electric vehicle supervisor system

3588 Plymouth Road, Box #274

Ann Arbor, MI 48105-2603

Phone 877.234.1410, Fax 928.395.2114

ELECTRIC VEHICLE SUPERVISOR

SYSTEM

SUMMARY

Contact Information:

New Eagle

3588 Plymouth Road, #274

Ann Arbor, MI 48105-2603

Phone: (734) 649-8156

Date: 25 May 2012


Ann Arbor, MI 48105-2603 Phone 877.234.14102

CONTENTS

Overview ...................................................................................................... 3

Introduction .......................................................................................................... 3

System Summary .................................................................................................. 3

Inputs ............................................................................................................................... 4

Outputs ............................................................................................................................. 4

New Eagle Electric Vehicle Supervisor Products and Services ..................................... 5

New Eagle EV/HEV Supervisor Start-Up Kit .......................................................................... 5

New Eagle EV/HEV Supervisor Source Code ......................................................................... 5

EV/HEV Application Engineering Development Program ........................................................ 6

Controls Software ........................................................................................... 7

Plant Interface ...................................................................................................... 8

Physical & CAN-based Inputs .............................................................................................. 8

Actuators & Messages ...................................................................................................... 10

Display Faults .................................................................................................................. 11

Controller ............................................................................................................ 12

Virtual Sensors ................................................................................................................. 12

Control Algorithm ............................................................................................................. 14

Actuator Characterization .................................................................................................. 15

Appendix ...................................................................................................... 18

Source Code for a Typical EV Supervisor Application ............................................... 18

Table of Contents ............................................................................................................. 18

Model Screenshots ........................................................................................................... 21

Controller – ECM 5554-112-0904 .......................................................................... 29

MotoTune Calibration Software ............................................................................. 31

Reprogramming the Main Controller .................................................................................. 32

More information .............................................................................................................. 32

HMI – VeeCAN 320 Display................................................................................... 33

Features .......................................................................................................................... 33

Reprogramming the HMI .................................................................................................. 35



OVERVIEW

INTRODUCTION

The need for a rapid transition towards electrification in today’s transportation industry is clear, but

the experience and knowledge required to transform these new ideas to reality are scarce. Until a

definitive pathway to a fossil-fuels free future is created, a number of technological as well as

economic hurdles continue to be a part of automotive industry’s day to day business. Overcoming

these hurdles requires a collaboration of skills from a wide range of engineering disciplines and

therefore, we at New Eagle continue to grow our hybrid and electric vehicles team. Our expertise lies

in the integration of the vehicle electronics, energy-storage and powertrain controls. Due to the

number of components in an electric/hybrid powertrain and their respective suppliers, the need for a

flexible controller cannot be over emphasized. With our development tools and engineering team, we

have designed an Electric Vehicle supervisory control strategy that meets the needs of a range of

systems with minimal effort.

SYSTEM SUMMARY

Figure 1: New Eagle's Vehicle Supervisor Summary

Figure 1 illustrates a variety of components that interact with New Eagle’s EV supervisor in the center,

which is 112-pin MotoHawk controller, ECM-5554-112-0902/04. In addition to the controller

programmed with the application software, the system consists of an optional wiring harness package

and optional sensor/actuator and display components, which are connected with solid lines above.



INPUTS

The EV Supervisor application software is fed by both direct wired sensors as well as CAN-based

inputs from different components as follows:

DRIVER INPUTS

Key Switch

Accelerator Pedal

Brake Switch

Gear Shifter

Emergency Brake

HMI Display Input

VEHICLE INPUTS

Wheel Speed Sensor

Vehicle Dynamics

Charge Plug

HVAC System

Energy Storage System

OUTPUTS

COMPONENT CONTROL

Motor torque command generation

Charger commands

DC/DC converter commands

HVAC System commands

Instrument Cluster & Fault Information to HMI

DISCRETE OUTPUTS

Power Relay

Cooling Pump/Fan Relay

Inverter Enable

Power Steering Pump Relay

Pre-charge Circuits

Lamps



NEW EAGLE ELECTRIC VEHICLE SUPERVISOR PRODUCTS AND SERVICES

Using its network of component suppliers and years of experience developing electric vehicle control

algorithms, New Eagle has developed three Electric Vehicle Products and Services. These products and

services are:

