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Difference between revisions of "PiPrius"

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'''Rich Rudman of [http://www.manzanitamicro.com manzanitamicro], and [[User:Rjf|Ryan]]''' are working on a [[Prius PHEV]] implamentation using an upgraded PFC-30 as a DC-DC converter and charger, and Rich is hoping to develop and offer conversion kits.
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Rich Rudman of [[Manzanita Micro]], [[User:Rjf|Ryan]], and [[PriusBlue]], are working on a [[Prius PHEV]] implementation using a [[MM-PFC|PFC40H]], an upgraded PFC30, as a DC-DC converter and charger.
 +
[[Mk 3 Reg]]s are also used to keep the pack healthy and determine when to stop discharging the new pack.
 +
You can find out more about the [[PiPrius conversion process]] with these instructions.
 +
 
 +
'''Converted Vehicles:'''
 +
# 2006 May - [[PriusBlue]] was/is the original testbed for these kits.
 +
# 2006 Oct - [[WhiteBird]] for Chelan County’s [[Advanced Vehicle Innovations Consortium]].
 +
# 2006 Nov - [[GrayPearl]] for Todd Dore's of the Fox Vally EAA.
 +
# 2007 Sep - The [[Green Car Company]] delivered their first conversion to King County.
 +
 
 +
* [http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=260165466473 ebay #260165466473]
 +
 
 +
Some old pages that need to be cleaned up...
 
* [[Prius PHEV#PFC Based]]
 
* [[Prius PHEV#PFC Based]]
 
** [[Prius PHEV Battery Options#PFC Based]]
 
** [[Prius PHEV Battery Options#PFC Based]]
 
** [[State Of Charge Manipulation#PFC Based]]
 
** [[State Of Charge Manipulation#PFC Based]]
 
** [[Prius PHEV Schematics#PFC Based]]
 
** [[Prius PHEV Schematics#PFC Based]]
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 +
Misc development related stuff:
 +
* Good Electrical-Boxes at [http://www.canev.com/KitsComp/Components/Electrical-Boxes.html www.canev.com]
 +
 +
Some EVDL threads
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* 2006.08.17 - [http://autos.groups.yahoo.com/group/ev-list-archive/message/72339 Grants,  Re: Plug in Hybrid retro fits for Prius, Escape wanted for NY state fleet.]
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* 2006.05.31 - [http://autos.groups.yahoo.com/group/ev-list-archive/message/66842 PiPrius ...]
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 +
==Conversion Procedures==
 +
See:
 +
* [[PiPrius conversion process]]
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* [[Prius OEM fan control]]
  
 
==Logs==
 
==Logs==
 +
[[Image:capture0040-41.png|thumb|right|[[:Image:Capture004.zip|Cap0040-41]], 11 miles >99.9 mpg<br>3.44 mi/kWh or 116 [[MPGe]]]]
 +
[[Image:capture0060.png|thumb|right|[[:Image:Capture006.zip|Cap0060]], 28 miles 78.5 mpg<br>1.807 mi/kWh or 61 [[MPGe]]]]
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[[Image:capture0120.png|thumb|right|[[:Image:Capture012.zip|Cap0120]], 22 miles 58 mpg<br>1.446 mi/kWh or 49 [[MPGe]]]]
 +
 +
Current [[CAN-View]] Relay settings, see [[PiPrius conversion process#CAN-View Configuration]]:
 +
: RL2: Low speed HV mode trigger
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: RL3: High speed HV mode trigger
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: RL4: OEM/PHEV selection
 +
: RL5: OEM Battery fan control
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: RL6: Future use for a OEM->PHEV battery regen mode.
 +
:: RL2 ''(Low)'' and RL2 ''(High)'' speed SOC driven relays are connected in parallel to trigger the PFC to enter NiMH High Voltage setpoint (~242V), otherwise PFC is in NiMH Low Voltage setpoint (~228v).
 +
 
[[CAN-View]] Logs from Initial PHEV Test & Tune runs:
 
