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Difference between pages "Prius PHEV" and "GrayPearl"

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(→‎Prius Conversions Chronology: GrayPearl misspelled)
 
(Data, spreadsheet, and images.)
 
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[[Image:Calcars-logo-large.png|right|160px]]
 
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[[Image:Pluginpartnerslogo.gif|right|80px]]
 
  
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To this date there have been a number of successful [[Toyota Prius|Prius]] [[PHEV]]<ref>[[Maillist]] & http://groups.yahoo.com/group/gridable-hybrids</ref> conversions beginning with [[User:Rgremban|Ron]] of [[:Category:CalCars|CalCars]]<ref>http://www.CalCars.org & http://groups.yahoo.com/group/calcars-news</ref> [[PriusPlus History|Original]]<ref>http://groups.yahoo.com/group/priusplus</ref> and current [[PriusPlus]].
+
'''"GrayPerl"''' is the name of the Todd Dore, of the [http://www.fveaa.org Fox Valley EAA chapter], Prius was converted in mid Nov 2006 with the third [[PiPrius]] kit.
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Other small startups include the [[PiPrius]]<ref>http://www.PiPrius.com & http://www.manzanitamicro.com</ref> ''(WA)'' and [[Hybrids-Plus]]<ref>http://hybrids-plus.com & http://energysense.com</ref> ''(CO)'' projects.
+
Todd has a PV system and a new Sunny boy grid tie inverter which will now help provide some of his transportation fuel needs.
−
[[EDrive|EDrive/EnergyCS]]<ref>http://www.edrivesystems.com</ref> ''(CA)'' will offer consumer conversion soon, and has produced the most evaluation Prius PHEVs to this point.
 
−
Canadian [[Hymotion]]<ref>http://www.hymotion.com</ref> ''(Toronto, ON)'' is offering conversion kits to fleets and eventually consumers.
 
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The tenth conversion of [[PriusBlue]] was undertaken in public at the [[Inaugural Maker Faire]] to help enhance the documentation and help promote PHEVs in the pacific northwest and midwest.
 
−
Recently CalCars has begun working to perfect various '''[[#Hybrid-Pack Method]]''' techniques to remedy the [[State Of Charge Manipulation#Charge Limit Conundrum|CCL Conundrum]].
 
  
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At this time there are two common conversion methods for the Prius.
+
==Data==
−
The '''[[#Original CalCars Method]]''' used in Rons [[PriusPlus History]], [[EDrive]], and [[Hybrids-Plus]] conversions replace the stock battery with a new [[Battery Pack Configurations#Simple|simple string]].
+
Here is some data that Todd has collected...
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The second '''[[#Hybrid-Pack Method]]''' is used in the new [[PriusPlus]], [[PiPrius]], and believed to be used by the [[Hymotion]] conversions.
+
* [[Image:GrayPearl_Mileage_Log.zip]] spreadsheets.
−
This second method should be easily adapted from the '04+ [[Toyota Prius|Prius]] to the ''Classic'' '00-'03 Prius, [[Ford Escape Hybrid|Escape]], and other [[Hybrid]]s as they use a [[Battery_Pack_Configurations#Hybrid|hybrid battery pack configuration]] which uses both a new simple string and the original stock batteries.
+
{| width=500
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Both types, of course, use a [[Battery Chargers]] to recharge from the grid.
+
| valign=top | [[Image:GrayPearl-MPG Date.jpg|thumb|[[GrayPearl]] MPG by Date]]
−
Toyota has stated that such a conversions will adversely affect your [[Warranty]].
+
| valign=top | [[Image:GrayPearl-MPG Temp.jpg|thumb|[[GrayPearl]] MPG by Temp]]
−
 
 
−
The [[Prius PHEV TechInfo]] page has a lot of technical information on the Prius which  may be useful when designing a PHEV conversion.
 
−
See the [[Template:Terms|Terms]] page is you aren't familiar with some of the acronyms used through the documentation.
 
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Also be aware of the [[Template:Disclaimer|Disclaimer]] should you be considering a conversion yourself.
 
