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(rv, if they weren't from the faire, at least move them into another section.)
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{{PriusPlus-Doc_Process}}
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{{PriusPlus-Doc_Process|mw-collapsed}}{{TOCright}}
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This page houses all raw reference materials and other data which have been uploaded to incorporate into documentation on the other pages.
{{TOCright}}
 
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This page houses all raw materials which have been uploaded for various people to work with and incorporate into documentation on the other pages. Add new documents to the list below and organize them if at all possible.
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==Specifications==
 +
The following two Excel files are specifications that I (Ron Gremban) wrote and copyrighted in early 2007, then placed into the public domain by publishing (including an appropriate copyright license message) on the eaa-phev maillist on Aug 6, 2007 ([http://autos.groups.yahoo.com/group/eaa-phev/message/1119 message 1119]).
  
Image files can be easily linked to by placing a ":" after the "<nowiki>[[</nowiki>", otherwise the image will be shown. If you want the image to appear then after the images name add "|thumb" to create a thumbnail for it, use "|200px" to specify a size other than the default, and use "|caption text" to describe the image as the last element before the closing "]]".
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[http://www.forsites.com/CalCars/EAA-PHEV/ControlSwSpecs_v01_20070128_rdg.xls ControlSwSpecs_v01_20070128_rdg.xls]
  
Other non-image files such as .pdf, .doc, .xls, .etc can be linked to with the same "<nowiki>[[</nowiki>Image:" type link or with a <nowiki>[[</nowiki>Media:" link. The :Image link will take you to the files page with a description of the file, list of pages on which it's used, and of course a link to the file itself. The Media link will instead take you directly to that file without visiting the files page first. See some examples in the "Intro Editing Help" section below.
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[http://www.forsites.com/CalCars/EAA-PHEV/TestSpec_v01_20070407rdg.xls TestSpec_v01_20070407rdg.xls]
  
==Files==
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The software specification is a complete specification for software to control a PRIUS+ conversion from data read from the CAN bus using the best algorithms I had developed up to January 28, 2007.  Since then, Chris Ewert, myself, and others have further refined the algorithms to handle special cases such as extreme temperatures and speeds just slightly above 34 mph.
Here are the files that are available thus far.
 
  
===Schematics===
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The test specification, written April 7, 2007, is a basic ordered list of tests that would be good to follow as part of completing and validating a PRIUS+ conversion.
* High Power [[:Image:EAA-PHEV-PRIUS-HighPowerSchematic.png]][[Image:EAA-PHEV-PRIUS-HighPowerSchematic.png|25px]]
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* Control Board [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.png]][[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|25px]]
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==Schematics==
** Control Board [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.zip]] schematic created in [http://www.expresspcb.com ExpressSCH].
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These are preview images of various schematics, click on the thumbnails for a larger preview and to download the full sized images. You will also find links to .zips of the original [http://www.expresspcb.com ExpressSCH] schematics from which these images were produced.
** Control Board [[:Image:EAA-PHEV-PRIUS-ControlBdPartsList.zip]] exported parts list from schematic in Excel format, also includes LED Board.
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** [[Template:EAA-PHEV-PRIUS-ControlBdPartsList]] use ''<nowiki>{{EAA-PHEV-PRIUS-ControlBdPartsList}}</nowiki>'' to include in a page.
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[[Image:EAA-PHEV-PRIUS-HighPowerSchematic.png|thumb|left|400px|Preview of High Power Schematics]]
* LED Board [[:Image:EAA-PHEV-PRIUS-LEDBdSchematic.png]][[Image:EAA-PHEV-PRIUS-LEDBdSchematic.png|25px]]
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** LED Board [[:Image:EAA-PHEV-PRIUS-LEDBdSchematic.zip]] schematic created in [http://www.expresspcb.com ExpressSCH].
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[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|thumb|left|400px|Preview of Control Board Schematics [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.zip|EAA-PHEV-PRIUS-ControlBdSchematic.zip]] schematic created in [http://www.expresspcb.com ExpressSCH].]]
** LED Board '''Now combined into [[:Image:EAA-PHEV-PRIUS-ControlBdPartsList.zip|ControlBdPartsList.zip]] above.'''
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 +
[[Image:EAA-PHEV-PRIUS-LEDBdSchematic.png|thumb|left|400px|Preview of LED Board Schematics [[:Image:EAA-PHEV-PRIUS-LEDBdSchematic.zip|EAA-PHEV-PRIUS-LEDBdSchematic.zip]] schematic created in [http://www.expresspcb.com ExpressSCH].]]
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{{Clear}}
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 +
===Battery Box Designs===
 +
See the following for designs for a hinged battery box:
 +
 
