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Difference between pages "PriusPlus-Theory" and "PriusPlus-Mechanical"

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(Clean-up, added CAN-View version info)
 
 
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Another Paragraph and such, you can get help at our [[Help:Contents#How do I use the Wiki Website]] page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref>  Feel free to simply remove or if you like move all of this example text to the pages discussion article.
 
Another Paragraph and such, you can get help at our [[Help:Contents#How do I use the Wiki Website]] page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref>  Feel free to simply remove or if you like move all of this example text to the pages discussion article.
  
Please feel free to hack this up or delete it, as I could have this all wrong.  I just wanted to get this started. Jim P.
+
==A Major Topic==
  
*Prius plus:
+
*Sub Parts construction and install
 +
**Air vents in tire well - This is a quick project that you can do to your car today. Remove spare tire and the two black drain plugs that sit in the tire well.  You may have to use a dremmel to open the hole so you can drop in the [Delete later-(Ron I think I found a piece of conduit that will flush mount in here. The PVC pipe can be glued to it.  I’ll get you a part number and picture. By doing this a project could be prepped weeks in advance and the spare will still fit in there until the final conversion days.)  ] 2” PVC threaded coupling.  Next connect the 2” 90 deg. Elbow and then a length of 2” PVC pipe per this photo (add photo showing underside of car with both pipes pointing back to the rear.)
 +
**Battery box base (Tom)
 +
**Battery trays (Tom)
 +
**Plastic parts mounting board (Little Jim)
 +
**Anti arc mounted to contactor - You will need a (identifying terminology here) capacitor part number (#) and solder one side to a “ ” ohm resistor and a matching length of wire to the other side of the capacitor. Once this has been completed cover the exposed wires with shrink wrap.  Finally, crimp ring connectors to each end and solder in place for a better connection.  (Add photo)
 +
**Heating pad power boxes (Ron, can this now be shrunk down to a single three outlet box?)
 +
**Charger mounting
 +
**Battery box mounting (Tom)
 +
**Power cord mounting (Little Jim or Tom)
 +
**Kil-a-watts meter mounting (Little Jim) Isn’t this just plugged in?
 +
**Amp meter mounting (Ron is the amp meter still needed?  Should we put this as optional?)
 +
**Diagnostic LEDs mounting - Use Velcro to mount it just inside the glass door under the radio. To run the ribbon cable, open up the dash and run a cable as shown it this diagram.  (Make and add diagram.)
 +
**V4 Screen mounting
 +
**[[CAN-View]] mounting
 +
**Prius disassembly and reassembly
  
The Prius plus system on the surface is remarkably simple...Genus in fact. The three main parts are;
+
===Sub Topic===
# The extra battery pack
+
Yes, this is a sub topic
# The CAN-View
 
# And, one circuit board
 
  
Now that is where this project starts but it get more complex than that.
+
===Sub Topic number two===
 
+
Final Install of Mechanical Parts
==The PHEV Battery Pack==
 
 
 
The PHEV battery pack has a higher nominal voltage than the stock NiMH battery and, in this design, is used to charge the stock NiMH battery.  Contactors (large relays) are used to connect and disconnect the PHEV battery pack from the stock battery.  The PHEV pack consists of twenty 12 volt 20 amp hour sealed lead acid batteries connected in series.  The nominal voltage of the pack is 240 volts and has a total energy storage of about 4.8 kWh (not all usable.)  The batteries are connected together with 8 gage wire and are protected by 60 amp fuses.  A hall sensor attached to this system can give you valuable information of how much power the pack is sending to the stock battery.
 
 
 
From end to end the pack goes something like this;
 
 
 
negative end – relay – shunt – hall sensor – fuse - (batteries 1-20) – fuse – relay – positive end
 
 
 
==The CAN-View==
 
 
 
The [[CAN-View]] monitors activity on the CAN bus (the bus which the different microprocessors in the Prius communicate) and provides a user interface to the PHEV and instructs the contactors on the PHEV battery pack to open and close to charge the stock battery.  CAN-View itself is simple to install and typically requires between a half hour to one and a half hours to install.  There are 2 versions of CAN-View currently available.  Version 2 requires an '04 or '05 Prius and makes use of the built in display (or [[MFD]]) while Version 3 works with an 04-07 Prius but requires an external touchscreen.  For more information, see [[CAN-View]].
 
 
 
==Circuit Board==
 
 
 
A circuit board is added to control the heaters, fans, contactors, etc.  This board also provides an interlock for the charger so that the car cannot be driven away while plugged into a live outlet. 
 
 
 
Sub parts of this board are;
 
* Power management
 
* Battery Heating & Cooling
 
* System diagnostics
 
* The board itself
 
 
 
===Power Management===
 
 
 
You want the system to know when to send power to the original battery and when it should take power from the regenerative braking system. It should also know when to shut the pack completely down such as when it is empty or when it is charging. Also, you want to tell the Prius battery computer that it has a high State of Charge so it keeps trying to use up the power.
 