1. EV/HEV Supervisor Start-Up Kit

2. EV/HEV Supervisor Start-Up Source Code

3. EV/HEV Application Engineering Development Program

NEW EAGLE EV/HEV SUPERVISOR START-UP KIT

The New Eagle EV/HEV Supervisor Start-Up Kit provides the basic components to integrate into an

electric vehicle in order to demonstrate a proof of concept vehicle. This kit is intended for prototype

vehicles to quickly demonstrate feasibility. After proof of concept demonstration, the vehicle

integrator can then either develop their own system by purchasing the EV/HEV Supervisor Start-Up

Source Code or contract New Eagle through an EV/HEV Application Engineering Development

Program. The bill of materials for the New Eagle EV Supervisor Start-Up Kit is shown in Table 1.

Table 1: EV Supervisor Start-Up Kit Bill of Materials

# Part Number Description Qty 1 ECM-5554-112-0904-C00-M 5554-112-0904 Calibratable Engine Control Module 1 ea

2 HARN-P112-001 Pigtail Harness for a 5554-112 1 ea

3 CON-FEML-018-00 Connector Female – 1 Fuse 1 ea

4 CON-COVR-003-00 Connector Cover – 1 Fuse 1 ea

5 CON-TMFL-015-00 Connector Terminal Female 18 ga 2 ea

6 EFP-136-01 Electronic Foot Pedal Throttle Assemblt – Floor Mount 1 ea

7 ASM-EFP-CONKIT-01 Connector Kit – Electronic Foot Pedal Throttle Assembly 1 ea

8 CANvu VEM 400N CANvu 350 400NIT J1939 / Tier 4 Color Embedded Display 1 ea

9 ASM-DIS-CONKIT-001 Deutch Connector Mating Kit 12 Way for CANvu 320, 350 and KAntrak

1 ea

10 NE-EVS-SW-01 New Eagle Electric Vehicle Supervisor Software V1 1 ea

11 LBR-PRGM-ECU-001 ECU Programming Labor

12 LBR-PRGM-GAGE-001 Gage Programming Labor

NEW EAGLE EV/HEV SUPERVISOR SOURCE CODE

The New Eagle EV/HEV Supervisor Source Code is the model source that generates the New Eagle

Electric Vehicle Supervisor Software, part number NE-EVS-SW-01. The algorithms are developed using

the Motohawk code generation toolset completely within the Matlab/Simulink environment. This

software can be used by the vehicle integrator as a base platform for developing an application

specific model. The supervisor code has been verified and field tested across multiple applications.

The major subsystems of the code are outlined in Table 2. Portions of the model source are shown in

the appendix “Source Code for a Typical EV Supervisor Application”.



Table 2: EV/HEV Supervisor Major Subsystems

# Title Description

I/O

1 Input and Output Module I/O connections, user dependent. Top level I/O diagram provided as part of base model. Applications Support is available

2 Shifter User Interface Stateflow Based

Converts shifter voltage to drive states.

Co

ntr

ol

Str

ate

gy

3 BMS Fault system and Vehicle Power Moding

Manages contactor actuation, plug in charging, and limp home mode designation.

4 Charge manager Commands charging commands for current and voltage to charger. Also manages float charging once fully charged.

5 Warning Buzzer Sends notification to driver that Parking brake is applied when attempting to drive, and / or when SOC is low

6 Motor Direction Control Sends enables to the motors for directional control

7 DCDC Converter Control Enables DCDC converter based on SOC.

8 System Cooling Control Enables the cooling pump circuit for the EV components.

9 Accelerator Torque mapping Translates percent accel pedal to torque demand to motor.

10 eParkingBrake Actuates eParkingBrake function.

11 Regenerative Braking Braking torque based on brake pressure.

Dia

gn

ost

ics 12 CAN Input Diagnostics Adds diagnostics on message receive blocks.

13 Analog Input Diagnostics Adds diagnostics on Accelerator pedal and other analog inputs.

14 Internal Diagnostic Application Code

Applies the faults to specific outputs for safe operation.

EV/HEV APPLICATION ENGINEERING DEVELOPMENT PROGRAM

New Eagle Consulting specializes in developing controls solutions for a broad range of applications

utilizing production validated electronic control units and our model based code generation platform.

