General Disclaimer: (HV) (DC) injury or death hazard, use at your own risk, may void warranty. |
Difference between revisions of "Prius PHEV Schematics"
(LV Schematics.) |
(→PFC Based: Added simplified relay layout (no regen)) |
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Line 195: | Line 195: | ||
* Use a Honking Big diode and a properly sized PbA Pack. | * Use a Honking Big diode and a properly sized PbA Pack. | ||
* Use a contactor and a diode and a properly sized PbA Pack. | * Use a contactor and a diode and a properly sized PbA Pack. | ||
+ | |||
+ | |||
+ | ====Automatic Charge - PHEV Drive Mode Change (No Regen)==== | ||
+ | ''View with fixed-width fonts'' <font color=red>'''This has not yet been validated for proper opperation'''</font> | ||
+ | '''Automatic [ Charge - PHEV Drive ] Mode Change, HV & LV Layout''' | ||
+ | coil 01 is a pair of DPDT or a single 4PDT | ||
+ | coil 02 is a SPST (Rated 40+ Amps for DC MAKE/BREAK) | ||
+ | * Ignition energizes mode change (unless PFC is running from grid) | ||
+ | * CAN-View RL4 (OEM/PHEV Mode) energizes Coil 02 powering up PFC (DC MAKE) | ||
+ | * Once PFC is running mode change is energized by both ignition and PFC RegBus | ||
+ | ** Ignition off results in CAN-View RL4 releasing powering down PFC (DC BREAK) | ||
+ | ** Mode change can only return to grid once PFC RegBus goes offline | ||
+ | |||
+ | (+)[Grid](-) (+)[PbA](-) (-)[NiMH](+) | ||
+ | | | | | | | | ||
+ | | |====|========#=======|==========|====| | | ||
+ | | | | | | | | | ||
+ | | | | |=======| #======| | | | | ||
+ | | | | | __|____|__ | | | | | ||
+ | | | | | | # ,, # ! | | | | | ||
+ | __|___|____|___|__ ! ---- ! __|___|____|___|__ | ||
+ | ! # # # # ! ! %%%% ! ! # # # # ! | ||
+ | ! \ , %%%% \ , ! ! coil ! ! \ , %%%% \ , ! | ||
+ | ! \ coil \ ! !___02___! ! \ coil \ ! | ||
+ | !___#___01___#___! !___#___01___#___! | ||
+ | | | \ / | | | ||
+ | |(+) (-)| \ / |(-) (+)| ( +5v from ) | ||
+ | [PFC Input] \ / [PFC Output] ( PFC RegBus ) | ||
+ | \<===#===>/ | | | ||
+ | | | | (Ign +12v)---< | ||
+ | |=====| |=====#==========|====================| | | | | ||
+ | | __|____|__ | | | | | | | ||
+ | | | # ,, # ! | (coil / 01) |========| | | | | |=====| | ||
+ | | ! ---- ! | ______|________|__ __|____|__ | | __|____|__ | | ||
+ | | g===%%%%====| | ! # # # # ! | # ,, # ! | | | #____# ! | | ||
+ | | ! NO ! | |====%\ ,%%%%%%\ ,%==g ! ---- ! | | ! .... ! | | ||
+ | | !________! | ! \ \ ! |====%%%%=====#=|=====%%%%====| | | ||
+ | | | !___#________#___! | ! NO ! | ! NC ! | | | ||
+ | | | | | | !________! | !________! | | | ||
+ | |===(Bat +12)==|========#========# |===============#=============| | | ||
+ | | | | | ||
+ | ^ |========================================================| | ||
+ | --[[User:Rjf|Rjf]] 06:51, 2 September 2006 (CDT) | ||
[[Category:PHEV]] | [[Category:PHEV]] | ||
[[Category:Prius]] | [[Category:Prius]] | ||
[[Category:Prius PHEV]] | [[Category:Prius PHEV]] |
Revision as of 11:51, 2 September 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, HV Layout 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] --Rjf 15:49, 14 June 2006 (CDT)
This has not yet been validated for proper opperation 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)