 +
* [[Image:076610.1004-PP2-1.PDF]] - assembled view
 +
* [[Image:076610.2039-pp2.pdf]] - Bottom Plate
 +
* [[Image:076610.2040-PP2.pdf]] - Side Panel, Right
 +
* [[Image:076610.2041-PP2.pdf]] - Side Panel, Left
 +
* [[Image:076610.2042-pp2.pdf]] - Top Cover
  
 
===Photos===
 
===Photos===
Line 58: Line 67:
 
Image:P10386.JPG|Electronics housing semi-populated.
 
Image:P10386.JPG|Electronics housing semi-populated.
 
Image:P10387.JPG|Electronics housing semi-populated.
 
Image:P10387.JPG|Electronics housing semi-populated.
Image:P10393.JPG|Wire Taps into OEM contactor controls.
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Image:P10393.JPG|Wire Taps into OEM battery fan controls.
Image:P10394.JPG|Wire Taps into OEM contactor controls.
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Image:P10394.JPG|Wire Taps into OEM battery fan controls.
  
 
Image:P10380.JPG|Electronics housing (front).
 
Image:P10380.JPG|Electronics housing (front).
Line 86: Line 95:
 
Image:P10402.JPG|Ah Meter.
 
Image:P10402.JPG|Ah Meter.
  
Image:P10405.JPG|Electronics Board.
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Image:P10405.JPG|Old Electronics Board.
Image:P10406.JPG|Electronics Board.
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Image:P10406.JPG|Old Electronics Board.
Image:P10407.JPG|Electronics Board.
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Image:P10407.JPG|Old Electronics Board.
Image:P10408.JPG|Electronics Board.
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Image:P10408.JPG|Old Electronics Board.
  
 
Image:P10404.JPG|Inside corner of battery box top.
 
Image:P10404.JPG|Inside corner of battery box top.
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<!-- These are photos provided by Felix of [http://www.calcars.org CalCars.org]. -->
 
<!-- These are photos provided by Felix of [http://www.calcars.org CalCars.org]. -->
Image:IMG 1171.jpg|The Make Faire team: left to right, Ron Gremban, Jim Bernard, Carolyn Coquillete, Chris Ewert, Walt Ferris , Nick Rothman, Cody Philippi, Robb Protheroe, Tom Driscoll, Felix Kramer, Jim Philippi. Not shown: Randy Reisinger, Ailian Chong, Amanda Kovattana, Marc Geller, Fraser Smith.
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Image:IMG 1171.jpg|The Make Faire team: left to right, Ron Gremban, Jim Bernard, Carolyn Coquillete, Chris Ewert, Walt Ferris , Nick Rothman, Cody Jackson, Robb Protheroe, Tom Driscoll, Felix Kramer, Jim Philippi. Not shown: Randy Reisinger, Ailian Chong, Amanda Kovattana, Marc Geller, Fraser Smith.
 
