General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

Difference between revisions of "Prius PHEV Schematics"

From My wiki
Jump to navigation Jump to search
Line 55: Line 55:
  
 
====Automatic Charge - PHEV Drive Mode Change====
 
====Automatic Charge - PHEV Drive Mode Change====
  ''View with fixed-width fonts''
+
  ''View with fixed-width fonts'' <font color=red>'''This has not yet been validated for proper opperation'''</font>
  '''Automatic Charge - PHEV Drive Mode Change'''
+
  '''Automatic [ Charge - PHEV Drive - Regen ] Mode Change'''
  Pair of DPDT or 4PDT, and SPST (40+ Amps, 12v coils)
+
  Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
+
     (+)[Grid](-)
     [ DaGrid ]       coil 03 DPDT ''only available while RL4''
+
    |        |
    |        |      NC = Grid
+
    |   |====|======================================|
Grid Lockout (NC)   NO = Regen
+
    |  |   |                                     |
    |        |
+
    |  |    |  |==================================|========|
    |''--------|--(dc immune, ac interlock)''
+
  __|___|____|___|__                                |        |
    |       |
+
  ! #  #    #  # !                                |        |
    #========|============== coil 03 =============|
+
  !  \ , %%%% \ ,  ! coil 03 only while RL4=1      |        |
    |       |               (NO)                |
+
  !  \  coil  \  !                                |        |
    |       #============== coil 03 =============|========|
+
  !___#___03___#___!                                |        |
    |        |                                    |        |
+
      |        |                                    |        |
  (+)[Grid](-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]]
+
      (+)     (-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]]
    |       |       |      |          |        |  ''Inverter side of OEM contactor''
+
(no dc|ac inter|lock)  |      |          |        |  ''Inverter side of OEM contactor''
    |        |        |      |          |        |
+
      |        |        |      |          |        |
    |  |====|========#=======|==========|====|  |
+
      |        |        |      |          |        |
    |  |    |                |          |    |  |
+
      |  |====|========#=======|==========|====|  |
    |  |    |  |=======|    #======|  |    |  |
+
      |  |    |                |          |    |  |
    |  |    |  |    __|____|__    |  |    |  |
+
      |  |    |  |=======|    #======|  |    |  |
    |  |    |  |    | # ,, # !    |  |    |  |
+
      |  |    |  |    __|____|__    |  |    |  |
  __|___|____|___|__  !  ----  !  __|___|____|___|__
+
      |  |    |  |    | # ,, # !    |  |    |  |
  ! #  #    #  # !  !  %%%%  !  ! #  #    #  # !
+
    __|___|____|___|__  !  ----  !  __|___|____|___|__
  !  \ , %%%% \ ,  !  !  coil  !  !  \ , %%%% \ ,  !
+
    ! #  #    #  # !  !  %%%%  !  ! #  #    #  # !
  !  \  coil  \  !  !___02___!  !  \  coil  \  !
+
    !  \ , %%%% \ ,  !  !  coil  !  !  \ , %%%% \ ,  !
  !___#___01___#___!              !___#___01___#___!
+
    !  \  coil  \  !  !___02___!  !  \  coil  \  !
      |        |                      |        |
+
    !___#___01___#___!              !___#___01___#___!
      |(+)  (-)|                      |(-)  (+)|
+
        |        |                      |        |
12  [PFC Input]                      [PFC Output]
+
        |(+)  (-)|                      |(-)  (+)|
 +
        [PFC Input]                      [PFC Output]
 
  '''''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?'''''
 
   
 
   
 +
12
 
       Charge Mode
 
       Charge Mode
  00 - coil 01 open  = Grid -> PbA, Charge if AC is present.
+
  00 - coil 01 open  = Grid -> PbA, Charge if AC is present (PFC V set PbA ''default'')
  00 - AC driven (Drive/coil 01/coil 03/RLx) interlocks.
+
  00 - DC immune & AC driven (Drive/coil 01/coil 03/RLx lockout) interlock.
 
  01 - ''nothing changes'', can't enguage RL4 without Key On.
 
  01 - ''nothing changes'', can't enguage RL4 without Key On.
 
 
       Power up sequence
 
       Power up sequence
  10 - coil 01 closed = PbA -> NiMH, (PFC V set NiMH) '''Key On'''
+
  10 - coil 01 closed = PbA -> NiMH, (PFC V set NiMH) '''Key On''' ''maybe this should lock out AC seperate from coil 03''
 
  11 - coil 02 closed = PbA (-)neg input, (PFC powers on) '''[[CAN-View]] Relay RL4''' (Stock/PHEV Mode)
 
  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 - 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.
 
  11 - '''RL4 locks out AC input''' so plugging in while on won't change anything.
 