 
 
===Battery Heating & Cooling===
 
 
 
Lead acid batteries do not function properly when they are either hot or cold.  The pack is heated and cooled as necessary by three Wal-Mart heating pads and three fans.  When cooling, the warm air has to go somewhere so it now goes out the two 2” holes under where the spare use to be.  The circuit board is responsible for controlling the heaters and fans.
 
 
 
===System Diagnostics===
 
 
 
Let’s say you blow a fuse or something is wrong somewhere how would you know? A ribbon cable is sent to the dash from the circuit board to show lights for what systems are working when.
 
 
 
===The Circuit Board===
 
 
 
It is a small board about 6” by 5” is my guess. I’ve held it but I did not measure it. So you now know what it controls, but it still needs power to run so that is another cable. It talks to the Canview to so yet another cable. It needs cables to the fans, the on off of the heating pads, and the charger too.
 
  
 
==References==
 
==References==
 
<references/>
 
<references/>

Revision as of 20:47, 11 December 2006

Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.

For Prius conversion details see the Prius PHEV article and comparisons table.

  1. Ron's Original PriusPlus History and current Contactor Based PriusPlus documentation for DIY projects.
  2. Ryan's PriusBlue is the testbed for DC-DC PFC Based PiPrius kits and documentation for DIY projects.
  3. Toyota OEM Prius PHEV and Prime Could use some work on this page
  4. Enginer China. But the rest of these appear to all be defunct as of 2020?
  5. |~- Hybrids-Plus USA/Colorado/Li -~|~- EnergyCS USA -~|~- Hymotion USA/Canada -~|~- Amberjac UK. -~|~- EDrive USA -~| Peter mentioned Plug-In Conversions |~-

--={ Project Overview }={ 2007 Maker Faire }={ Theory }={ Instructions }={ Parts List }={ RawData }={ Latest News }=--
--={ Doc Process }={ Mechanical }={ Electrical }={ Electronic }={ Interest }={ Talk:PriusPlus Main Discussion }=--

--={ Historic }={ Battery }={ Schematics }={ PseudoCode }={ Photos }=--

Team Photo from the PriusPlus conversion of Sven's Prius from Nov 2006.

This is the home of the PRIUS+ PHEV DIY (Do-it-Yourself) documentation. These pages are currently anonymously editable, which may change in the future. Please feel free to use the Discussion page for general discussion and commentary on the main article. If you would like to add to an existing section use the "edit" link near that topic's heading. Don't forget to use the Summary field to describe your changes. While editing use the "Show Preview" button to make sure your changes look like you expect them to, before you click "Save Page".



Intro Paragraph here maybe with a link to the main PriusPlus article, links to external sites can appear as formatted CalCars, just plain URLs like http://www.calcars.com, or fancy references such as that in the next paragraph.

Another Paragraph and such, you can get help at our Help:Contents#How do I use the Wiki Website page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref> Feel free to simply remove or if you like move all of this example text to the pages discussion article.

A Major Topic

  • Sub Parts construction and install
    • Air vents in tire well - This is a quick project that you can do to your car today. Remove spare tire and the two black drain plugs that sit in the tire well. You may have to use a dremmel to open the hole so you can drop in the [Delete later-(Ron I think I found a piece of conduit that will flush mount in here. The PVC pipe can be glued to it. I’ll get you a part number and picture. By doing this a project could be prepped weeks in advance and the spare will still fit in there until the final conversion days.) ] 2” PVC threaded coupling. Next connect the 2” 90 deg. Elbow and then a length of 2” PVC pipe per this photo (add photo showing underside of car with both pipes pointing back to the rear.)
    • Battery box base (Tom)
    • Battery trays (Tom)
    • Plastic parts mounting board (Little Jim)
    • Anti arc mounted to contactor - You will need a (identifying terminology here) capacitor part number (#) and solder one side to a “ ” ohm resistor and a matching length of wire to the other side of the capacitor. Once this has been completed cover the exposed wires with shrink wrap. Finally, crimp ring connectors to each end and solder in place for a better connection. (Add photo)
    • Heating pad power boxes (Ron, can this now be shrunk down to a single three outlet box?)
    • Charger mounting
    • Battery box mounting (Tom)
    • Power cord mounting (Little Jim or Tom)
    • Kil-a-watts meter mounting (Little Jim) Isn’t this just plugged in?
    • Amp meter mounting (Ron is the amp meter still needed? Should we put this as optional?)
    • Diagnostic LEDs mounting - Use Velcro to mount it just inside the glass door under the radio. To run the ribbon cable, open up the dash and run a cable as shown it this diagram. (Make and add diagram.)
    • V4 Screen mounting
    • CAN-View mounting
    • Prius disassembly and reassembly

Sub Topic

Yes, this is a sub topic

Sub Topic number two

Final Install of Mechanical Parts

References

<references/>