Image:IMG 1179.jpg|Outside the building, at the main entrance to Maker Faire,  the team posed Ron's car (world's first Prius conversion) and Felix's car (with Valence lithium-ion batteries)
 
Image:IMG 1179.jpg|Outside the building, at the main entrance to Maker Faire,  the team posed Ron's car (world's first Prius conversion) and Felix's car (with Valence lithium-ion batteries)
 
Image:IMG 1154 2.jpg|Applying the vinyl lettering to Jim's car.
 
Image:IMG 1154 2.jpg|Applying the vinyl lettering to Jim's car.
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</gallery>
 
</gallery>
  
====Alternative Mounting Method====
 
This is very much a work-in-progress.  There may be unresolved design flaws with this method.  More details and photos to follow.
 
  
The battery box can optionally be mounted forward and lower which allows more components to be installed in the spare tire well, maximizing usable trunk space.  The charger can be located below the battery pack, and the electronics and electrical wiring are lowered and partially under the battery pack.  This method allows the conversion to be completely below the false floor and may also provide some benefit for stability and/or safety. 
 
  
The four battery trays are assembled the same way as on the [[PriusPlus-Mechanical]] page.  The trays are supported by 4 aluminum angle irons which sit on rubber mounts that sit directly on the steel trunk of the Prius.  The supports are held in place by 2 steel angle irons bolted (or welded) to the trunk and 2 brackets anchoring into the OEM battery supports. 
 
  
# 2 modified I-beam hangers (normally used for mounting electrical conduits to I-beams) are modified and bolted onto the supports for the battery box and both hold the forward most support angle iron in place (does not hold weight) and provides a bolt down point for the top of the battery box.
 
# All support angle irons are offset from the trunk of the car by rubber pads (about 1/4 inch thick)
 
# One of the pegs for mounting the OEM SmartKey sensor in the trunk can also be used to hold the forward most support angle in place.
 
# The middle 2 angles are bolted together on the ends and in the middle and are held in place by bolts from the battery box top.
 
# The rear most support angle is mounted by 2 1 1/2 inch steel angle irons welded to the trunk.  Holes are drilled on the outside of where the trays sit and are bolted through the angle iron and the aluminum angle iron on both sides.
 
# Steel angle irons with a hole and a bolt welded (or bolted) to one side are used to provide mounting points for the battery box top.
 
# Battery box top bolts down into steel angle irons which are bolted onto the support angle irons.  Front battery box top bolts down into modified I-beam hangers.
 
 
OEM battery support bolts are metric 8mm diameter, 1.25 thread bolts.  A bolt with a 30mm length seems to be the ideal length for a replacement.  The OEM bolts appear to be about 20mm in length.
 
 
The battery box cannot block easy access to the OEM orange emergency disconnect.
 
 
====Older PriusPlus Images====
 
Coming soon some photos from Rons original [[PriusPlus History]] conversion which may still be applicable to this project...
 
  
 
===General Reference Materials===
 
===General Reference Materials===
 
These are some other General Reference Materials we use elsewhere on the site.  This is also an example of how to use references within the page text.  See [[PiPrius conversion process]] for another example of a page with multiple reference tages.   
 
These are some other General Reference Materials we use elsewhere on the site.  This is also an example of how to use references within the page text.  See [[PiPrius conversion process]] for another example of a page with multiple reference tages.   
  
* Prius Dismantle Manual <ref>[[Media:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref>
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* Prius Dismantle Manual <ref>[[Image:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref>
  
* Stereo Installation, Dash Dismantle <ref>[[Media:Stereo Accessory Install Guide 04 Prius v1.03.pdf]] from http://www.chrisdragon.com/downloads/Stereo%20Accessory%20Install%20Guide,%2004%20Prius,%20v1.03.pdf</ref>  
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* Stereo Installation, Dash Dismantle <ref>[[Image:Stereo Accessory Install Guide 04 Prius v1.03.pdf]] from [http://web.archive.org/web/*/http://www.chrisdragon.com/downloads/Stereo%2520Accessory%2520Install%2520Guide,%252004%2520Prius,%2520v1.03.pdf http://www.chrisdragon.com]</ref>  
  
