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PriusPlus-Theory

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Revision as of 23:24, 3 December 2006 by 67.184.99.141 (talk) (Wrote short intro, added charger information)
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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.

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 is a contactor based conversion for an '04 or newer Prius. A sealed lead-acid battery pack is added along with a standard 120 volt charger and supporting electronics. The converted Prius Plus has an electric only range of about 10-12 miles.

The main components are:

  1. The PHEV battery pack
  2. The Charger
  3. The CAN-View
  4. Control board


The PHEV Battery Pack

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 PHEV battery pack has a higher nominal voltage than the stock NiMH battery and 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 when charging is needed. 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 information of how much power the pack is providing.

The Charger

The charger runs on standard 120v (or 240v) AC power and is used to recharge the PHEV pack. Three options are planned:

  • a Delta-q charger (http://www.delta-q.com) designed for the PbA battery pack, at a projected price of $800. We are in discussions with the company and will soon know if/when pre-production units will be available; UL-approved units are likely to be available in 2007.
  • the Brusa NLG503 charger, available through http://www.metricmind.com/index1.htm for $2650 retail including cables (a group rate is possible). Users can reprogram this charger for other voltages and battery chemistries, so it would be a good purchase for developers anticipating an eventual high-tech replacement battery.
  • (eventually) the Manzanita Micro PFC-40 charger, available through http://manzanitamicro.com for around $2000. This charger has programmable but less sophisticated charging algorithms, but can also double as a high-power DC:DC converter between the battery packs. Its output is not line isolated. Its incorporation will require modifications/enhancements of this conversion, and control circuitry and algorithms that have not yet been developed.

Useful information on charging lead-acid batteries can be found at http://batteryuniversity.com/partone-13.htm

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 3 requires an '04 or '05 Prius and makes use of the built in display (or MFD) while Version 4 works with an 04-07 Prius but requires an external touchscreen. For more information, see CAN-View.

Control 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 in to 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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