[[CAN-View]] Logs from Initial PHEV Test & Tune runs:
* 2006.05.27 - [[:Image:Capture001.zip]] 2 short PHEV tests, no relays used, CCL issues, 1 charge.
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* 2006.05.27 - [[:Image:Capture001.zip]] - 2 short PHEV tests, no relays used, CCL issues, 1 charge.
* 2006.05.29 - [[:Image:Capture002.zip]] 4 PHEV tests, SOC relay trigger, 30.2 miles, 3 charges.
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* 2006.05.29 - [[:Image:Capture002.zip]] - 4 PHEV tests, SOC relay trigger, 30.2 miles, 3 charges.
''Each .zip file contains a main description .txt file similar to the comments which describe it.  There are also multiple CAN-View Capture "raw" .txt files and their resultant .csv files.  Each capture file is described with dash miles-mpg|CAN-View Trip screen miles-mpg|CAN-View Ah Count down from 10Ah, a description of the trip, and the ammount of recharge.''
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* 2006.07.15 - [[:Image:Capture003.zip]] - Trip to Manzanita HEV/PHEV mixed-mode
 +
Added LowBatReg, a single MarkIII regulator which communicates with PFC to lower current levels in order to keep ''known'' lowest PbA battery above 10.0v.  Eventually all batteries will have such regulators protecting each from over and under voltage events.  Regs will also enhance the ability to equalize the pack and charge safely without manual monitoring.
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* 2006.07.16 - [[:Image:Capture004.zip]] - 3 short mostly EV-Only trips & a P3000 DTC.
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Restored OEM cooling system to original state, finished testing degraded OEM cooling.
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* 2006.07.17 - [[:Image:Capture005.zip]] - Ryans commute, and repeat of Cap004.
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* 2006.07.18 - [[:Image:Capture006.zip]] - Ryans commute, much improved performance on return trip.
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* 2006.07.19 - [[:Image:Capture007.zip]] - Ryans commute.
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* 2006.07.20 - [[:Image:Capture008.zip]] - Ryans commute.
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* 2006.07.23 - [[:Image:Capture009.zip]] - Four consecutive tanks during a road trip.
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* 2006.09.16 - [[:Image:Capture010.zip]] - Pair of Mixed mode trips.
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* 2006.09.17 - [[:Image:Capture011.zip]] - Short low speed trip.
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* 2006.10.02 - [[:Image:Capture012.zip]] - Trip with new relay box, colder weather.
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* 2006.11.22 - [[:Image:Capture013.zip]] - Trip from work to apt, need to up NiMH-HighV setpoint to ~240v.
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* 2006.11.26 - [[:Image:Capture014.zip]] - Testing with current through OEM HAL sensor, got DTC's @ .95 miles.
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* See also [[PriusBlue Mileage]] & [[Image:PriusBlueMileage.zip]] spreadsheets for more trip data and details.
 +
 
 +
''Each .zip file contains a main description .txt file similar to the comments which describe it.  There are also multiple CAN-View Capture "raw" .txt files and their resultant .csv files.  Each capture file is described with dash miles-mpg|CAN-View Trip screen miles-mpg|CAN-View Ah Count down from 10Ah, a description of the trip, and the amount of recharge.''
  
 
==Photos==
 
==Photos==
 +
More photos at:
 +
* [[WhiteBird#Photos]]
 +
* [[GrayPearl#Photos]]
 
<gallery>
 
<gallery>
 
Image:100 1332.JPG|Battery Layout for [[PiPrius]]
 
Image:100 1332.JPG|Battery Layout for [[PiPrius]]
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Image:100 1379.JPG|Other end of CAN-View relays # 2-6
 
Image:100 1379.JPG|Other end of CAN-View relays # 2-6
 
Image:100 1381.JPG|Other end of CAN-View relays # 2-6 (closeup)
 
Image:100 1381.JPG|Other end of CAN-View relays # 2-6 (closeup)
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Image:100 1438.JPG|Dry fitting early battery box
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Image:100 1439.JPG|Battery box and [[MM-PFC]]
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Image:100 1440.JPG|Will hold 15 Hawker EP26 or Areo AB26's
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Image:100 1441.JPG|1 of 3 rails shown which will house battery regs.
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Image:100 1442.JPG|OEM HV tie-in.
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Image:DSC00062.JPG|An early plastic version of the interlock box
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Image:DSC00238.JPG|Fitted aluminum cubby area interlock box
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Image:DSC00343.JPG|Modular interlock box (far left)
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Image:DSC00338.JPG|Tray with regulators for modular battery bank
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Image:DSC00341.JPG|Tray with regulators for modular battery bank
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Image:DSC00353.JPG|Modular battery box with cover (24 batteries)
 
</gallery>
 
</gallery>
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 +
==References==
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<references/>
 +
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[[Category:PHEV]]
 +
[[Category:Prius]]
 +
[[Category:PiPrius]]

Latest revision as of 13:10, 14 June 2020

Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.

