Prius PHEV Schematics
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
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_]
No new Schematics for these methods yet...
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](-) Inputs --> State|Machine --> Outputs __|________|__ +12v-|->(CAN RL3, NO, RGN )-->|-->(Execute Regen mode Procedure below) ! |coil 05 | ! Key |->(CAN RL2, NO, SOC )-->|-->(PFV V set NiMH high) ! |AC rated| ! |->(CAN RL4, NO, PHEV)-->|-->(coil 04) !_|________|_! |-NC->(Key On, +12v, Brown)-->|-->(Interlock, coil 01 & 02, PFC V set NiMH low) | | | |-NC----------->|-->(Open OEM HV+ Contactor ground control, Black) (|AC sense|)---|-------------|----110vac---->|-->(PFC Current <15Amps) | | | |====|======================================| | | | | | | | |==================================|========| __|___|____|___|__ | | ! # # # # ! | | ! \ , %%%% \ , ! | | ! \ coil \ ! (+)[PbA](-) (-)[NiMH](+)[NiMH](-)Regen Mode? !___#___03___#___! | | | | Inverter side of OEM contactor | | | | | | | |====|========#=======|==========|====| | | | | | | | | | | | |=======| #======| | | | | | | | __|____|__ | | | | | | | | | # ,, # ! | | | | __|___|____|___|__ ! ---- ! __|___|____|___|__ ! # # # # ! ! %%%% ! ! # # # # ! ! \ , %%%% \ , ! ! coil ! ! \ , %%%% \ , ! ! \ coil \ ! !___04___! ! \ coil \ ! !___#___01___#___! !___#___02___#___! | | | | |(+) (-)| |(-) (+)| [PFC Input] [PFC Output] coils Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch? 12345 ----- Charge Mode 00000 - Grid -> PbA, (PFC V set PbA default) ////0 - 110v AC Present (DC immune) coil 01-04, Key On, and RLx interlock. (Set PFC Current < 15A) ////0 - 220v AC Present (DC immune) coil 01-04, Key On, and RLx interlock. (Leave PFC Current Full) - Key On Interlock opens a NC relay which grounds the (+)pos OEM Contactor. - Run Interlock opens a NC relay which would otherwise go (+12) upon Key On. - Open a NC relay which provides coil 01-04 & CAN RLx grounds, disabling all. ----- Power up sequence Key On 00000 - Key Off, ready to but not charging state 00001 - open coil 05 (NC), ac interlock 01001 - coil 02 Output -> NiMH, PFC V set NiMH low 11001 - coil 01 Input -> PbA CAN-View "PHEV" Mode, Relay RL4^ 11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On) CAN-View ?RL2^? (SOC/CCL Driven) 11011 - PFC V set NiMH high ----- Power down sequence Key Off 11011 - Key On, and PHEV run state 11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off) 01001 - coil 01 Input -> Grid 00001 - coil 02 Output -> PbA, PFC V Set PbA 00000 - close coil 05 (NC), ac interlock ----- CAN-View ?RL3^? (Enter Regen Mode) 1 - only while grid interlock is active 11011 - Key On, and PHEV run state Do Power down sequence Emulate Key Off less last state 11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off) 01001 - coil 01 Input -> Grid 00001 - coil 02 Output -> PbA, PFC V Set PbA 00101 - coil 03 NiMH(Regen) -> Grid Input (PFC On) ----- CAN-View ?RL3v? (Exit Regen Mode) 00101 - Key On, and PHEV regen state 00001 - coil 03 Grid -> Grid Input (PFC Off) 01001 - coil 02 Output -> NiMH, PFC V Set NiMH low 11001 - coil 01 Input -> PbA 11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On) ----- Other Notes 01001 - coil 02 & 01 states may be safe to combined 11001 - coil 01 & 02 states may be safe to combined Forced PbA Charge Mode (One could manually enter forced PbA charge mode by safely enguaging stationary regen ?RL3^?) Further, External Charging by: (Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge) --Rjf 15:49, 14 June 2006 (CDT)
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.