire in temperature sensors for Aux battery and DC-DC 
  • Consider validating and integrating Power Distribution Rev 3, or work on Rev 4 and swap that in when complete 
  • Test and validate cruise control functionality and logic 
  • Test and validate/add regen logic
  • Provide drivers with a way of manually disabling regen braking (useful for brakes testing)
  • Verify BPS strobe and BPS dash indicator works as intended
  • Reharness the broken motor to use as a spare for FSGP 2019
  • Validate and integrate solar sense into the car 
  • Figure out what's going on with our ADC and SPI drivers 
  • Add a way to manually reset the motor controllers (Using control stalk maybe?) incase we hit a SW limit. 
  • Attempt to dump more data over CAN when a fault condition is reached
  • Create pinout/wiring diagram for PJB

Business

  • Keysight sponsorship decal sticker
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