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Dala's Leaf buildthread (2015 Nissan Leaf)

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  • #46
    Nice progress Dala! Look forward to following your trials and tribulations with this project!

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    • #47
      This has been a rollercoaster Dala, I love this thread!

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      • #48
        Thanks guys! And now for something completely different.

        My friend Johan was bitten by the 3d-printing bug, and I am so intrigued! I searched thingiverse for a J1772 holder, and found this simple design:
        https://www.thingiverse.com/thing:2481870

        So I sent him a message, and little over an hour later, a prototype was printed.

        Started


        Finished


        I was told this was a really fast prototype (Layer-height was 0.3mm), and if I wanted a better looking one it would take roughly 4.5h to print one. I am so excited by such a small piece of plastic Thanks Johan

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        • #49
          So let's talk wheels. Winter is long over and it's time for summer tires. This is the first car I've owned with a Tire Pressure Monitoring System (TPMS). I got a new to me set of alloys, and naturally wanted to keep the TPMS functioning. First order of business was to order another set of pressure sensors, but the local Nissan dealership had these for 100€/sensor! So ebay was naturally the next place to look, and for 17€/sensor I won't complain.

          Here are the wheels fitted, stock Bridgestone Ecopias, 16", 17.1kg rims. The exact same weight as the OEM steelwheels, so not very high quality rims these. But they look better than the steelies


          So, let's tackle the TPMS warnings. The Leaf warns you about the TPMS on both the lower and upper instrument cluster. It also flashes them for a solid few minutes, so you'll definitely notice it and want to fix it asap!


          The solution is LeafSpy Pro. The instructions are so simple that anyone can remap the sensors. It took me 10 minutes!


          After getting the car to accept the new sensors I let it cool down for 30mins. Then I filled the tires up to the eco-miling spec of 3.1bar front, 3.0 bar rear. Instrument cluster is happy again!


          My 3d-priting obsession continues, I wanted to personalize the wheels, so 3d printing center caps seemed like a perfect tiny project.

          Started by modelling this "Toyota Prius Wheel Center Cap - Power Symbol" https://www.thingiverse.com/thing:44003 to fit my wheels, made new hooks. It's so easy to model, using sketchup since it's free.


          Printed a prototype, worked almost too good, now to print more in higher quality and paint them


          I promise I'll get back to the CAN stuff soon, just wait

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          • #50
            Neat wheels, suits it really well! The wheel centre cap is also a neat touch, will be interesting to see the finished product.

            Must say it is rather fascinating to see you resolve various issues with your Leaf, you do make it look very easy!

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            • #51
              I used to spend a lot of time racing electric RC cars, and this thread somehow brought a lot of memories! Fascinating how many of the concepts are the same, just on a WAY bigger scale!

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              • #52
                Thanks Now here's some progress,

                I took delivery of the first battery-pack from Norway! It was dusty, came from a crashed 30kWh Leaf. Shipping from Norway->Finland was only 200€!


                After getting it home and cleaning it up, the label identifies it as a 30kWh pack made in the UK.


                After splitting the case open. You can already spot the big double-stacked modules! The complete battery weighs roughly 20-30kg more than a 24kWh battery!


                Next on the agenda is to extract all the modules! NOTE, I am not going into detail on the safety aspects since they will differ from country to country. 400VDC can kill, always get certified (SFS 6002 in Finland), attend safety trainings and use the correct safety gear when dealing with high voltages.

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                • #53
                  Very good point Dala re safety when working with electrics, one can never be too careful about that sort of black magic!!

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                  • #54
                    So, I've run some capacity tests on a few cells, here are the results


                    Antimatter Test, 5Amp discharge, from 4.1V -> 3.3V
                    USA 24kWh cell: 39,77Ah
                    Italy 24kWh cell: 43,30Ah
                    30kWh cell: 59,0Ah

                    So if I have a USA cell in my pack now, I would get a 48% capacity increase by installing the 30kWh cells. My summer vacation starts on Friday, so then I can start working on this fulltime!

                    Sideproject, printed grocery bag hooks for the luggage space. Makes the car a better grocery-hauler!


                    Worked really well! Found them on thingiverse: https://www.thingiverse.com/thing:361948

                    Oh, and I started modeling my own creation for another sideproject on the Leaf More on that later!

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                    • #55
                      After completing the pilot project upgrade on my personal car, here are some random thoughts and info for the bruteforce 24-30kWh upgrade.


                      Here are the two battery management systems. Nissan refers to these boxes as LBCs, (Lithium Battery Controller) The top is from the 24, bottom 30.

                      Serial 24: 293A09RB3A
                      Serial 30: 293A04NR5B

                      They are mechanically very similar, but you cannot use the 24 LBC with a 30 Busbar. There are people on the forums who tried this, and supposedly it will short the module, since a pin or two are not the same. It would be good to document this later on, since it takes quite some time to do a busbar swap, but I am playing it safe this time.

