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Difference between revisions of "Prius PHEV Schematics"

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Line 59: Line 59:
 
  Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
 
  Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
 
     (+)[Grid](-)
 
     (+)[Grid](-)
−
     |       |
+
     | coil 5 | (ac rated)
 
     |  |====|======================================|
 
     |  |====|======================================|
 
     |  |    |                                      |
 
     |  |    |                                      |
Line 86: Line 86:
 
         |(+)  (-)|                      |(-)  (+)|
 
         |(+)  (-)|                      |(-)  (+)|
 
         [PFC Input]                      [PFC Output]
 
         [PFC Input]                      [PFC Output]
−
  '''''Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?'''''
+
  '''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&02&03&04&RLx interlock. (Set PFC Current < 15A)
 +
////0 - 220v AC Present (DC immune) coil 01&02&03&04&RLx interlock. (Leave PFC Current Full)
 
   
 
   
−
12
+
      Power up sequence '''Key On'''
−
      Charge Mode
+
  00001 - open coil 05 (NC), ac interlock
−
00 - coil 01&02 open  = Grid -> PbA, Charge if AC is present (PFC V set PbA ''default'')
+
  01001 - coil 02 Output -> NiMH, PFC V set NiMH low
−
  00 - DC immune & AC driven (Drive/coil 01&02&03/RLx lockout) interlock.
+
11001 - coil 01 Input -> PbA
−
01 - ''nothing changes'', can't enguage RL4 without Key On.
+
      CAN-View "PHEV" Mode, Relay RL4^
−
      Power up sequence
+
  11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
−
  10 - coil 01&02 closed = PbA -> NiMH, (PFC V set NiMH) '''Key On''' ''maybe this should lock out AC seperate from coil 03''
+
      CAN-View ?RL2^? (SOC/CCL Driven)
−
  11 - coil 04 closed = PbA (-)neg input, (PFC powers on) '''[[CAN-View]] Relay RL4''' (Stock/PHEV Mode)
+
  11011 - PFC V set NiMH high
−
  11 - CAN-View RL2 drives dither (PFC V set NiMH high).
+
      Power down sequence '''Key Off'''
−
11 - '''RL4 locks out AC input''' so plugging in while on won't change anything.
+
  11011 - Key On, and PHEV run state
−
      Power down sequence
+
  11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
−
10 - 1. Drop coil 04, wait ''(PFC powers off)''
+
  01001 - coil 01 Input -> Grid
−
00 - 2. Drop coil 01, wait ''(Grid -> PbA, PFC V set PbA)''
+
  00001 - coil 02 Output -> PbA, PFC V Set PbA
−
123
+
  00000 - close coil 05 (NC), ac interlock
−
      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 04, wait ''(PFC powers off)''
 
−
000- 2. Drop coil 01, 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&02 closed = PbA -> NiMH, (PFC V set NiMH)
 
−
  110- 3. coil 04 closed = PbA (-)neg input, (PFC powers on)
 
−
    ''? Charge external mode ?''
 
 
   
 
   
−
123 '''Potential alternate logic sequence for use with DPDT Grid<->NiMH contactor'''
+
      CAN-View ?RL3^? (Enter Regen Mode)
−
000 = 0// ('''AC''' locks out coils 04 & 03)
+
    1 - ''only while grid interlock is active''
−
101 (AC is locked out by '''key on''' via coil 03)
+
  11011 - Key On, and PHEV run state
−
  111 (phev mode enabled and opperational via '''RL4''')
+
    Do Power down sequence '''Emulate Key Off''' less last state
−
  111 ('''RL2''' is SOC driven voltage dither)
+
  11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
−
110 '''Regen''' ('''RL3''' enter regen mode after sane CAN-View timeout)
+
  01001 - coil 01 Input -> Grid
−
        ''(we can loose grid interlock since we must be at speed? right?)''
+
  00001 - coil 02 Output -> PbA, PFC V Set PbA
−
  100 PFC Off
+
  00101 - coil 03 NiMH(Regen) -> Grid Input (PFC On)
−
  000 Grid->PbA
+
      CAN-View ?RL3v? (Exit Regen Mode)
−
  001 '''Now Regenning''' from NiMH -> Grid
+
  00101 - Key On, and PHEV regen state
−
  000 Nothing->Grid
+
00001 - coil 03 Grid -> Grid Input (PFC Off)
−
  100 PbA->NiMH
+
  01001 - coil 02 Output -> NiMH, PFC V Set NiMH low
−
  110 (phev mode enabled)
+
  11001 - coil 01 Input -> PbA
−
  111 (lockout grid again)
+
11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
−
  ''(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)''
+
''Forced PbA Charge Mode''
−
  --[[User:Rjf|Rjf]] 04:45, 9 June 2006 (CDT)
+
  ''(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)''
 +
  --[[User:Rjf|Rjf]] 04:34, 14 June 2006 (CDT)
  
 
====Enhanced Regen====
 
====Enhanced Regen====

Revision as of 09:34, 14 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 5 | (ac rated)
    |   |====|======================================|
    |   |    |                                      |
    |   |    |   |==================================|========|
  __|___|____|___|__                                |        |
  ! #   #    #   # !                                |        |
  !  \ , %%%% \ ,  ! 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  \   !   !___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&02&03&04&RLx interlock. (Set PFC Current < 15A)
////0 - 220v AC Present (DC immune) coil 01&02&03&04&RLx interlock. (Leave PFC Current Full)

      Power up sequence Key On
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)

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 04:34, 14 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.
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