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Hacking the Nissan Leaf EV

An anonymous reader writes "The New York Times is running a story on people hacking the Nissan Leaf electric vehicle. 'Using Mr. Giddings’s home-brewed E.V. fuel-level display, Leaf drivers get the confidence to extend their driving range by 10 percent or more. His gauge, which displays the actual state of charge, reveals that the Leaf dashboard’s "zero bars" display comes on when the battery pack has several miles remaining.' Here's an interesting quote from one of the hackers, Phil Sadow, who was interviewed for the story: 'I don't like the term hacking because it's been portrayed by the media as something evil. To me, hacking is actually very American. Go out to the garage. Take it apart. Make it better.'"

28 of 199 comments (clear)

  1. Better you say? by BiggerIsBetter · · Score: 4, Insightful

    Perhaps Nissan knows something about their batteries and BMS that he doesn't, and the false zero reading is there to ensure the batteries last as long as they're intended to? Last I heard, you weren't supposed to completely discharge lithium batteries if you wanted to ensure a usefully long service life.

    --
    Forget thrust, drag, lift and weight. Airplanes fly because of money.
    1. Re:Better you say? by queazocotal · · Score: 3, Insightful

      Taking cells all the way to 'zero' in a battery is generally a bad plan, it both stresses the cells more - discharging them at high currents at the very end of the discharge is harsh on them, causes extra wear due to deeper cycle life, and risks overdischarging weaker cells in the battery.

    2. Re:Better you say? by jtownatpunk.net · · Score: 4, Insightful

      It's also probably intended to keep people from running out of juice on the freeway or some other place where it would be dangerous to be unable to move the vehicle. Honestly, if you're down to the last few miles, it's time to recharge.

    3. Re:Better you say? by vadim_t · · Score: 5, Informative

      No, you shouldn't with any kind of modern battery.

      Li-Ion doesn't like full discharges, and in fact the internal circuitry should make it impossible. Lead-acid will very quickly become unusable if left fully discharged. And for battery packs, full discharge risks cell reversal, which causes damage.

      The only case where you should still do that is when there is some sort of internal statistics being kept of how long the battery is estimated to last, which is out of sync with the actual battery.

      That's not for any sort of cleaning though. It's just for fixing incorrect estimations of remaining battery time, which causes devices to turn off too soon, or have them fail to shut down nicely before the battery runs out.

    4. Re:Better you say? by nlogaxx · · Score: 2

      Erroneous. Lithium ion cells do not need to be discharged periodically like NiCd and NiMH rechargable cells. Full discharge and recharge cycles on lithium ion cells only serve to shorten its life.

    5. Re:Better you say? by Fallingwater · · Score: 2

      The only case where you should still do that is when there is some sort of internal statistics being kept of how long the battery is estimated to last, which is out of sync with the actual battery.

      It's worth noting that even in this case, the cells don't actually go to zero - in LiIon batteries, the circuitry cuts out at about 3V per cell. Lower than that, and damage WILL occur.

    6. Re:Better you say? by Zocalo · · Score: 3, Insightful

      I too keep hearing conflicting advice on this, but as far as I can tell the underlying truth is what is indicated in the parent's post.

      I'm looking at a Canon LP-E4 battery (from a 1 series EOS camera) and it definitely says "Li-ion" on it, and I also have the manual for the camera with me. These are quite intelligent batteries, with very accurate charge remaining indictors, etc. Every now and then they indicate the need for a "calibration charge" to ensure accurate battery life indication, and to quote the manual on the process "After the calibration is completed and the battery is totally drained, it will take a further two hours to recharge the battery fully." At a guess, I get this maybe warning once per year, per battery - and perhaps even less frequently than that.

      I've come across this kind of thing on other "high-end" Li-Ion batteries too, including on laptops, a high-end GPS unit and a satellite comms system. I've never seen this kind of thing on cheaper clones, in lower-end devices like phones, or in any other gadgets where the battery might be regarded as disposable once it deteriorates. Unless the battery in question has a means of asking for a calibration charge, or some such, and a charger that has a dedicated mode for doing so, then you should always try and recharge the battery before it fully drains.

      --
      UNIX? They're not even circumcised! Savages!
    7. Re:Better you say? by vlm · · Score: 2

      I've come across this kind of thing on other "high-end" Li-Ion batteries too, including on laptops, a high-end GPS unit and a satellite comms system. I've never seen this kind of thing on cheaper clones, in lower-end devices like phones, or in any other gadgets where the battery might be regarded as disposable once it deteriorates. Unless the battery in question has a means of asking for a calibration charge, or some such, and a charger that has a dedicated mode for doing so, then you should always try and recharge the battery before it fully drains.