                      Oh, and the 30 box speaks kind of the same language, but pairing it with an 24 vehicle control module will result in a whole can of worms in the form of DTCs and turtle mode, since the bootup handshake afaik is different. This is being worked on by multiple people, so this will change soon.

                      Speaking about busbars, here is the rear stack of modules.


                      These are 30kWh modules, identified as "16B70 04###". You can also see the busbars, along with the tiny sensoring and balancing leads. These will only shunt 9mA, so it is OK for them to be such a tiny diameter. I am pairing the 30 cells with the 24 busbars.

                      Funfact, the 24 pack has 2/3 temperature measurements on the outside edge of the cells, but the 30 pack has temperature measurements directly on the busbars. Measuring it directly on the busbars will for sure result in higher and more responsive temperature measurements, so I guess that is why the 24 pack also "measures" colder than 30/40 packs.

                      Another thing I dediced to play safe was the contactors


                      The contactors had slightly different serial numbers, but they probably would have been interchangable. Didn't feel like this was the correct time to gamble

                      Getting the 30kWh cells to fit presented a few minor problems. First, the rear stack's support beams wouldn't fit onto the cells. The cutouts at the end had to be made oval instead of round to fit the stack. Nothing a saw can't fix.


                      Then, the mounting holes for the rear stack did not align properly with the bottom shell


                      So I had to lift out the rear stack again (heavy!) and carefully file the holes to the proper shape. After that the bolts could be installed.


                      After everything was swapped over, I installed the hybrid 24/30 pack into the car, and it happily booted up with the lovely startup sound. After having the 12V battery disconnected the car always goes into miles/Fahrenheit mode, minor annoyance :P


                      I will now do a shakedown of the car before diving into correcting the instrument-cluser with the CAN-bridge.
                      Last edited by Dala; 05-07-2019, 06:00 PM.

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                      • #56
                        I now have some data! Did a lot of driving over the past days to get a feel for the new pack. I managed a comfortable 205km at 15-13*C with no AC or heat. I averaged 7.3km/kWh, due to me slowing down after going past 0.0% SOC.

                        The first 100km I drove 85-100km/h. The second 100km I drove between 70-85km/h. Here is what the 24 LBC instrumentation said:

                        16% dash, 114km travelled. Low battery warning!
                        8% dash, 135km travelled. - - - km remaining
                        - - -% dash, 142km travelled, - - - 3.66V min cell voltage (Leafspy 12.3% SOC)
                        150km travelled, 3.64V min voltage (3.61V under load), (Leafspy 7.6% SOC)
                        165km travelled, 3.58V min voltage (3.53V under load), (Leafspy 0.0% SOC)
                        205km travelled, 3.37V min voltage (3.30V under load) (Leafspy gave up a long time ago...)

                        I could probably have kept driving until turtle, and waited for the contactors to open, but I really didn't want to strand myself. Taking it slow, it would probably been possible to drive 220-230km on a single charge. I love the 30kWh battery, but the instrumentation needs fixing asap, Half of the range is left after it indicates the first low battery voltage lol!

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                        • #57
                          I have been thinking about shedding some weight of the car. Preferably in places that you won't notice (unless reading it here). The fuse cover is beefy on the leaf, and weighs more than you'd think. You can see in this picture that the casting material is very thick, so I dremeled off half of it. Didn't bother with an after picture, it was quite messy...


                          Speaking about removing stuff, I decided to de-badge the LEAF emblem in the rear


                          Maybe I should remove the 'zero emission' badge aswell?


                          Here's another interesting thing, look at how the Ahr,SOH and HX(internal resistance) has changed over just a few days


                          The LBC is quickly sensing that the new battery is performing great!

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                          • #58
                            Originally posted by Dala View Post
                            Maybe I should remove the 'zero emission' badge aswell?
                            Yes, looks good without the LEAF badge, and I agree it would look even better if you also remove the 'zero emission' badge. it looks a little lopsided now, unfortunately... And perhaps remove the same badges from the doors as well while you're at it?

                            It would give the car an overall cleaner look.
                            Last edited by Kaktus; 10-07-2019, 07:51 PM.

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                            • #59
                              Something that has been bothering me is how the underside of the car looked. The front subframe had some damage that probably came from when it was shipped in a container and strapped down. Two sheetmetal holes on both sides were ripped, so I smacked the metal back into shape with a hammer, and painted over it with some paint so it wont rust prematurely.

                              Second annoying thing is the ripped splashshield. This is an important piece, both for aerodynamic reasons, but it also prevents dirt and slush from being slinged up into the engine bay, and back to the battery pack.


                              I fashioned a temporary fix made out of some leftover plastic, tied it togheter with zipties. I will try to source a proper replacement piece later on, preferably from a used car, since they charge $$$ for a new OEM one.


                              The zero emissions rear badge also went. Looks soo much cleaner!


                              Oh, and someone had a bit of a tumble in Norway last week. You know what this implies...

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                              • #60
                                Looks great with the debadged boot lid!

                                As for the beaten up Norwegian LEAF, are you planning on getting the batteries or something from it? Or perhaps buy it outright and do it up?!?!

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