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This [http://www.airlabcorp.com/Prius/priusdisman.pdf PriusDisMan.pdf] <ref>[[Media:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref> might be handy for its dismantle and safety warnings''
 
−
 
 
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==Prius Conversions Chronology==
 
−
For a more detailed chronology of Prius conversions, including pictures, locations and contact information of the owners, see [http://www.calcars.org/where-phevs-are.html where-phevs-are] at calcars.org.
 
−
# Fall 2004 - CalCars [[PriusPlus History|PRIUS+/Ron Gremban]] by [[User:Rgremban|Ron Gremban]], [[EDrive|EnergyCS]] and CalCars team
 
−
# Mar. 2005 - [[EDrive|EnergyCS]] by Greg Hanssen, Pete Nortman and team
 
−
# May 2005 - Energy CS/Clean-Tech by [[EDrive|EnergyCS]]
 
−
# Sept. 2005 - Amberjac Projects Ltd UK, by [[EDrive|EnergyCS]]/[[Amberjac]]
 
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# Feb. 2006 - [[Hymotion]] by Hymotion
 
−
# Mar. 2006 - Electro Energy by CalCars and [http://www.electroenergyinc.com/ Electro Energy]
 
−
# Mar. 2006 - South Coast Air Quality Management District by [[EDrive|EnergyCS]]
 
−
# Apr. 2006 - CalCars/Felix Kramer by [[EDrive|EnergyCS]]
 
−
# Apr. 2006 - Sacramento Municipal Utility District by [[EDrive|EnergyCS]]
 
−
# Apr. 22-24 - [[User:Rjf|Ryan Fulcher]] of the [[SEVA:|Seattle EVA]] by CalCars and the [[Inaugural Maker Faire|Maker Faire team]]
 
−
# May 2006 - City of Santa Monica by [[EDrive|EnergyCS]], (Los Angeles County, contact rick.sikes [at] smgov.net)
 
−
# July 2006 - Pacific Gas & Electric/Bay Area Air Quality Management District by [[EDrive|EnergyCS]], (San Francisco County, contact sxtg [at] pge.com
 
−
# Aug. 2006 - Hourcar by [[Hymotion]], (Twin Cities, MN, contact info@hourcar.org)
 
−
# Aug. 2006 - Southern California Edison by [[EDrive|EnergyCS]], (Los Angeles County)
 
−
# Aug. 2006 - South Coast Air Quality Management District #2, by [[EDrive|EnergyCS]] (Los Angeles County)
 
−
# Sept. 2006 - Hybrids-Plus by [[Hybrids-Plus]], (Boulder, CO, contact info@hybrids-plus.com)
 
−
# Sept. 2006 - Manitoba Hydro by [[EDrive|EnergyCS]], (Winnipeg, Manitoba)
 
−
# Sept. 2006 - Veridian Corp. by [[Hymotion]], (Ajax, Ontario, contact dhillsmilligan [at] veridian.on.ca)
 
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# Oct. 2006 - Chelan County (WA) [http://www.ncwctc.com/205.html Advanced Vehicle Initiative]'s "[[WhiteBird]]" was converted with the second [[PiPrius]] kit, (Contact Ron Johnston-Rodriguez: info [at] plugincenter.com or (509) 663-5159)
 
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# Nov. 2006 - Todd Dore of the [http://www.fveaa.org/ Fox Valley EAA chapter], Prius [[GrayPearl]] was converted with the third [[PiPrius]] kit.
 
−
# Nov. 2006 - CalCars new [[PriusPlus]] conversion of Sven Thesen's 2005 Prius
 
−
# ?
 
−
 
 
−
==Original CalCars Method==
 
−
Further development of the Original CalCars method has been postponed to check-out the [[#Hybrid-Pack Method]]:
 
−
{|
 
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| valign=top |
 
−
This method exploits the [[State Of Charge Drift]] portion of the vehicles battery management routines in order to accomplish [[State Of Charge Manipulation]] with the use of a [[Battery Tap Emulator]].  The result is the ability to effectively change the target [[SOC]] from the normal 3/4 to 1/4 which is more useful for [[PHEV]] applications.  The [[Prius EV Mode]] is also utilized to further enhance the use of the additional electric energy provided by a larger [[Prius PHEV Battery Options-CalCars]]. A [[CAN]] device is required to acts as a [[Prius PHEV User Interfaces|Prius PHEV User Interface]] and management device. Such hardware/software will need to follow logic similar to that laid out by [[Prius PHEV Pseudo Code]].  Ron's first [[PriusPlus]] conversion used early proprietary [[EDrive]] technology. Later conversions will use [http://www.hybridinterfaces.ca hybridinterfaces] [[CAN-View]] Scantool which is currently available only for 2004 and 2005 Prius.  You can take a looks at [[Prius PHEV Photos]] which are available to help visualize parts of the conversion process.
 