A main focus of our company is the EV and HEV market. Our customers benefit from the field tested

hardware and software solutions that we provide while tailoring the application to their particular

niche. We are efficient at reuse of hardware and software while keeping the distinctive applications of

our customers confidential and protected. We do not waste time developing non-differentiating

solutions but are able to focus on the critical product parameters, thus saving significant overall non-

recurring engineering costs by as much as 80%.

As part of dedication to lean product development and reuse, we have designed an EV/HEV product

development framework. This framework allows New Eagle to quickly work with our customers to

tailor a product development plan to their needs. We use our Talon Product Development Process to

take our programs from proof of concept through product launch and then to production. Our

development phases are divided into concept validation (CV), design validation (DV), product

validation (PV) and series production phases. A copy of the product development framework can be

found in the appendix.



CONTROLS SOFTWARE

New Eagle’s EV/HEV Supervisor controls software is developed within the Motohawk code generation

environment. The EV/HEV supervisor model inputs raw sensor or CAN information in its digital form.

Based on sensor calibration data and CAN message specification, this raw information is then

converted to engineering units. The controls strategy estimates a number of other parameters from

the inputs and uses them for temperature, voltage, torque, mode, state and discrete control of

components connected to the module. With direct access to PWM voltage and current drivers, the

output command generation is converted from its engineering value to driver configuration

parameters. The general flow of software is summarized by the diagram below and within the

functional description that follows.

The system software design and architecture is based on New Eagle’s model-based software platform.

As seen in the figure below, the top level of the model consists of a split between controller and plant

model with the plant defined as the Electric Vehicle.

Figure 2: EV/HEV Supervisor System Level Model



PLANT INTERFACE

Inside the plant subsystem, the interface is defined between the controller and physical inputs,

actuators, CAN transceiver and HMI display. The plant interface subsystem model is shown in Figure

3.

Figure 3: The Plant Interface Subsystem

PHYSICAL & CAN-BASED INPUTS

The Physical & CAN-Based Inputs subsystem is divided into 2 major parts, CAN-based inputs and

physical inputs.

CAN-BASED INPUTS

Battery Management System (BMS) – Several parameters of interest such as battery voltage,

cell voltages (lowest, highest), battery pack current, state of charge, depth of discharge, cell

temperatures, fault flags etc. are useful information for generation of torque command taking

into account the constraints imposed by the battery pack.

Anti-lock Braking System (ABS) – Signals such as wheel speeds (for each wheel), regeneration

status and fault information are received from ABS module via CAN.

Inverter (Motor Controller) – This set of inputs contains relevant information about Inverter

state, stator/rotor temperatures, bus voltages, actual motor speed, thermal & power limits

and fault flags.

HVAC System – Used in HVAC system control, signals such as compressor speed, power

consumption and compressor status are relevant inputs.



Charger (High Voltage) – For efficient use of power, charging control requires some basic

information like available current, voltage, power supply status, wake-up signals and fault

data.

DC/DC converter – The DC/DC converter is the link between LV and HV battery, buck/boost

mode information and other physical data such as temperature, voltage and fault information

are received.

Electronic Power Steering (EPS) – Basic information like steering angle, steering speed,

commanded torque, and temperature and fault data is received from EPS system.

PHYSICAL INPUTS

Key Switch Input – Ignition key voltage input to connect battery power to module.

Accelerator Pedal Position (APP) – The first expression of driver’s demand torque comes from

accelerator pedal, typically a dual potentiometer sensor with isolated power supplies.

Brake Pedal – The brake input comes in the form of brake pedal position and is converted to

brake pressure for the control algorithm subsystem.

Park Brake – The park brake switch is a discrete voltage input.

PRND State – Based on gear selection, the PRND state is typically a resistive ladder based

input that determines the gear state in virtual sensors subsystem.

HVAC System – Discrete inputs from HVAC system contain the AC enable switch and percent

dial information.

The Physical Input Subsystem model is shown in Figure 4.

Figure 4: Physical Input Subsystem Model



ACTUATORS & MESSAGES

The Actuator & Messages subsystem controls both CAN message transmission to the motor controller,

the general vehicle modules & the LCD display as well as some of the discrete outputs to control relay

based power enables for lamps, the inverter and few other components. The motor controller

command, as generated by the Control Strategy subsystem, is converted into speed set point, direction

control and state command with applicable torque limits, power limits during acceleration & regen

and some correction factors.