      Your perception is its "high end" because it gets you involved in the recalibration process. The cheap ones recalibrate, they just don't let you know, therefore you perceive them as cheaper.

      --
      "Science flies us to the moon. Religion flies us into buildings." - Victor Stenger
    8. Re:Better you say? by Smidge204 · · Score: 2

      This hack doesn't let you use more capacity from the battery. The car WILL NOT LET YOU drive the battery dead - it will shut itself off before you can do any serious damage.

      Instead, this hack gives you useful information about how much charge you actually have left. Okay, you got a "Low Battery" warning and you're 5 miles from home. The range indicator and battery level gauge are both gone. Do you try to make it home and risk getting stuck in the middle of the street, or pull over and call a tow truck now? With the external SOC gauge, you are better informed to make that decision.
      =Smidge=

    9. Re:Better you say? by SuricouRaven · · Score: 2

      That is only true for ni-cad batteries. You don't see many of those today.

    10. Re:Better you say? by Zocalo · · Score: 2

      Not quite, it seems to be purely cost based to me as I've only ever seen the recalibrate process on more expensive, so called "luxury" or "premium" devices. That's not to say that cheaper ones (or more expensive ones that lack an overt process) are not doing something behind the scenes as well, but I think that is actually quite unlikely in most cases.

      It's simple economics; when you are building an expensive device with a reasonable profit margin, then including recalibration circuitry isn't a big deal. When you are designing something on the pile 'em high and sell 'em cheap ethos then margins are much lower and the few bucks extra for the recalibration might make your product more expensive than the competition and result in lost sales.

      Then again, it would be perfectly possible to do it behind the scenes; all it would take is to detect when the calibration is required and then quietly let the battery go completely flat before starting the next recharge. That sounds like a recipe for a poor user experience to me though; imagine your laptop's battery is running low and due a calibration recharge, you put it on charge for an for an hour expecting it to be topped up only to find it's still running low when you power it on...

      --
      UNIX? They're not even circumcised! Savages!
    11. Re:Better you say? by Aqualung812 · · Score: 4, Insightful

      It's simple economics;

      No, it isn't so simple. There are many examples of expensive devices requiring many more manual steps because it gives the perception of value. "Mine requires more work because it is such a precision device" seems to be a very common thing.
      Sometimes, this is a good thing, because it allows for better control by the end user *IF* they know what they're doing. SLR vs point & shoot, for example.
      Other times, it is simply a status thing. For example, I have a solar powered watch that is synced to the atomic clock in Colorado every morning. My watch will always be within 0.5 seconds of actual time. However, a Rolex that costs thousands more doesn't include the solar charging or atomic clock sync will never be as accurate as my watch, and requires more effort. Still, a Rolex has the perception of higher value.

      --
      Grammer Nazis - I mod you "troll" unless you actually add something on-topic. Yes, I know I have mispellings in my sig.
    12. Re:Better you say? by spire3661 · · Score: 2

      http://www.apple.com/batteries/iphone.html

      "Use iPhone Regularly
      For proper maintenance of a lithium-based battery, it’s important to keep the electrons in it moving occasionally. Be sure to go through at least one charge cycle per month (charging the battery to 100% and then completely running it down )."

      "Use Your iPad Regularly
      For proper reporting of the battery’s state of charge, be sure to go through at least one charge cycle per month (charging the battery to 100% and then completely running it down)."

      --
      Good-bye
    13. Re:Better you say? by cffrost · · Score: 2, Funny

      There are women in the world that will possibly fuck you because you have a Rolex.

      If a woman is fucking you because of your Rolex, you're probably getting fucked in more ways than one.

      --
      Thank you, Edward Snowden.

      "Arguments from authority are worthless." —Carl Sagan
    14. Re:Better you say? by ScrewMaster · · Score: 2

      http://www.apple.com/batteries/iphone.html "Use iPhone Regularly For proper maintenance of a lithium-based battery, it’s important to keep the electrons in it moving occasionally. Be sure to go through at least one charge cycle per month (charging the battery to 100% and then completely running it down )." "Use Your iPad Regularly For proper reporting of the battery’s state of charge, be sure to go through at least one charge cycle per month (charging the battery to 100% and then completely running it down)."

      "keep the electrons moving." That is so typical of Apple: dumb things down so even a moron will think he understands it.

      In any event, as another poster pointed out, that has nothing to do with maximizing the longevity of the battery: in fact, it's going to lessen the total number of charge/discharge cycles that you get. I don't know of any chemical system whereby periodic deep cycling is considered good for the cells (even Ni-Cads: the memory effect is real, but you still don't need to deep cycle the things to prevent that.) This is actually a matter of keeping the battery management system in sync with the battery's actual state of charge, to get more run time before the device thinks the battery is almost dead.