View with fixed-width fonts This has not yet been validated for proper opperation Automatic [ Charge - PHEV Drive - Regen ] Mode Change, LV Layout (-)12v Acc(+) | | |======# |========| | ____|____ ____|____ | ! # ! ! # ! (-)12v | ! \ ! ! \ ! (+)12v When======#===#%,%\%#===| |====#%,%\%#=======(Brown) AC Exists !_#___#_! | | !_#___#_! Key On | | | | | | MM-PFC=========| #====|===| | | LowCurrent | | | | if 110vac | |=========|===| | | OEM (-) Contactor | | Leg (Black)========| | AC/Run Interlocks ...................................|..................... (+) |=========================| | | SPDT #===NO==(Coil 01 & Coil 02), MM-PFC Vset Ni-Low=======(-(1) 12v)===# | (Cap to Delay Opening and Closing) | | | | SPDT | #===NO==CAN-RL4, Coil 04 (Pb->MM-PFC, Power On)=======(-(1) 12v)===# | (No Cap, Opens and Closes Instantly) | | | | SPDT | #===NO==CAN-RL2+3, (SOC Driver) MM-PFC Vset Ni-High===(-(1) 12v)===# | | | | | | | (-) 12v=!=NC======================!=============>==(-(1) 12v)=>=# | !DPDT CAN-RL5+6, (Regen) ! #==========!=NO======================!=Coil 03===(-) 12v ( Remove (-(1) 12v) Coil 04 Drops Immediatly ) ( Coil 01&02 Delayed ) ( Coil 03 Delayed More ) ( Adding (-(1) 12v) Coil 03 Drops Immediatly ) ( Coil 01&02 Delayed ) ( Coil 04 Delayed More ) --Rjf 00:24, 22 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.
Automatic Charge - PHEV Drive Mode Change (No Regen)
View with fixed-width fonts This has not yet been validated for proper opperation Automatic [ Charge - PHEV Drive ] Mode Change, HV & LV Layout coil 01 is a pair of DPDT or a single 4PDT coil 02 is a SPST (Rated 40+ Amps for DC MAKE/BREAK) * Ignition energizes mode change (unless PFC is running from grid) * CAN-View RL4 (OEM/PHEV Mode) energizes Coil 02 powering up PFC (DC MAKE) * Once PFC is running mode change is energized by both ignition and PFC RegBus ** Ignition off results in CAN-View RL4 releasing powering down PFC (DC BREAK) ** Mode change can only return to grid once PFC RegBus goes offline (+)[Grid](-) (+)[PbA](-) (-)[NiMH](+) | | | | | | | |====|========#=======|==========|====| | | | | | | | | | | | |=======| #======| | | | | | | | __|____|__ | | | | | | | | | # ,, # ! | | | | __|___|____|___|__ ! ---- ! __|___|____|___|__ ! # # # # ! ! %%%% ! ! # # # # ! ! \ , %%%% \ , ! ! coil ! ! \ , %%%% \ , ! ! \ coil \ ! !___02___! ! \ coil \ ! !___#___01___#___! !___#___01___#___! | | \ / | | |(+) (-)| \ / |(-) (+)| ( +5v from ) [PFC Input] \ / [PFC Output] ( PFC RegBus ) \<===#===>/ | | | | | (Ign +12v)---< |=====| |=====#==========|====================| | | | | __|____|__ | | | | | | | | # ,, # ! | (coil / 01) |========| | | | | |=====| | ! ---- ! | ______|________|__ __|____|__ | | __|____|__ | | g===%%%%====| | ! # # # # ! | # ,, # ! | | | #____# ! | | ! NO ! | |====%\ ,%%%%%%\ ,%==g ! ---- ! | | ! .... ! | | !________! | ! \ \ ! |====%%%%=====#=|=====%%%%====| | | | !___#________#___! | ! NO ! | ! NC ! | | | | | | | !________! | !________! | | |===(Bat +12)==|========#========# |===============#=============| | | | | ^ |========================================================| --Rjf 06:51, 2 September 2006 (CDT)