 
       Power down sequence
 
       Power down sequence
 
  10 - 1. Drop coil 2, wait ''(PFC powers off)''
 
  10 - 1. Drop coil 2, wait ''(PFC powers off)''
 
  00 - 2. Drop coil 1, wait ''(Grid -> PbA, PFC V set PbA)''
 
  00 - 2. Drop coil 1, wait ''(Grid -> PbA, PFC V set PbA)''
   
+
  123
 
       Regen Mode / Charge PbA Mode / ?Charge external mode?
 
       Regen Mode / Charge PbA Mode / ?Charge external mode?
 
  110- While running ''regen mode'', triggered by CAN-View RL3
 
  110- While running ''regen mode'', triggered by CAN-View RL3
Line 114: Line 114:
 
  110- 3. coil 02 closed = PbA (-)neg input, (PFC powers on)
 
  110- 3. coil 02 closed = PbA (-)neg input, (PFC powers on)
 
     ''? Charge external mode ?''
 
     ''? Charge external mode ?''
  --[[User:Rjf|Rjf]] 03:53, 9 June 2006 (CDT)
+
 +
123 '''Potential alternate logic sequence for use with DPDT Grid<->NiMH contactor'''
 +
000 = 0// ('''AC''' locks out coils 2 & 3)
 +
101 (AC is locked out by '''key on''' via coil 3)
 +
111 (phev mode enabled and opperational via '''RL4''')
 +
111 ('''RL2''' is SOC driven voltage dither)
 +
110 '''Regen''' ('''RL3''' enter regen mode after sane CAN-View timeout)
 +
        ''(we can loose grid interlock since we must be at speed? right?)''
 +
100 PFC Off
 +
000 Grid->PbA
 +
001 '''Now Regenning''' from NiMH -> Grid
 +
000 Nothing->Grid
 +
100 PbA->NiMH
 +
110 (phev mode enabled)
 +
111 (lockout grid again)
 +
''(One could manually enter external charge mode by safely enguaging stationary regen)''
 +
''(Shut off PFC, manually enable RL3, hyjack PFC output via Andersons, tune and charge)''
 +
  --[[User:Rjf|Rjf]] 04:45, 9 June 2006 (CDT)
  
 
====Enhanced Regen====
 
====Enhanced Regen====

Revision as of 09:45, 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 This has not yet been validated for proper opperation
Automatic [ Charge - PHEV Drive - Regen ] Mode Change
Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
   (+)[Grid](-)
    |        |
    |   |====|======================================|
    |   |    |                                      |
    |   |    |   |==================================|========|
  __|___|____|___|__                                |        |
  ! #   #    #   # !                                |        |
  !  \ , %%%% \ ,  ! coil 03 only while RL4=1       |        |
  !   \  coil  \   !                                |        |
  !___#___03___#___!                                |        |
      |        |                                    |        |
     (+)      (-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH](-)Regen Mode?
(no dc|ac inter|lock)   |       |          |        |  Inverter side of OEM contactor
      |        |        |       |          |        |
      |        |        |       |          |        |
      |   |====|========#=======|==========|====|   |
      |   |    |                |          |    |   |
      |   |    |   |=======|    #======|   |    |   |
      |   |    |   |     __|____|__    |   |    |   |
      |   |    |   |     | # ,, # !    |   |    |   |
    __|___|____|___|__   !  ----  !  __|___|____|___|__
    ! #   #    #   # !   !  %%%%  !  ! #   #    #   # !
    !  \ , %%%% \ ,  !   !  coil  !  !  \ , %%%% \ ,  !
    !   \  coil  \   !   !___02___!  !   \  coil  \   !
    !___#___01___#___!               !___#___01___#___!
        |        |                       |        |
        |(+)  (-)|                       |(-)  (+)|
       [PFC Input]                      [PFC Output]
Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?

12
     Charge Mode
00 - coil 01 open   = Grid -> PbA, Charge if AC is present (PFC V set PbA default)
00 - DC immune & AC driven (Drive/coil 01/coil 03/RLx lockout) interlock.
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 maybe this should lock out AC seperate from coil 03
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)
123
     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 ?

123 Potential alternate logic sequence for use with DPDT Grid<->NiMH contactor
000 = 0// (AC locks out coils 2 & 3)
101 (AC is locked out by key on via coil 3)
111 (phev mode enabled and opperational via RL4)
111 (RL2 is SOC driven voltage dither)
110 Regen (RL3 enter regen mode after sane CAN-View timeout)
       (we can loose grid interlock since we must be at speed? right?)
100 PFC Off
000 Grid->PbA
001 Now Regenning from NiMH -> Grid
000 Nothing->Grid
100 PbA->NiMH
110 (phev mode enabled)
111 (lockout grid again)
(One could manually enter external charge mode by safely enguaging stationary regen)
(Shut off PFC, manually enable RL3, hyjack PFC output via Andersons, tune and charge)
--Rjf 04:45, 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.