      Battery management isn't exactly trivial. It's a hell of a lot easier with a lead-acid battery, since the terminal voltage drops pretty linearly with the state of charge. That's a problem for electronics, since you need a much higher nominal voltage than you actually need and have to regulate it down, or must use a DC-DC converter to maintain a minimum level after the terminal voltage drops below what your equipment needs. Still, it's pretty straightforward to determine how much charge is left.

      It's much more complicated with nickel-cadmium, nickel-metal-hydride or lithium-ion cells, since they do not have a linear discharge curve. Ni-Cads, for example, remain damn near flat until near the very end, where the voltage drops suddenly to a lower value for a while before going to zero. If you go beyond that "knee", you will likely damage cells (or in the case of a series pack, drive one or more cells into reverse ... bad news.) On the other hand, that flat discharge curve is great for electronic devices since your terminal voltage stays relatively constant. The problem comes in when trying to figure out how much juice you have left: you have to make an estimate of the amount of energy put in during charging, and how much taken out in operation.

      Eventually, your estimate is going to be off. Batteries age and lose capacity, and errors in data acquisition occur. That's a real problem when charging: if you don't know when the pack is fully charged you're going to overcharge it and reduce its lifespan. Consequently, most commercial batteries have a thermistor or other temperature sensor in them which is monitored by battery management: when the battery has reached full charge, any additional charging current comes out as heat. The sudden rise in temperature indicates that the battery is charged.

      --
      The higher the technology, the sharper that two-edged sword.
  2. Re:Atleast he knows what hacking is by Noughmad · · Score: 2, Funny

    Happy hacking - and it's your cars - you are allowed to destroy the batteries.

    Until the iCar appears.

    --
    PlusFive Slashdot reader for Android. Can post comments.
  3. Empty Never Means Empty by Entropy98 · · Score: 2

    Gas powered cars still go many miles after the gas gauge hits empty. A fuel gauge reading empty is suppose to tell you "Fill up as soon as possible" not tell you need to get out and push.

    1. Re:Empty Never Means Empty by vlm · · Score: 3, Informative

      Gas powered cars still go many miles after the gas gauge hits empty. A fuel gauge reading empty is suppose to tell you "Fill up as soon as possible" not tell you need to get out and push.

      Empty means buy a new fuel pump because the old one just sucked up all the water, rust, sand, whatever from the bottom of the tank. Also the in-tank pumps are notorious for overheating and burning out in air/vapor and only running cool when immersed in fuel, so even a perfectly clean tank can burn out the pump if the pump is in an empty tank. Maybe more so in summer than winter... Also if the pump fails after pumping rusty water for awhile rather than instantly, you'll probably end up replacing the fuel filter, maybe the injectors, who knows.

      --
      "Science flies us to the moon. Religion flies us into buildings." - Victor Stenger
  4. Yes, better, not different by dutchwhizzman · · Score: 3, Informative

    It just shows how much of the last bar you still have. Once you go from one bar to zero, you essentially only know you have "less than one bar" left, but not how much. There is no change to how deep the batteries get discharged, you just know better what risk you are taking if you decide to drive on. The TFA also tells about the software "hack" to the 120V charge cable to make it work with 240V as well. That's not so special, considering the same cable is used with different software in Europe, where 240V is the standard. Also improving it to be better, but not different.

    --
    I was promised a flying car. Where is my flying car?
  5. Re:Why is it "american"? by icebraining · · Score: 2

    Jules Verne does just that in From the Earth to the Moon: The Yankees, the first mechanicians in the world, are engineers-- just as the Italians are musicians and the Germans metaphysicians-- by right of birth..

  6. Re:Why is it "american"? by TeknoHog · · Score: 2

    I also failed to understand why "American" is the opposite of "evil". There are many things that are both, and many things that are neither. I understand why the DIY culture is associated with Americans, but then again, so is the consumerist sheeple culture.

    --
    Escher was the first MC and Giger invented the HR department.
  7. Extended range by jamesh · · Score: 2

    If he wants to extend the range, he could try installing one of these...

  8. He is going to regret this shit. by crow_t_robot · · Score: 2

    Bottoming out batteries is absolutely retarded. Even "deep cycle" batteries are only supposed to be discharged to 20% AT THE VERY LOWEST. And doing so reduces the number of cycles by orders of magnitude. Another thing to point out is that batteries become EXTREMELY non-linear in discharge rate at the bottom of their SoC. I like his comment about hacking but everything else is retarded.

    1. Re:He is going to regret this shit. by OnionFighter · · Score: 2

      Deep cycle batteries are a type of lead-acid battery. The Leaf uses lithium-ion batteries, which behave very differently. Still, lithium-ion batteries should never be fully discharged, which may be a risk with his modifications.