OPTION TO CHOOSE INVERTER/MOTOR COMBINATION

New Eagle has experience in CAN based control command generation for a number of motor/inverter

hardware combinations, some of which are Rinehart, Remy and Azure. This can be translated into a

user selectable parameter in software as well as customized code can be written to meet the needs of

a new inverter.

STARTUP/SHUTDOWN SEQUENCE (MAIN POWER RELAY CONTROL)

The supervisor controls software controls a proper startup and a safe shutdown sequence by

controlling power the main power relay when the ignition key is turned off or the powertrain mode is

shutdown. All non-volatile data is stored in EEPROM for later recovery, before the controller goes to

sleep. The Startup/Shutdown Sequence (Main Power Relay Control) subsystem is illustrated in Figure

5.

Figure 5: Main Power Relay Control Subsystem



DISPLAY FAULTS

Diagnostics are tied with the control strategy throughout the software. The plant interface contains

the Display Faults subsystem where all of the HMI display faults are collected and conditioned to be

sent to display. As seen in Figure 6, the faults may be related to motor controller or general vehicle.

Figure 6: Display Faults Subsystem



Figure 7: Sample HMI Fault Displays

CONTROLLER SUBSYSTEM

Within the Controller Subsystem, there are three major subsystems, Virtual Sensors, Control

Algorithm and Actuator Characterization. A depiction of the controller subsystem is shown in Figure 8.

Figure 8: Controller Subsystem

VIRTUAL SENSORS

Figure 9 shows how the control architecture is laid out within the Virtual Sensors subsystem.



Figure 9: Virtual Sensor Subsystem

The main blocks in this subsystem are:

USER INTERFACE

The user interface reads the gear shifter and heater user interface. This subsystem calculates the drive

mode based on tap up or down requests from the driver while maintaining stability and smooth gear

shifts. Based on these gear states, it also commands Electric Park Brake to enable or disable. From the

heater user interface inputs from the driver, this block, generates heater On/Off or PTC enable/disable

request.

BRAKE SWITCH

This part of the virtual sensor is fed by the brake input signal and it determines the brake switch

parameter based on brake pressure thresholds and hysteresis limits.

VEHICLE SPEED CALCULATION

The vehicle speed calculation is performed by measuring actual motor speed as reported by the

inverter via CAN. The wheel speed information coming from the ABS module can also be used to

perform and/or verify against the value obtained from motor speed calculation.

POWER MODE LOGIC

A state machine is used to determine the powertrain state and generate BMS contactor ON request

based on inputs such as PRND state, key switch voltage, charge plug status, BMS discharge status, AC

compressor speed and fault data. These power modes, such as idle, shutdown, limp and BMS



contactors off/on, are used by the control algorithm subsystem to limit torque commands and for safe

propulsion of the vehicle.

MOTOR CONTROL

An important subsystem of the virtual sensors block, the Motor Control subsystem receives PRND

state, accelerator and brake pedal requests, vehicle speed and battery information from the BMS. The

objective of this subsystem is to determine appropriate torque for each gear (zero, forward, reverse

etc). It takes into account the previous torque command to avoid abrupt changes in torque command

and limits the torque command due to Battery current-based, SOC-based and voltage-based torque

limit curves to protect the battery from being damaged.

CONTROL ALGORITHM

The Control Algorithm subsystem is shown in Figure 10. This system uses real and virtual sensor

inputs to calculate the EV/HEV control logic.

Figure 10: Control Algorithm Subsystem



MOTOR CONTROL

Motor torque generation is calculated in the Virtual Sensor subsystem. This subsystem calculates

motor direction, drive mode and motor state based on powertrain status and operator drive mode.

Important drivability concerns are accounted for in terms of maintaining proper slew rates for the

generated torque commands.

CHARGING CONTROL

The inputs to the Charging Control subsystem consist of battery pack voltage, state of charge (SOC),

charging status, contactors status, J1772 duty cycle percentage and any faults in the BMS. It outputs

BMS charge enables and charge requests, which are transmitted to the BMS via CAN. The J1772 duty

cycle signal is used to determine the current limits from a duty vs. current map.

