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Difference between revisions of "PriusPlus-Theory"

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(Clean-up, added CAN-View version info)
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Now that is where this project starts but it get more complex than that.
 
Now that is where this project starts but it get more complex than that.
  
==The Battery Pack==
+
==The PHEV Battery Pack==
  
The extra battery pack is simply twenty 12volt batteries linked together in series with 8 gage wire for a final voltage of 240 volts. Just think of two batteries end to end in a flash light and you get the idea. Now you are going to want to charge that pack every night so you are going to need a charger to plug into the wall and to take proper care of your batteries. And you are going to want to put in a couple of fuses to protect the car and you incase of a problem. Then you will want to be able to shut them on and off with a couple of oversized relay switches. A hall sensor attached to this system can give you valuable information of how much power the pack is sending to the Prius’ original battery.  
+
The PHEV battery pack has a higher nominal voltage than the stock NiMH battery and, in this design, is used to charge the stock NiMH battery. Contactors (large relays) are used to connect and disconnect the PHEV battery pack from the stock battery.  The PHEV pack consists of twenty 12 volt 20 amp hour sealed lead acid batteries connected in series. The nominal voltage of the pack is 240 volts and has a total energy storage of about 4.8 kWh (not all usable.)  The batteries are connected together with 8 gage wire and are protected by 60 amp fuses. A hall sensor attached to this system can give you valuable information of how much power the pack is sending to the stock battery.  
  
 
From end to end the pack goes something like this;
 
From end to end the pack goes something like this;
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==The CAN-View==
 
==The CAN-View==
  
The [[CAN-View]] comes pre-made with cables and is a very easy install. It has five wires One cable goes from the computer connection under the dash on the driver’s side to the CAN-View box. Another goes to a second screen normally placed on your dash. (04-05 Prius can us the existing [[MFD]] but I don’t know why you would want to when you could have one screen for the normal Prius features and another for the CAN-View information.) One wire goes to EV mode. One wire goes to the control board. The last cable is for power. Very simple!
+
The [[CAN-View]] monitors activity on the CAN bus (the bus which the different microprocessors in the Prius communicate) and provides a user interface to the PHEV and instructs the contactors on the PHEV battery pack to open and close to charge the stock battery.  CAN-View itself is simple to install and typically requires between a half hour to one and a half hours to install.  There are 2 versions of CAN-View currently available. Version 2 requires an '04 or '05 Prius and makes use of the built in display (or [[MFD]]) while Version 3 works with an 04-07 Prius but requires an external touchscreen.  For more information, see [[CAN-View]].
  
 
==Circuit Board==
 
==Circuit Board==
  
Last is the circuit board. It listens to the system and tells it what to do.
+
A circuit board is added to control the heaters, fans, contactors, etc.  This board also provides an interlock for the charger so that the car cannot be driven away while plugged into a live outlet.
  
 
Sub parts of this board are;
 
Sub parts of this board are;
 
* Power management
 
* Power management
* Battery cooling
+
* Battery Heating & Cooling
* Battery Heating
 
 
* System diagnostics  
 
* System diagnostics  
 
* The board itself
 
* The board itself
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You want the system to know when to send power to the original battery and when it should take power from the regenerative braking system. It should also know when to shut the pack completely down such as when it is empty or when it is charging. Also, you want to tell the Prius battery computer that it has a high State of Charge so it keeps trying to use up the power.
 
You want the system to know when to send power to the original battery and when it should take power from the regenerative braking system. It should also know when to shut the pack completely down such as when it is empty or when it is charging. Also, you want to tell the Prius battery computer that it has a high State of Charge so it keeps trying to use up the power.
  
===Battery Cooling===
+
===Battery Heating & Cooling===
  
The Prius plus uses three fans to cool down the batteries. That warm air has to go somewhere so it now goes out the two 2” holes under where the spare use to be. Those fans need to go on and off as needed by the second pack.
+
Lead acid batteries do not function properly when they are either hot or cold.  The pack is heated and cooled as necessary by three Wal-Mart heating pads and three fans.  When cooling, the warm air has to go somewhere so it now goes out the two 2” holes under where the spare use to be. The circuit board is responsible for controlling the heaters and fans.
 
 
===Battery Heating===
 
 
 
This is no joke. The pack can be heated as needed by three Wal-Mart heating pads. There is no need for high temp heat so low power heating pads is all you use. Now you will want those to go on and off by them selves as needed too.
 
  
 
===System Diagnostics===
 
===System Diagnostics===

Revision as of 22:12, 3 December 2006

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".



Intro Paragraph here maybe with a link to the main PriusPlus article, links to external sites can appear as formatted 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.

Please feel free to hack this up or delete it, as I could have this all wrong. I just wanted to get this started. Jim P.

  • Prius plus:

The Prius plus system on the surface is remarkably simple...Genus in fact. The three main parts are;

  1. The extra battery pack
  2. The CAN-View
  3. And, one circuit board

Now that is where this project starts but it get more complex than that.

The PHEV Battery Pack

The PHEV battery pack has a higher nominal voltage than the stock NiMH battery and, in this design, is used to charge the stock NiMH battery. Contactors (large relays) are used to connect and disconnect the PHEV battery pack from the stock battery. The PHEV pack consists of twenty 12 volt 20 amp hour sealed lead acid batteries connected in series. The nominal voltage of the pack is 240 volts and has a total energy storage of about 4.8 kWh (not all usable.) The batteries are connected together with 8 gage wire and are protected by 60 amp fuses. A hall sensor attached to this system can give you valuable information of how much power the pack is sending to the stock battery.

From end to end the pack goes something like this;

negative end – relay – shunt – hall sensor – fuse - (batteries 1-20) – fuse – relay – positive end

The CAN-View

The CAN-View monitors activity on the CAN bus (the bus which the different microprocessors in the Prius communicate) and provides a user interface to the PHEV and instructs the contactors on the PHEV battery pack to open and close to charge the stock battery. CAN-View itself is simple to install and typically requires between a half hour to one and a half hours to install. There are 2 versions of CAN-View currently available. Version 2 requires an '04 or '05 Prius and makes use of the built in display (or MFD) while Version 3 works with an 04-07 Prius but requires an external touchscreen. For more information, see CAN-View.

Circuit Board

A circuit board is added to control the heaters, fans, contactors, etc. This board also provides an interlock for the charger so that the car cannot be driven away while plugged into a live outlet.

Sub parts of this board are;

  • Power management
  • Battery Heating & Cooling
  • System diagnostics
  • The board itself

Power Management

You want the system to know when to send power to the original battery and when it should take power from the regenerative braking system. It should also know when to shut the pack completely down such as when it is empty or when it is charging. Also, you want to tell the Prius battery computer that it has a high State of Charge so it keeps trying to use up the power.

Battery Heating & Cooling

Lead acid batteries do not function properly when they are either hot or cold. The pack is heated and cooled as necessary by three Wal-Mart heating pads and three fans. When cooling, the warm air has to go somewhere so it now goes out the two 2” holes under where the spare use to be. The circuit board is responsible for controlling the heaters and fans.

System Diagnostics

Let’s say you blow a fuse or something is wrong somewhere how would you know? A ribbon cable is sent to the dash from the circuit board to show lights for what systems are working when.

The Circuit Board

It is a small board about 6” by 5” is my guess. I’ve held it but I did not measure it. So you now know what it controls, but it still needs power to run so that is another cable. It talks to the Canview to so yet another cable. It needs cables to the fans, the on off of the heating pads, and the charger too.

References

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