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PriusPlus-Theory

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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.

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A Major Topic

Please feel free to hack this up or delete it. 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 that that.

  • The 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.

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 Canview

The Canview 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 Canview 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 Canview information.) One wire goes to EV mode. One wire goes to the control board. The last cable is for power. Very simple!

  • Circuit board

Last is the circuit board. It listens to the system and tells it what to do. Sub parts of this board are;

1. Power management

2. Battery cooling

3. Battery Heating

4. System diagnostics

5. 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 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.

  • 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

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.


Sub Topic

Yes, this is a sub topic

Sub Topic number two

You guessed it, another sub topic.

References

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