HVAC CONTROL

With the PTC enables and heater On/Off requests the HVAC Control subsystem integrates the AC dial

position, AC enable and powertrain status to output Fan Duty Cycle, AC compressor On/Off command

and several other HVAC parameters of interest for monitoring.

SYSTEM COOLING

Based on vehicle parameters such as speed and motor/driver temperature as well as thresholds, the

System Cooling subsystem determines if coolant has overheated then generates a cooling pump

request and a cooling fan duty cycle.

DC/DC CONVERTER

DC/DC Converter is placed between the Low Voltage battery and High Voltage Battery Pack and can

operate in either Buck or Boost mode to charge or discharge the HV Battery Pack based on SOC and

other conditions. The DC/DC Converter subsystem calculates the DC/DC converter mode based on

battery contactors status, key switch status, driver power and fault status.

KEY SOLENOID & BUZZER CONTROL

In the Key Solenoid & Buzzer Control subsystem, the ignition key solenoid state is determined and the

buzzer control commands are generated to indicate low SOC or parking brake engaged.

ACTUATOR CHARACTERIZATION

The Actuator Characterization subsystem converts the control outputs into actuator commands that

are specific to the actuators on the vehicle. The actuators are characterized separate from the controls

in order to make the system adaptable. The Actuator Characterization subsystem is shown in Figure

11.



Figure 11: Actuator Control Subsystem

CLUSTER CONTROLS

In the Cluster Controls Subsystem, various parameters related to vehicle in general or components,

such as BMS faults, Low SOC warning, parking brake warning, powertrain state, PRND state are

watched in order to display them or flash a lamp on the instrument cluster. Distance travelled is also

calculated here from the measured vehicle speed.

COOLING SYSTEM

In the Cooling System block final cooling fan duty cycle as well as final coolant pump command is

determined here based on HVAC Fan duty cycle percentage and battery contactor status respectively.

BMS CONTACTORS

In the BMS Contactors subsystem, the final command to turn the BMS contactors on or off command is

calculated, raw commands consisting of BMS charge enable, battery current, contactor on request,

temperature and fault conditions.



ELECTRIC PARK BRAKE

The electric park brake is engaged when it is commanded by the driver, but is also engaged to set the

vehicle immovable, when module senses that HV Battery is charging via J1772 charger plug.

BRAKE LAMP

The brake lamps and reverse lights request is finalized in the Brake Lamp subsystem using the

transmission state, torque command and brake pressure.

MOTOR

After the motor torque command and direction have been determined considering all limits, the final

motor torque request is converted from percentage to a value in Nm based on motor’s rated torque

and torque speed characteristics.



