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Difference between revisions of "Prius PHEV Schematics"

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Line 58: Line 58:
 
  '''Automatic Charge - PHEV Drive Mode Change'''
 
  '''Automatic Charge - PHEV Drive Mode Change'''
 
  Pair of DPDT or 4PDT, and SPST (40+ Amps, 12v coils)
 
  Pair of DPDT or 4PDT, and SPST (40+ Amps, 12v coils)
 +
 +
    [ DaGrid ]      coil 03 DPDT ''only available while RL4''
 +
    |        |      NC = Grid
 +
Grid Lockout (NC)  NO = Regen
 +
    |        |
 +
    |''--------|--(dc immune, ac interlock)''
 +
    |        |
 +
    #========|============== coil 03 =============|
 +
    |        |              (NO)                |
 +
    |        #============== coil 03 =============|========|
 +
    |        |                                    |        |
 
   (+)[Grid](-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]]
 
   (+)[Grid](-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]]
     |        |        |      |          |        |       |
+
     |        |        |      |          |        | ''Inverter side of OEM contactor''
     |        |        |      |          |        |        |
+
     |        |        |      |          |        |
     |  |====|========#=======|==========|====|  |        |
+
     |  |====|========#=======|==========|====|  |
     |  |    |                |          |    |  |        |
+
     |  |    |                |          |    |  |
     |  |    |  |=======|    #======|  |    |  |        |
+
     |  |    |  |=======|    #======|  |    |  |
     |  |    |  |    __|____|__    |  |    |  |       ?
+
     |  |    |  |    __|____|__    |  |    |  |
 
     |  |    |  |    | # ,, # !    |  |    |  |
 
     |  |    |  |    | # ,, # !    |  |    |  |
 
   __|___|____|___|__  !  ----  !  __|___|____|___|__
 
   __|___|____|___|__  !  ----  !  __|___|____|___|__
Line 74: Line 85:
 
       |(+)  (-)|                      |(-)  (+)|
 
       |(+)  (-)|                      |(-)  (+)|
 
  12  [PFC Input]                      [PFC Output]
 
  12  [PFC Input]                      [PFC Output]
00 - coil 01 open  = Grid -> PbA, Charge if AC is present. - Add ac driven (Drive/coil 01/RLx) interlocks.
 
01 - ''no change''
 
10 - coil 01 closed = PbA -> NiMH, open  PbA (-)neg input  - Enabled by Vehicle On (Change PFC V setpoint)
 
11 - coil 02 closed = PbA -> NiMH, close PbA (-)neg input  - Enabled by [[CAN-View]] Relay RL4 (Stock/PHEV Mode)
 
 
  '''''Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?'''''
 
  '''''Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?'''''
  11 - CAN-View RL2 drives dither.
+
  --[[User:Rjf|Rjf]] 02:56, 9 June 2006 (CDT)
+
      Charge Mode
 +
00 - coil 01 open  = Grid -> PbA, Charge if AC is present.
 +
00 - AC driven (Drive/coil 01/coil 03/RLx) interlocks.
 +
01 - ''nothing changes'', can't enguage RL4 without Key On.
 +
 +
      Power up sequence
 +
10 - coil 01 closed = PbA -> NiMH, (PFC V set NiMH) '''Key On'''
 +
11 - coil 02 closed = PbA (-)neg input, (PFC powers on) '''[[CAN-View]] Relay RL4''' (Stock/PHEV Mode)
 +
  11 - CAN-View RL2 drives dither (PFC V set NiMH high).
 +
11 - '''RL4 locks out AC input''' so plugging in while on won't change anything.
 +
 +
      Power down sequence
 +
10 - 1. Drop coil 2, wait ''(PFC powers off)''
 +
00 - 2. Drop coil 1, wait ''(Grid -> PbA, PFC V set PbA)''
 +
 +
      Regen Mode / Charge PbA Mode / ?Charge external mode?
 +
110- While running ''regen mode'', triggered by CAN-View RL3
 +
    ''Execute power down sequence''
 +
100- 1. Drop coil 2, wait ''(PFC powers off)''
 +
000- 2. Drop coil 1, wait ''(Grid -> PbA, PFC V set PbA)''
 +
    ''Connect NiMH (via regen points) to Grid input, inside grid lockout contactor.''
 +
001- 3. coil 03 closed = NiMH(Regen) -> Grid '''Regenning'''
 +
    ''When CAN-View RL3 goes from closed to open''
 +
000- 1. coil 03 open, wait ''(PFC powers off)''
 +
100- 2. coil 01 closed = PbA -> NiMH, (PFC V set NiMH)
 +
110- 3. coil 02 closed = PbA (-)neg input, (PFC powers on)
 +
    ''? Charge external mode ?''
 +
  --[[User:Rjf|Rjf]] 03:53, 9 June 2006 (CDT)
  
 
====Enhanced Regen====
 
====Enhanced Regen====

Revision as of 08:53, 9 June 2006

This is where you will find schematics, PCB layout, and parts lists for various Prius PHEV conversions.

Original CalCars Method

Further development of the PriusPlus or Prius PHEV#Original CalCars Method has been postponed to persue the Prius PHEV#Hybrid-Pack Method so the original schematics can be found at Prius PHEV Schematics-CalCars

Hybrid-Pack Method

There is no longer a need for the Battery Tap Emulator.

The HV interface with the original battery is made after the HAL sensor.

