Drive Flange and speed sensor

Thanks to Geoff O'Toole for your fantastic machine work.

Here is a photo of the drive flange assembled with the inductive pickup (AE1-AP-4A) from AutomationDirect.com.au.

The speed sensor is used to provide feedback to the controller for closed loop operation.

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The Drive Flange has been machined, drilled and tapped to accept a Hilux universal joint.

Brake Vacuum Pump and Manifold complete

The brake vacuum pump and associated fittings are installed.

The pump is quite quiet. At higher vacuum the vibration is less.

From left to right:

1. T goes to brake booster and to the vacuum tank. (Aluminium drink bottle from Katmandu)
2. T and vacuum cutoff swithch
3. T and vacuum gauge
4. One way valve
5. Vacuum pump.

I bought the brass fittings (5/16") from ENZED

Throttle Pot Installation

On the weekend I installed the throttle pot.

I fabricated what was needed from scrap aluminium. All in all I am happy with how it turned out. Placement in the engine bay is a little awkward due to the limited length and the stiffness of the cable.



The rubber dust boot should be pushed back over the cable shroud.

12 Volt Power Requirements

The maximum 12V power requirement for the vehicle is just under 50A. After replacing the bulbs with LEDs this will be reduced significantly.

Power Requirements:
Accessory	Current Draw		Include in Max total
	Incadessent	LED
Brake	3.2		x
Fan 1	2.7
Fan 2	4.2
Fan 3	6.9
Fan 4	12		x
Idicator L	4.5
Indicator R	4.2
Hazzard	8.9		x
Park	3		x
Headligh L	12.1
Headligh H	13.4		x
Wiper L	3.3
Wiper H	5.5		x
Demister	0.2		x	Faulty
Dome Light	0			Needs Bulb
Total Draw Amps			46.2

12 volt charger mods.

I am using 2 x 'off the shelf' 230v to 12 volt 25A switch mode power supplies for my 12 volt system. One is powered from 0 to +300v and the other from 0v to -300v respectively.

As a consequence 2 modifications were required.

1. The feedback circuit needed changing to increase the adjustable output to 13.8V. This was done by tracing the voltage divider circuit and adding the required resistor in parallel with an existing resistor.

2. The 20 ohm bleed resistor needed removing in order for it not to discharge the battery while the vehicle is not being driven.

The image below shows the modifications. (zoom in for detail)

The completed power supplies have been installed into the Variable Speed Drive where some of the AC filter components have been removed. The device between the power supplies is a 50A circuit breaker that will be used for the 12V protection. The Power supplies will be wired in parallel.

The maximum 12V power requirement for the vehicle is just under 50A. After replacing the bulbs with LEDs this will be reduced significantly.

Speedo

I have been browsing the workshop manual for a 93 Hilux / Tacoma and checked the vehicle and it has an electronic speedo. This is brilliant because I wont have to retrofit one.

The speedo just requires a 4 pulse per revolution input from the shaft.

There is a pulse output from the Danfoss VFD that is programmable. I will also be able to adjust the VFD output to compensate for the change in differential ratio.

This setup will require that I use closed loop control to have an accurate speedo.