APPENDIX

SOURCE CODE FOR A TYPICAL EV SUPERVISOR APPLICATION

TABLE OF CONTENTS

VCM902P

................................................................ 19

Fgnd_Software

................................................................ 23

1 Controller

............................................................ 24

1.1 Virtual_Sensors

........................................................ 25

1.1.1 BrakeSwitch

................................................................ 26

1.1.2 Veh_Spd

................................................................ 27

1.1.3 Vehicle_PowerMode

................................................................ 28

1.1.4 User_Interface

................................................................ 30

1.1.5 MotorControl

................................................................ 33

1.1.5.1 TorqueCommand

................................................................ 34

1.1.5.2 Battery Protection

................................................................ 35

1.1.5.2.1 BatteryProtection

................................................................ 36

1.1.6 Probes

................................................................ 38

1.2 Control_Algo

........................................................ 39

1.2.1 HVAC

................................................................ 40

1.2.2 Charging

................................................................ 43

1.2.3 Buzzer Contol

................................................................ 47

1.2.4 Motor Control

................................................................ 49

1.2.5 DCDC Converter

................................................................ 52

1.2.6 System_Cooling

................................................................ 55

1.2.7 Key Solenoid

................................................................ 58

1.3 Actuator_Charaterization

........................................................ 60



1.3.1 Cluster_Controls

................................................................ 61

1.3.2 Cooling

................................................................ 64

1.3.3 BMS_Contactors

................................................................ 65

1.3.4 ePark_Brake

.................................................... 68

1.3.5 Brake_Lamp

................................................................ 69

1.3.6 Motor

.................................................... 70

1.3.7 DiagApplied

................................................................ 71

2 Plant

............................................................ 73

2.1 Probes

................................................................ 74

2.2 Physical Inputs

................................................................ 75

2.2.1 CAN Receive

................................................................ 76

2.2.1.1 MCU

................................................................. 77

2.2.2 Sensors

................................................................ 78

2.2.2.1 PRNDM_Input

................................................ 79

2.2.2.1.1 PRNDL Select Switch

................................................................ 80

2.2.2.2 ParkBrake_Input

................................................................ 82

2.2.2.3 Accel_Ped_Input

................................................................ 83

2.2.2.4 Brake_Input

................................................................ 84

2.2.2.5 HVAC_Input

................................................ 85

2.2.2.6 Key_Sw_Input

................................................ 86

2.2.2.7 Module_Pwr_Input

................................................................ 88

2.2.2.8 ChargePort_Input

................................................ 89

2.2.2.9 PowerSave

................................................................ 90

2.3 Actuators_and_Messages

........................................................ 91

2.3.1 CAN_Communications

................................................................ 92

2.3.1.1 MotorController_CAN

................................................................ 93

2.3.1.2 GeneralVehicle

................................................................ 94



2.3.1.3 LCD_Display

................................................................ 95

2.3.1.4 Display

................................................ 95

2.4 DisplayFaults

................................................................ 96

2.5 MCU Faults

........................................................ 97



MODEL SCREENSHOTS

MotoHawk Function Trigger

FGND_RTI_PERIODIC

Priority Order: 0

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VCM902PVCM902P............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

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Operating_System_Setup

Fgnd_Software



MotoHawk (RTW)

Code Coverage Test BitAutoDoc

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Fgnd_SoftwareVCM902P / Fgnd_Software............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

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Plant

Controller

f()

f



1

CommBus

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1 ControllerVCM902P / Fgnd_Software / Controller............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

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In Sensor_Out

Virtual_Sensors

In Control_Signals

Control_Algo

Contrl_Bus_In Actuator_Out

Actuator_Charaterization

1

SensorsComm_Bus



1

Sensor_Out

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1.1 Virtual_SensorsVCM902P / Fgnd_Software / Controller / Virtual_Sensors............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

In1

BMS_DisChrgOK

Out3

Vehicle_PowerMode

Sensors Output

Veh_Spd

In1

BMS_DisChrgOKOut

User_Interface

In1

Probes

VehSpeed

Sensors

UI_Bus

MotorBus

MotorControl

Sensors Output

BrakeSwitch

1

In

Virtual_SensorsMainBus



1

Output

VbVCM_BrakeSw_

KeVCM_kPa_BrakeSwitchOffThres = 3

(Calibration)

KeVCM_kPa_BrakeSwitchOnThres = 4

(Calibration)

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1.1.1 BrakeSwitchVCM902P / Fgnd_Software / Controller / Virtual_Sensors / BrakeSwitch............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

Calibrations............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

KeVCM_kPa_BrakeSwitchOff...

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

KeVCM_kPa_BrakeSwitchOnT...

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

Probes............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

VbVCM_BrakeSw_

MotoTune Path:

MotoTune Path:

MotoTune Path:

VCM902P | Fgnd_Software | Controller | Virtual_Sensors | BrakeSwitch



>HiThresh

Signal

LowThresh

ThresholdHYSTERISIS

Hysterisis

1

Sensors

Brake_SwitchVbVCM_BrakeSw

<VeVCM_kPa_BrakePress>



1

Output

VehicleSpeed

VehicleSpeed

KeVCM_k_MotorAxleGearRatio = 100

(Calibration)

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1.1.2 Veh_SpdVCM902P / Fgnd_Software / Controller / Virtual_Sensors / Veh_Spd............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

Calibrations............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

KeVCM_k_MotorAxleGearRatio

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

Probes............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

VehicleSpeed

MotoTune Path:

MotoTune Path:

VirSensors | VehSpd

VCM902P | Fgnd_Software | Controller | Virtual_Sensors | Veh_Spd

1

Sensors<VeMCU_RPM_ActualMotorSpeed>

VeVCM_mph_VehSpeedVeVCM_mph_VehSpeed



2

Out3

1

BMS_DisChrgOK

PowerTrainState_EnumMainRlyOFF_Timer = 2

(Calibration)

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1.1.3 Vehicle_PowerModeVCM902P / Fgnd_Software / Controller / Virtual_Sensors / Vehicle_PowerMode............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

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Calibrations............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

MainRlyOFF_Timer

............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

Probes............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ............................................................................................................................. ...................