View with fixed-width fonts
                       |======[? (-) for Genset Mode ?]
                       |
=(-)=[=#=OEM_Contactor=#=]===[|]==#========(-)
                             HAL  |      [_OEM_Battery_]
To HSD                    SENSOR  |    |===(+)
                                  |    | 
=(+)=[=#=OEM_Contactor=#=]========|====| 
                       |          |      
                       |====|     |      
                            |     |      
(     # interconnect )     (+)   (-)     
( = & | 6 guage wire )  [_PHEV_Battery_]

Contactor Based

No new Schematics for these methods yet...


PFC Based

No new Schematics for these methods yet, Only ASCII Art...

Manual Anderson Quick Mode Change.

View with fixed-width fonts
Manual Anderson Quick Mode Change.
( 6 red, 6 black )
 _______________ _ _____________________               
 In   PFC AC(+) \ / (+) 110/220AC   CHG |              
 _____PFC_AC(-)_/_\_(-)____________ CHG______          
 Out  PFC DC(+) \ / (+) PbA (PHEV)  CHG PHEV |         
 _____PFC_DC(-)_/_\_(-)________________ PHEV_____      
                  / (+) NiMH (OEM)      PHEV RGN |     
 _ _ _ _ _ _ _ _ _\_(-)____________ _ _ _____RGN |     
                  / (+) PbA (PHEV)           RGN |     
 _ _ _ _ _ _ _ _ _\_(-)____________ _ _ _ _ _____|     

                 _ ________________                    
  "Special Mode"  / (+) HSD (? HAL sensor ?)           
  Wayland at the _\_(-)____________                    
  track charging  / (+) DC Output (! NEDRA !)          
  Genset Mode ?? _\_(-)____________                    
--Rjf 00:40, 26 May 2006

Automatic Charge - PHEV Drive Mode Change

View with fixed-width fonts
Automatic Charge - PHEV Drive Mode Change
Pair of DPDT or 4PDT, and SPST (40+ Amps, 12v coils)

   [ DaGrid ]       coil 03 DPDT only available while RL4
   |        |       NC = Grid
Grid Lockout (NC)   NO = Regen
   |        |
   |--------|--(dc immune, ac interlock)
   |        |
   #========|============== coil 03 =============|
   |        |               (NO)                 |
   |        #============== coil 03 =============|========|
   |        |                                    |        |
  (+)[Grid](-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH](-)Regen Mode?
   |        |        |       |          |        |  Inverter side of OEM contactor
   |        |        |       |          |        |
   |   |====|========#=======|==========|====|   |
   |   |    |                |          |    |   |
   |   |    |   |=======|    #======|   |    |   |
   |   |    |   |     __|____|__    |   |    |   |
   |   |    |   |     | # ,, # !    |   |    |   |
 __|___|____|___|__   !  ----  !  __|___|____|___|__
 ! #   #    #   # !   !  %%%%  !  ! #   #    #   # !
 !  \ , %%%% \ ,  !   !  coil  !  !  \ , %%%% \ ,  !
 !   \  coil  \   !   !___02___!  !   \  coil  \   !
 !___#___01___#___!               !___#___01___#___!
     |        |                       |        |
     |(+)  (-)|                       |(-)  (+)|
12  [PFC Input]                      [PFC Output]
Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?

     Charge Mode
00 - coil 01 open   = Grid -> PbA, Charge if AC is present.
00 - AC driven (Drive/coil 01/coil 03/RLx) interlocks.
01 - nothing changes, can't enguage RL4 without Key On.

     Power up sequence
10 - coil 01 closed = PbA -> NiMH, (PFC V set NiMH) Key On
11 - coil 02 closed = PbA (-)neg input, (PFC powers on) CAN-View Relay RL4 (Stock/PHEV Mode)
11 - CAN-View RL2 drives dither (PFC V set NiMH high).
11 - RL4 locks out AC input so plugging in while on won't change anything.

     Power down sequence
10 - 1. Drop coil 2, wait (PFC powers off)
00 - 2. Drop coil 1, wait (Grid -> PbA, PFC V set PbA)

     Regen Mode / Charge PbA Mode / ?Charge external mode?
110- While running regen mode, triggered by CAN-View RL3
   Execute power down sequence
100- 1. Drop coil 2, wait (PFC powers off)
000- 2. Drop coil 1, wait (Grid -> PbA, PFC V set PbA)
   Connect NiMH (via regen points) to Grid input, inside grid lockout contactor.
001- 3. coil 03 closed = NiMH(Regen) -> Grid Regenning
   When CAN-View RL3 goes from closed to open
000- 1. coil 03 open, wait (PFC powers off)
100- 2. coil 01 closed = PbA -> NiMH, (PFC V set NiMH)
110- 3. coil 02 closed = PbA (-)neg input, (PFC powers on)
   ? Charge external mode ?
--Rjf 03:53, 9 June 2006 (CDT)

Enhanced Regen

Regen may need to transfer power through the OEM HAL sensor in order to:

  • Avoid Negative State Of Charge Drift which may not work like +Drift.
  • Allow current to be counted instantaneously and thus recover from or avoid CCL.
  • Allow for the use of the Prius as a DC Genset if PFC sources NiMH pack.

Potential Enhanced Regen methods

  • Use the PFC as is, switch Input/Output and change voltage setpoint.
    • Modify the PFC so it can move 2x amps in DC modes only.
    • Use a PFC power stage.. so we can stuff 150 amps in any direction.
  • Use a Honking Big diode and a properly sized PbA Pack.
  • Use a contactor and a diode and a properly sized PbA Pack.