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Difference between revisions of "Conversion Interest"

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Per [[EAA-PHEV_Maillist:2006./7./5]] or [http://autos.groups.yahoo.com/group/eaa-phev/message/333 Y!]
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'''Please see the current state of documentation and questions at [[PriusPlus]]; and discussion at [[Talk:PriusPlus]].'''
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''Per [http://autos.groups.yahoo.com/group/eaa-phev/message/448 eaa-phev maillist 'Conversion instructions' message of 10/18/2006]''
  
 
Request for Show of Interest in Converting Prius to PHEV Instructions
 
Request for Show of Interest in Converting Prius to PHEV Instructions
  
Calcars, in collaboration with the EAA’s Eaa-Phev SIG,  intends to assemble and
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Please respond directly to [mailto:tdriscoll@calcars.org tdriscoll@calcars.org] by copying these questions into your message and adding your answer after each oneAny response is not a commitment to buy anything, or an order, but a way to help us make it easy for you by helping determine how far to go in having components made.
publish public domain instructions for converting a 2004-5 Prius* into a PRIUS+
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We want to know from the converters the following:
plug-in hybrid.  The first versions of this conversion will use 20 BB Battery
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EVP20-12B1 AGM PbA batteries
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:1. How definite are you about doing a conversion with our open source plans?
(http://www.electricrider.com/batteries/specsheets/evp20-12.pdf), along with the
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OEM hybrid battery, because of their cost and easy availabilityThey will
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:2. What is your timeframe?
provide a 10+ mile pure electric range in EV-only mode (at up to 34 mph), or  
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assist the ICE for the first 20+ miles of  mixed driving at around double the  
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:3. What fabricated components or assemblies are you interested in buying, at the following estimated prices?
Prius’ normal mileage. This battery pack costs about $800 and can be expected
 
to deliver 200-400 full (80% DOD) cycles. The added weight is around 300 lbs,
 
which existing conversions have been handling without upgraded springs. We
 
aren’t removing the OEM battery or changing the HSD system, but the spare tire
 
space will not be accessible.
 
  
A li-ion and/or NiMH battery pack may become available within a year, probably
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::{| border=1 cellpadding=2 |
capable of 20-25 EV-only miles, weighing 100-200 lb, lasting 2000-4000 cycles,
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| colspan=2 |
and selling for in the ballpark of $6000.  Such a pack should be retrofitable
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Estimated Fabrication Costs
into either version (below) of the conversion.
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|-
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| Assembled and tested circuit board || $250-500
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|-
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| Battery tray (4 needed) || $150-250
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|-
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| Battery box top || $150-200
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|-
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| Battery box foundation || $150-200
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|-
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| Electronics tray, assembled and wired || $500-1K
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|-
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| Set of pre-built battery cables || $150-200
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|-
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| Pre-built low-power wiring harness || $150-300
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|-
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| Total (including 4 trays) || $1950-2500
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|}
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These are estimates for the labor only; approximate components costs are at [http://www.eaa-phev.org/wiki/PriusPlus#Parts_availability PriusPlus#Parts_availability].
  
Two versions, both with similar performance and using Hybrid Interfaces’
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:4. Are you interested in becoming a fabricator and/or kit supplier?
CAN-View device (http://www.hybridinterfaces.ca), are anticipated:
 
* The first version is the cheapest, using contactors and a homemade wirewound power resistor for control of the current between the OEM and PHEV battery, and a Delta-Q (http://www.delta-q.com/products/quiq.shtml) overnight charger.
 
* In the second, more sophisticated, version, the Delta-Q charger is replaced with a high-power (PFC-40) charger from Manzanita Micro (http://manzanitamicro.com/chargers3.htm), which doubles as a DC:DC converter, used, in place of the resistor, to more carefully control current into and out of the PHEV battery while driving.
 