PowerTrainState_Enum

(enum.)

MotoTune Path:

MotoTune Path:

VirSensors | Vehicle Power Mode

VirtualSensors | BMS_System

OFF_TMR

ACcomp_Spd

Key

DriveMode

ChrgePlugActv

BMSDischrgOK

LimpReq

CriticalFault

State

Powertrain_Ready

ContactOnReq

VehCharging

Vehicle Power Mode

boolean(1)

boolean(0)

boolean(0)

boolean(0)

boolean(1)

1

In1

VintVCM_PowertrainState

VbVCM_PowertrainReady

VbVCM_BMSContactorOnReq

VbVCM_VehChargingActvVbVCM_BMS_CriticalFault

<VeVCM_rpm_AC_CompActSpd>

<VeVCM_int_Key Switch>

<VeVCM_int_PRNDLState>

PowerModing

VbVCM_BMS_DisChrgOK

VbVCM_ContactorsON



CONTROLLER – ECM 5554-112-0904

For more details, visit:

http://www.neweagle.net/support/wiki/docs/Datasheets/112pin/36350_0904.pdf

http://www.neweagle.net/support/wiki/docs/Datasheets/112pin/36350_0904.pdf



MOTOTUNE CALIBRATION SOFTWARE

MotoTune is a Calibration/Display tool, part of MotoHawk Control Solutions.

Features include:

Flashing production and development controllers

Create calibrations

Develop displays

Communicate with two controllers at once



REPROGRAMMING THE MAIN CONTROLLER

To reprogram the engine controller, you will need to use 'MotoTune'.

With 'MotoTune' open, select the 'Program' button.

This will open a dialog that will allow you to select the new application binary (*.srz) that you would

like to reprogram into the ECU. Make certain that the location is selected to 'PCM-1' as it signifies the

identification of controller on CAN-1 bus and default city ID 0x0B.

MORE INFORMATION

For more information on how to use MotoTune, please visit New Eagle Learning center at:

http://www.neweagle.net/support/wiki/index.php?title=MotoHawk_Control_Solutions#MotoTune

http://www.neweagle.net/support/wiki/index.php?title=MotoHawk_Control_Solutions#MotoTune



HMI – VEECAN 320 DISPLAY

This embedded display has diverse I/O capabilities including two CAN buses, seven analog inputs,

three digital inputs, four outputs, and a USB port.

The VeeCAN 320 utilizes a powerful Freescale i.MX286 processor running

at 454 MHz. New Eagle also offers custom application programming and testing for the VeeCAN

display.

FEATURES

QVGA 320*240 pixel color display with LED backlight

Maximum brightness of 750 nits (cd/m^2) ensures visibility in full sun

Sealed to IP67 with two molded-in 12 way Deutsch connectors and one USB port

Software development kit (SDK) providing a huge library of functions allowing

control over all the display

Visible using polarized sunglasses

Internal buzzer

Potential for multiple display screens accessed by user defined soft keys

Front mounting kit supplied

Can act as part of a control system, not just a gauge display or data logger

For More Information on this display, please visit:

http://www.neweagle.net/support/wiki/index.php?title=Veethree_Instruments#VeeCAN_320_Displa

y

http://www.neweagle.net/support/wiki/index.php?title=Veethree_Instruments#VeeCAN_320_Display

http://www.neweagle.net/support/wiki/index.php?title=Veethree_Instruments#VeeCAN_320_Display



REPROGRAMMING THE HMI

The HMI can be reprogrammed in the field if new versions are released. HyperTerminal, or another

commonly available terminal emulator, is used to carry out the reprogramming. The directions are as

follows:

Configure the serial port with 57600 baud (8N1)

http://www.neweagle.net/support/wiki/index.php?title=File:CANtrakManual1.JPG



When the HMI is powered up, hold down the left two buttons until the boot screen appears. You may

need to tap the 'Enter' button to get the Flash Utility menu in the terminal window.

Use Option 2 to begin reprogramming. You will want to send the file across using 'Transfer->Send

File' with 1K Xmodem.



electric vehicle supervisor system

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