As mentioned elsewhere, I'm also following this project with much interest. Although I'm doing a conversion using Leaf parts, I'm currently retaining the complete Leaf control system. That might make an interesting test bed to see whether this kind of upgraded inverter could eventually be retrofitted back into a stock Leaf. I would think the main difference from a non-Leaf application would be making the controller talk and respond to Leaf CAN messages. That's not trivial perhaps, but seems like it should be doable.
From a quick look at the service manuals, the basic messages seem to be:
Inverter->VCM
- HV power supply preperation complete (condensor charged, VCM can close Main Contactors and turn off pre-charge)
- HV discharge permit (ready to power down?)
- Motor Speed signal
- Motor Torque Limit (derived from conditions like IGBT Temps, Cap Temps, Motor Temps, etc)
- Motor Temp High (power limited)
- Voltage Low (<240V) (power limited)
- DTC Detected (various failsafe conditions)
VCM->Inverter
- Target motor torque (positive or negative I believe for drive / regen)
- Pulse signal off
- HV supply status
- System cut off
- Vibration control switching
- Motor charge preparation request
- Motor discharge request
- Regenerative torque command signal (so maybe not same as negative target torque?)
- Shift Position
ESC->Inverter
- Shift Position
There's already considerable evidence that both the Leaf battery and motor are capable of much more than what they do in the stock configuration. The motor appears to be rated to operate continuously at the 80kW output that is the max in the Leaf. As I understand peak ratings for short duration are often 2-3X continuous rating. The batteries have also been characterized as having ~44V droop at 600A, which is not bad at almost 3X the max current in the stock configuration.
There might be other complications, with other controllers complaining about excessive current draw, or just not ever requesting more than stock torque, or the larger voltage droop freaking the SOC calibration, etc. And as with any performance enhancements, there would likely be impacts on reliability and longevity. Still, pretty interesting possibility
Rob