* Stereo Installation, Dash Dismantle <ref>[[Media:PriusXMradio3.2.pdf]] from https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf</ref>
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* Stereo Installation, Dash Dismantle <ref>[[Image:PriusXMradio3.2.pdf]] from https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf</ref>
  
* [[CAN-View]] install without Nav <ref>[[Media:CAN-View installNONAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installNONAV.html</ref>
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* [[CAN-View]] install without Nav <ref>[[Image:CAN-View installNONAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installNONAV.html</ref>
  
* [[CAN-View]] install with Nav <ref>[[Media:CAN-View installWNAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installWNAV.html</ref>
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* [[CAN-View]] install with Nav <ref>[[Image:CAN-View installWNAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installWNAV.html</ref>
  
* [[Prius EV Mode Button]] Installation <ref>[[Media:Prius-evbutton-install.pdf]] from http://www.calcars.org/prius-evbutton-install.pdf</ref>
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* [[Prius EV Mode Button]] Installation <ref>[[Image:Prius-evbutton-install.pdf]] from http://www.calcars.org/prius-evbutton-install.pdf</ref>
  
* Factory EV Mode Button <ref>[[Media:FactoryEV.pdf]] from http://www.scubadivervideo.com/Files/factoryEV.pdf</ref>
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* Factory EV Mode Button <ref>[[Image:FactoryEV.pdf]] from http://www.scubadivervideo.com/Files/factoryEV.pdf</ref>
  
 
You should be familiar with these reference materials and standard operating procedures around high voltages.
 
You should be familiar with these reference materials and standard operating procedures around high voltages.
 
<references/>
 
<references/>
 
===ToDo===
 
Stuff to be imported/uploaded:
 
  
 
==Intro Editing Help==
 
==Intro Editing Help==
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{{Clear}}
 
{{Clear}}
 
====Raw Large====
 
* The raw image will be shown in a large size so probably shouldn't be used within a document like this.  Rather visitors should click on a smaller image, thumbnail, or link to see the Images page, from there they can use a link to get the fill sized original image. [[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png]]
 
 
===General Help===
 
 
Intro Paragraph here maybe with a link to the main [[PriusPlus]] article, links to external sites can appear as formatted [http://www.calcars.com CalCars], just plain URLs like http://www.calcars.com, or fancy references such as that in the next paragraph.
 
 
Another Paragraph and such, you can get help at our [[Help:Contents#How do I use the Wiki Website]] page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref>  Feel free to simply remove or if you like move all of this example text to the pages discussion article.
 
 
==A Major Topic==
 
Talking about the major topic.
 
 
===Sub Topic===
 
Yes, this is a sub topic
 
 
===Sub Topic number two===
 
You guessed it, another sub topic.
 
  
 
==References==
 
==References==
 
<references/>
 
<references/>
 +
 +
[[Category:PHEV]]
 +
[[Category:Prius]]
 +
[[Category:PriusPlus]]
 +
[[Category:CalCars]]

Latest revision as of 12:06, 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 |~-

--={ Project Overview }={ 2007 Maker Faire }={ Theory }={ Instructions }={ Parts List }={ RawData }={ Latest News }=--
--={ Doc Process }={ Mechanical }={ Electrical }={ Electronic }={ Interest }={ Talk:PriusPlus Main Discussion }=--

--={ Historic }={ Battery }={ Schematics }={ PseudoCode }={ Photos }=--

Team Photo from the PriusPlus conversion of Sven's Prius from Nov 2006.

This is the home of the PRIUS+ PHEV DIY (Do-it-Yourself) documentation. These pages are currently anonymously editable, which may change in the future. Please feel free to use the Discussion page for general discussion and commentary on the main article. If you would like to add to an existing section use the "edit" link near that topic's heading. Don't forget to use the Summary field to describe your changes. While editing use the "Show Preview" button to make sure your changes look like you expect them to, before you click "Save Page".