−
| valign=top |
 
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<center>'''[[Prius PHEV Schematics-CalCars]] are Dormant.'''</center>
 
−
{{PriusPlus Schematics Small}}
 
 
|}
 
|}
  
−
==Hybrid-Pack Method==
+
==Photos==
−
The Hybrid-Pack method:
 
−
 
 
−
<strike>As of yet unimplemented except</strike> perhaps by [[Hymotion]], until we know more, see [[Battery Pack Configurations#Hybrid]] for the core ideas surrounding this method or [[Prius PHEV Battery Options]] for more specific battery information.  CalCars is now working towards implementing this type of configuration in three Prii with much success thus far. Stay tuned...
 
−
 
 
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===Contactor Based===
 
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Ron is refining a contactor and resistor based setup in his car.
 
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* [[Prius PHEV Battery Options#Contactor Based]]
 
−
* [[State Of Charge Manipulation#Contactor Based]]
 
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* [[Prius PHEV Schematics#Contactor Based]]
 
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* Documents from 2004 with information and considerations regarding various configurations.
 
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** http://www.forsites.com/CalCars/EAA-PHEV/PriusPlusConfigurations040817rdg.pdf
 
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** http://www.forsites.com/CalCars/EAA-PHEV/PriusPlusConfigurations040817rdg.xls
 
−
* '''Good news: a hybrid-battery solution to the CCL conundrum'''<br>Ron Gremban - [[EAA-PHEV_Maillist:2006./5./5]] & [http://autos.groups.yahoo.com/group/eaa-phev/message/187 Y:187]
 
−
 
 
−
===PFC Based===
 
−
'''Rich Rudman of [http://www.manzanitamicro.com manzanitamicro], and [[User:Rjf|Ryan]]''' are working on an implementation using an upgraded PFC-30 as a DC-DC converter and charger, and Rich is hoping to develop and offer conversion kits.
 
−
 
 
−
'''See [[PiPrius]] for more details.'''
 
−
* [[Prius PHEV Battery Options#PFC Based]]
 
−
* [[State Of Charge Manipulation#PFC Based]]
 
−
* [[Prius PHEV Schematics#PFC Based]]
 