  
The total cost in materials (all commonly available), including batteries, is
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This question applies to for-profit businesses (we know of one or two who may be interested) as well as to individuals.
around $3,000 for the resistor/Delta-Q version or $4500 for the Manzanita Micro
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::a. Are you interested in fabricating subassemblies? If so, which ones?
versionThe time for two skilled people to assemble and install it (not
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::b. Are you interested in assembling components into full or partial kits?
including gathering parts) is probably at least 80 hours, though this is bound
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::c. Would you be interested in organizing the orders? We need a volunteer or for-profit business to organize this process of deciding what the interest is, what can be economically be built given that interest, who will do it; then how to commission, order, pay for, collect, store, and deliver the parts and subassemblies.
to decrease if and when kits become available with all parts included and some
 
of the pieces pre-cut and drilled. A printed circuit board is anticipated
 
becoming available either for a modest donation to Calcars or from a third
 
party.  That board is being designed to be usable with various battery packs
 
and modifications. EXPERIENCE IN SAFELY WORKING WITH HIGH VOLTAGES IS MANDATORY. 
 
If you do not have this experience yourself, hire an electrician.
 
  
These changes will void Toyota’s warranty on affected components (no doubt the
 
OEM hybrid battery and battery management computer; anything else is debatable). 
 
A modified Prius will operate as before the conversion when the PHEV battery
 
pack is depleted.  Slightly higher mileage than before is even possible despite
 
the extra weight, due to the decreased internal resistance and larger capacity
 
of the then-paralleled battery packs.
 
  
It will be valuable for us to learn how many DIYers actually intend to convert a
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== References ==
Prius into a PRIUS+ using the plans we are currently working on.  Therefore,
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<references/>
please send me an email if you do intend to do so.  Include answers to the
 
following questions:
 
# Do you already have a 2004-5 Prius available to convert?
 
# If not, do you have or expect to get 2006 Prius that you would like to convert?
 
# If a conversion kit -- probably costing a little more than the retail parts costs but saving much parts-gathering and some assembly time -- becomes available, would you buy it?
 
# When do you plan to begin your conversion, once the plans or a kit is available?
 
# If an NiMH or li-ion battery pack, as described above, were to become available, how much would you be willing to pay for it (in place of the $800 PbA pack)?
 
  
To respond, PLEASE DO NOT USE YOUR “Reply” BUTTON OR LINK, which will direct
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{{Disclaimer}}
your response to the whole internet group!  Instead, please mail to: 
 
[mailto://tdriscoll@calcars.org tdriscoll@calcars.org].
 
  
* The 2006 Prius’ multi-function display is incompatible with the
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<br><br><br><br><br><br><br><br><br><br>
current CAN-View electronics that is used in this conversion.  This
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<br><br><br><br><br><br><br><br><br><br>
limitation may be eliminated in the future.  If you are interested in
 
converting a 2006 Prius, please let us know so we can asses this demand.
 
  
 
[[Category:Prius]]
 
[[Category:Prius]]
 
[[Category:PHEV]]
 
[[Category:PHEV]]
[[Category:Prius PHEV]]
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[[Category:CalCars]]
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[[Category:PriusPlus]]

Revision as of 08:53, 9 October 2007

Please see the current state of documentation and questions at PriusPlus; and discussion at Talk:PriusPlus.


Per eaa-phev maillist 'Conversion instructions' message of 10/18/2006

Request for Show of Interest in Converting Prius to PHEV Instructions

Please respond directly to tdriscoll@calcars.org by copying these questions into your message and adding your answer after each one. Any response is not a commitment to buy anything, or an order, but a way to help us make it easy for you by helping determine how far to go in having components made. We want to know from the converters the following:

1. How definite are you about doing a conversion with our open source plans?
2. What is your timeframe?
3. What fabricated components or assemblies are you interested in buying, at the following estimated prices?

Estimated Fabrication Costs

Assembled and tested circuit board $250-500
Battery tray (4 needed) $150-250
Battery box top $150-200
Battery box foundation $150-200
Electronics tray, assembled and wired $500-1K
Set of pre-built battery cables $150-200
Pre-built low-power wiring harness $150-300
Total (including 4 trays) $1950-2500

These are estimates for the labor only; approximate components costs are at PriusPlus#Parts_availability.

4. Are you interested in becoming a fabricator and/or kit supplier?

This question applies to for-profit businesses (we know of one or two who may be interested) as well as to individuals.

a. Are you interested in fabricating subassemblies? If so, which ones?
b. Are you interested in assembling components into full or partial kits?
c. Would you be interested in organizing the orders? We need a volunteer or for-profit business to organize this process of deciding what the interest is, what can be economically be built given that interest, who will do it; then how to commission, order, pay for, collect, store, and deliver the parts and subassemblies.


References

<references/>

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General disclaimer