      Any program that measures charge is making a educated guess based on the past behavior of the battery. One of the people interviewed for the article states: “Until you can find out how much is really left in the batteries toward the end of its range, it’s just a guess-o-meter.” Any indicator of charge is making a guess. Perhaps his program is better at guessing, or maybe he just leaves less room for battery health, but any program that works to tell lithium-ion battery charge will have to take into account the discharge profile of that battery (which is non-linear when measured by voltage).

  9. Re:Why is it "american"? by vlm · · Score: 3, Interesting

    I'm a bit tired of people claiming that an activity is very american just because the person is from USA and likes it.

    You must be the life of the party when an american brings up the topic of "american football" (as opposed to real football = soccer). I'm from the US, our style of football is somewhat popular here (only around 5% really care, but at least 50% go along to get along with them). So our style of football is very american, oh well.

    The reason for "american DIY culture" is our profoundly anti-business anti-entrepreneur climate. If you own a set of wrenches in Ecuador even if you mostly work on your own vehicles you'll be considered a "pro car mechanic" by an American if you ever help your neighbor change their windshield wiper blades, so an Equadorian (?) in that situation can't be DIY if they're a businessman, so there is no DIY culture in Equador, even if the same percentage of guys are turning wrenches under a shade tree in their backyard... In the US we have a huge quantity of laws and regulations to prevent individual entrepreneurs from competing with the bigger businesses, because those bigger businesses have purchase the govt and "suggested" those laws to the purchased politicians to improve their profits. I can't even begin to imagine the paperwork and financial resources required to let me change my neighbor's oil for a couple bucks... but I can change my own (so far) without too much govt interference, although they're working on it...

    An american DIYer is pretty much just a frustrated entrepreneur. In a better country they're be a very small part time businessman, a dude with a "side job".

    --
    "Science flies us to the moon. Religion flies us into buildings." - Victor Stenger
  10. Lithium batteries, depth of (dis)charge by dr2chase · · Score: 2

    This suggests that there's a lot to be said for not driving your battery charge down to "zero" (as defined by the battery controllers and the 3V limit). You'll get many more cycles if you avoid the extremes (full charge, full discharge).

    http://batteryuniversity.com/learn/article/how_to_prolong_lithium_based_batteries

  11. Re:Why is it "american"? by vlm · · Score: 2

    That said, most/all jurisdictions allow "personal sales" between neighbors, which allow things like changing your neighbor's oil or having your kid mow their lawn or babysitting or whatever. Have you actually looked into this?

    The relevant language in this state is "occasional sales" and it requires a business license/registration, less than 20 days/yr of operation, no other licensing requirements (for example, all car air conditioning work requires a license, therefore all car AC work is sales taxable regardless of other conditions), well under poverty line annual income for the exempted work, can not be promoted as a regular ongoing business but solely as an individual transaction, and can not be the primary occupation / source of income for the business. Basically a lot of legal dancing around so church sponsored yard sales are tax exempt without actually writing "church sponsored yard sales are exempt".

    So, at least for sales tax, I would not be exempt because I do not have a business license in a non-related profitable line of work. If I owned a scrapbooking store, and then I mowed the neighbors lawn, then it would technically be legally exempt IF I document it, etc.

    Note this in no way removes my obligation to pay income tax. (We have a modest rate for both where I live)

    Furthermore if I change oil I have all kinds of crazy federal EPA and state requirements. Not crazy if I deal in thousands of gallons per week of toxic used oil, crazy if I do this "once" for a friend in addition to maintaining my own car.

    Also its illegal to operate a business of any sort on "my" property without a zoning variance. I'm generously allowed 8 rummage/garage sales per year, but no other exemptions. Technically I am zoned to work on my neighbors car in their driveway as a service to them, think of those mobile windshield repair vans or any building contractor, but I could not work on their car in my driveway.

    I paid a lot of extra money to get a non-HOA house, so at least I don't have those little hitlers breathing down my neck, and I have nicer neighbors.

    --
    "Science flies us to the moon. Religion flies us into buildings." - Victor Stenger
  12. Re:Why is it "american"? by swalve · · Score: 2

    Bullshit. Plenty of people in the US have side jobs, and the regulations are pretty much nil for those. Just pay your taxes and don't rip people off. Some regulations kick in once you start hiring people, but those too are pretty much common sense. Pay them fairly, don't put them in danger. The "onerous" regulations that are the darling of the Know Nothings these days don't kick in once someone has certain numbers of employees, and even then, they aren't really all that bad. I mean, what's the big mean ol' government doing that is so bad?