  
−
'''Electro Energy''' has successfully demonstrated a PFC based setup with [[SEVA:Ni|NiMH]] during CalCars trip to DC.
+
===Day 1===
−
* 2006.05.26 - financialnewsusa.com - [http://www.financialnewsusa.com/release.php?rlsid=5262 Electro Energy Participates in Plug-In Hybrid Vehicle Demonstration in Washington, D.C. and Power Air Lists on Frankfurt Stock Exchange]
+
<gallery>
 +
Image:Day_1_Image_1.jpg|batteries arrive in box on the pallet,  Notice the order of the batteries – they must be installed in the same pattern.
 +
Image:Day_1_Image_2.jpg|side view of battery box in pallet.
 +
Image:Day_1_Image_3.jpg|genesis XE30 sealed lead-acid batteries from Enersys. Provided by Dick Brown, who is a distributor.  These are 12V batteries rated at 28 amp-hours at 10C.
 +
Image:Day_1_Image_4.jpg|angle view of batteries in the box.
 +
Image:Day_1_Image_5.jpg|start to dis-assemble the false floor in the back of the Prius.
 +
Image:Day_1_Image_6.jpg|Rob Glowacki continuing the dis-assembly.
 +
Image:Day_1_Image_7.jpg|The Prius HV battery box. We must have turned off the flash on this one!
 +
Image:Day_1_Image_8.jpg|flash back on – lining up the battery box in the well at the back of the Prius.  Rich Rudman engineered the box to fit snuggly in the factory-made well.  The spare tire must be removed first.
 +
Image:Day_1_Image_9.jpg|flash off again – Rob and John Emde discussing the weather.
 +
Image:Day_1_Image_10.jpg|the front left corner of the back of the Prius.  The studs hold the keyless entry device, and must be sheared off to fit the battery box in.
 +
Image:Day_1_Image_11.jpg|John shearing the studs off.  Watch those sparks!
 +
Image:Day_1_Image_12.jpg|John cutting away part of the battery box flange to fit around a bolt on the floor of the Prius.
 +
Image:Day_1_Image_13.jpg|Sizing up the battery box with the flange that John just cut.
 +
Image:Day_1_Image_14.jpg|The back right side of the battery box with the flange – that’s where a bolt hole will have to go. Note the black plastic box that we are looking down on – this is next to the 12V battery in the Prius and drives anti-lock brakes or the air bags (not sure which).  Flash on with this photo!
 +
Image:Day_1_Image_15.jpg|Filing away the sharp edges for the portions cut out of the flange for the battery box.  Everything must be as flush as possible with the floor of the Prius.  Note the box fits over the empty well for the spare tire.  There is room for the spare tire, but you have to remove the battery box to get to it! (so take out the spare).
 +
Image:Day_1_Image_16.jpg|The left section of the cover for the Prius HV battery.  Studs have been sheared off for the PHEV kit battery box.
 +
Image:Day_1_Image_17.jpg|The Prius is hoisted up and we’re looking at the area that we have to drill a bolt hole.
 +
Image:Day_1_Image_18.jpg|John smiling underneath the car. The muffler and the heat shield are visible. The muffler has to be pushed aside and the heat shield taken off to drill the bolt holes on the right side (everything is put back in place afterwards).  Can’t see John’s entire face!
 +
Image:Day_1_Image_19.jpg|The center hole is where the bolt hole is drilled for the back left of the box (driver’s side).
 +
Image:Day_1_Image_20.jpg|Drilling the hole for the box.
 +
</gallery>
  
−
==References==
+
===Day 3===
−
<references/>
+
<gallery>
 +
Image:Day_3_Image_1.jpg|bolting the battery box by the muffler.
 +
Image:Day_3_Image_2.jpg|The heat shield removed and the battery bolt holes exposed.
 +
Image:Day_3_Image_3.jpg|The heat shield installed.  Notice the battery box bolt.
 +
Image:Day_3_Image_4.jpg|The [[CAN-View]] installed.  It is a very simple installation process (more images to follow).  Main read out screen and change of PHEV controls are all done on the Prius display screen.
 +
Image:Day_3_Image_5.jpg|Rich Rudman doesn’t want to be bothered!  [[CAN-View]] installation.
 +
Image:Day_3_Image_6.jpg|Removing the protective cover of the Prius HV battery box.  Underneath are the main contactors.
 +
Image:Day_3_Image_7.jpg|The orange cables are the most positive and most negative of the Prius HV system.
 +
Image:Day_3_Image_8.jpg|The Rudman kit – cables come off of the HV battery.  A couple of installation points inside.
 +
Image:Day_3_Image_9.jpg|John working on the sharp edges of the HV cover.
 +
Image:Day_3_Image_10.jpg|Inside the PHEV HV box where the main contactors are and cables.  The black-coated cables represent our installation.
 +
Image:Day_3_Image_11.jpg|tapping into the NAV system 12V wire to install the [[CAN-View]].
 +
</gallery>
  
−
==Kits and Conversions==
+
===Day 4===
−
===[[Template:Prius PHEV Options Summary]]===
+
<gallery>
−
{{Prius PHEV Options Summary}}
+
Image:Day_4_Image_1.jpg|[[CAN-View]].
−
===[[Template:PHEV Consumer Options]]===
+
Image:Day_4_Image_2.jpg|Rich standing by his [[MM-PFC|charger]].  The charger is bolted into a cavity on the driver’s side.  It also acts as a DC-DC converter for the PHEV system.
−
{{PHEV Consumer Options}}
+
Image:Day_4_Image_3.jpg|The [[CAN-View]] is on top of the NAV and underneath the driver’s seat.
−
===[[Template:Prius PHEV Options]]===
+
Image:Day_4_Image_4.JPG|The battery box, [[MM-PFC|charger]], and relay box (with contactors) are shown here.  All are part of the kit.
−
{{Prius PHEV Options}}
+
Image:Day_4_Image_5.JPG|The batteries have now been installed!
 +
Image:Day_4_Image_6.JPG|The inside of the relay box.  Notice the contactors.  This controls the [[MM-PFC|AC charging and the DC-DC function]].  It also has a safety so the DC-DC switches off when the car is charging or inactive completely.
 +
Image:Day_4_Image_7.JPG|Another view of the [[MM-PFC|charger]] when it’s on.
 +
Image:Day_4_Image_8.JPG|Rich is testing the voltage of the batteries.
 +
Image:Day_4_Image_9.JPG|The job is done!  Everyone smiling in front of the completed car on Saturday.  Everybody there helped out that day.
 +
</gallery>
  