For Prius conversion details see the Prius PHEV article and comparisons table.

  1. Ron's Original PriusPlus History and current Contactor Based PriusPlus documentation for DIY projects.
  2. Ryan's PriusBlue is the testbed for DC-DC PFC Based PiPrius kits and documentation for DIY projects.
  3. Toyota OEM Prius PHEV and Prime Could use some work on this page
  4. Enginer China. But the rest of these appear to all be defunct as of 2020?
  5. |~- Hybrids-Plus USA/Colorado/Li -~|~- EnergyCS USA -~|~- Hymotion USA/Canada -~|~- Amberjac UK. -~|~- EDrive USA -~| Peter mentioned Plug-In Conversions |~-

--={ PiPrius }={ Process }={ fan control }={ Manzanita Micro }={ MM-PFC }={ Mk 3 Reg }=--
--={ PriusBlue }={ Maker Faire }={ Photos }={ EVents }={ 2006 mpg }={ 2005 mpg }=--
--={ CAN-View }={ Schematics }={ User Interfaces }={ Battery Options }={ TechInfo }=--

--={ More Vehicles: AVI }={ WhiteBird }={ GrayPearl }={ GreenCarCo }=--

Team Photo from the PriusPlus conversion of Sven's Prius from Nov 2006.
  • Add a new thumbnail for PirusBlue and other cars?

Rich Rudman of Manzanita Micro, Ryan, and PriusBlue, are working on a Prius PHEV implementation using a PFC40H, an upgraded PFC30, as a DC-DC converter and charger. Mk 3 Regs are also used to keep the pack healthy and determine when to stop discharging the new pack. You can find out more about the PiPrius conversion process with these instructions.

Converted Vehicles:

  1. 2006 May - PriusBlue was/is the original testbed for these kits.
  2. 2006 Oct - WhiteBird for Chelan County’s Advanced Vehicle Innovations Consortium.
  3. 2006 Nov - GrayPearl for Todd Dore's of the Fox Vally EAA.
  4. 2007 Sep - The Green Car Company delivered their first conversion to King County.

Some old pages that need to be cleaned up...

Misc development related stuff:

Some EVDL threads

Conversion Procedures

See:

Logs

Cap0040-41, 11 miles >99.9 mpg
3.44 mi/kWh or 116 MPGe
Cap0060, 28 miles 78.5 mpg
1.807 mi/kWh or 61 MPGe
Cap0120, 22 miles 58 mpg
1.446 mi/kWh or 49 MPGe

Current CAN-View Relay settings, see PiPrius conversion process#CAN-View Configuration:

RL2: Low speed HV mode trigger
RL3: High speed HV mode trigger
RL4: OEM/PHEV selection
RL5: OEM Battery fan control
RL6: Future use for a OEM->PHEV battery regen mode.
RL2 (Low) and RL2 (High) speed SOC driven relays are connected in parallel to trigger the PFC to enter NiMH High Voltage setpoint (~242V), otherwise PFC is in NiMH Low Voltage setpoint (~228v).

CAN-View Logs from Initial PHEV Test & Tune runs:

Added LowBatReg, a single MarkIII regulator which communicates with PFC to lower current levels in order to keep known lowest PbA battery above 10.0v. Eventually all batteries will have such regulators protecting each from over and under voltage events. Regs will also enhance the ability to equalize the pack and charge safely without manual monitoring.

Restored OEM cooling system to original state, finished testing degraded OEM cooling.

Each .zip file contains a main description .txt file similar to the comments which describe it. There are also multiple CAN-View Capture "raw" .txt files and their resultant .csv files. Each capture file is described with dash miles-mpg|CAN-View Trip screen miles-mpg|CAN-View Ah Count down from 10Ah, a description of the trip, and the amount of recharge.

Photos

More photos at:

References

<references/>