This page houses all raw reference materials and other data which have been uploaded to incorporate into documentation on the other pages.

Specifications

The following two Excel files are specifications that I (Ron Gremban) wrote and copyrighted in early 2007, then placed into the public domain by publishing (including an appropriate copyright license message) on the eaa-phev maillist on Aug 6, 2007 (message 1119).

ControlSwSpecs_v01_20070128_rdg.xls

TestSpec_v01_20070407rdg.xls

The software specification is a complete specification for software to control a PRIUS+ conversion from data read from the CAN bus using the best algorithms I had developed up to January 28, 2007. Since then, Chris Ewert, myself, and others have further refined the algorithms to handle special cases such as extreme temperatures and speeds just slightly above 34 mph.

The test specification, written April 7, 2007, is a basic ordered list of tests that would be good to follow as part of completing and validating a PRIUS+ conversion.

Schematics

These are preview images of various schematics, click on the thumbnails for a larger preview and to download the full sized images. You will also find links to .zips of the original ExpressSCH schematics from which these images were produced.

Preview of High Power Schematics
Preview of Control Board Schematics EAA-PHEV-PRIUS-ControlBdSchematic.zip schematic created in ExpressSCH.
Preview of LED Board Schematics EAA-PHEV-PRIUS-LEDBdSchematic.zip schematic created in ExpressSCH.

Battery Box Designs

See the following for designs for a hinged battery box:

Photos

You can browse the entire gallery of images here at the eaa-phev site,
or visit some other galleries with potentially applicable photos:

Photo of OEM NiMH battery with case fully removed during Maker Faire, which is no longer necessary during current conversions.
Photo of the PriusBlue HV Tie in at the time of the Maker Faire, routed out of OEM battery case near service plug.
Photo of the PriusBlue HV Tie in later after PiPrius conversion, there is an additional unused wire on the neg(-) OEM contactor for use during "Genset mode"

Rons Images

Photos from Chris Ewert's Conversion

These are photos that User:Cewert has shared with us of his conversion via the CalCars PriusPlus method.

Photos from 2007 Maker Faire

Some photos from the 2007 Maker Faire conversion.



General Reference Materials

These are some other General Reference Materials we use elsewhere on the site. This is also an example of how to use references within the page text. See PiPrius conversion process for another example of a page with multiple reference tages.

You should be familiar with these reference materials and standard operating procedures around high voltages. <references/>

Intro Editing Help

File Specific Help

File link Examples, click the edit button for this section to see how it works.

Text Links:

Inline resized images:

25pxEAA-PHEV-PRIUS-ControlBdSchematic.png, 50pxEAA-PHEV-PRIUS-ControlBdSchematic.png, 150pxEAA-PHEV-PRIUS-ControlBdSchematic.png,

300pxEAA-PHEV-PRIUS-ControlBdSchematic.png

Thumbnails:

caption
  • Thumbnail tag will embed the image inline such that text will wrap arround the image. The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag. Thumbnails should also include some caption as their last "|caption element". Notice that the image code is placed above this text so that the text and image begin at the same place.

The {{Clear}} template can be used to force empty white space after a thumbnail before continuing with the next block of text.

  • A Second Example...
Small On Left
Small On Right

Thumbnail tag will embed the image inline such that text will wrap arround the image. The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag. Thumbnails should also include some caption as their last "|caption element". Notice that the image code is placed above this text so that the text and image begin at the same place. Thumbnail tag will embed the image inline such that text will wrap arround the image. The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag. Thumbnails should also include some caption as their last "|caption element". Notice that the image code is placed above this text so that the text and image begin at the same place. Thumbnail tag will embed the image inline such that text will wrap arround the image. The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag. Thumbnails should also include some caption as their last "|caption element". Notice that the image code is placed above this text so that the text and image begin at the same place.

References

<references/>