−
{{Maillist Archives}}
+
===Day 5===
 +
<gallery>
 +
Image:Day_5_Image_1.jpg|The kit installed with carpeting put back in.  Lots of cables and wires to be hidden yet!
 +
Image:Day_5_Image_2.jpg|testing some of the regs – the readout of the computer program.  Only 6 are in the kit now and they all don’t quite work.  Must make sure not to drain the batteries too much until all the regs arrive, are installed, and properly set.  The computer program sets the reg specifications.  Flash on!
 +
Image:Day_5_Image_3.jpg|The computer and the PC to test the regs.
 +
Image:Day_5_Image_4.jpg|The reg rails on top of the battery box and 4 regs installed.
 +
</gallery>
  
−
{{Disclaimer}}
 
  
 
[[Category:PHEV]]
 
[[Category:PHEV]]
 
[[Category:Prius]]
 
[[Category:Prius]]
 
[[Category:Prius PHEV]]
 
[[Category:Prius PHEV]]
 +
[[Category:PiPrius]]

Revision as of 00:51, 2 March 2007

"GrayPerl" is the name of the Todd Dore, of the Fox Valley EAA chapter, Prius was converted in mid Nov 2006 with the third PiPrius kit. Todd has a PV system and a new Sunny boy grid tie inverter which will now help provide some of his transportation fuel needs.

Data

Here is some data that Todd has collected...

GrayPearl MPG by Date
GrayPearl MPG by Temp

Photos

Day 1

  • batteries arrive in box on the pallet, Notice the order of the batteries – they must be installed in the same pattern.

  • side view of battery box in pallet.

  • genesis XE30 sealed lead-acid batteries from Enersys. Provided by Dick Brown, who is a distributor. These are 12V batteries rated at 28 amp-hours at 10C.

  • angle view of batteries in the box.

  • start to dis-assemble the false floor in the back of the Prius.

  • Rob Glowacki continuing the dis-assembly.

  • The Prius HV battery box. We must have turned off the flash on this one!

  • flash back on – lining up the battery box in the well at the back of the Prius. Rich Rudman engineered the box to fit snuggly in the factory-made well. The spare tire must be removed first.

  • flash off again – Rob and John Emde discussing the weather.

  • the front left corner of the back of the Prius. The studs hold the keyless entry device, and must be sheared off to fit the battery box in.

  • John shearing the studs off. Watch those sparks!

  • John cutting away part of the battery box flange to fit around a bolt on the floor of the Prius.

  • Sizing up the battery box with the flange that John just cut.

  • The back right side of the battery box with the flange – that’s where a bolt hole will have to go. Note the black plastic box that we are looking down on – this is next to the 12V battery in the Prius and drives anti-lock brakes or the air bags (not sure which). Flash on with this photo!

  • Filing away the sharp edges for the portions cut out of the flange for the battery box. Everything must be as flush as possible with the floor of the Prius. Note the box fits over the empty well for the spare tire. There is room for the spare tire, but you have to remove the battery box to get to it! (so take out the spare).

  • The left section of the cover for the Prius HV battery. Studs have been sheared off for the PHEV kit battery box.

  • The Prius is hoisted up and we’re looking at the area that we have to drill a bolt hole.

  • John smiling underneath the car. The muffler and the heat shield are visible. The muffler has to be pushed aside and the heat shield taken off to drill the bolt holes on the right side (everything is put back in place afterwards). Can’t see John’s entire face!

  • The center hole is where the bolt hole is drilled for the back left of the box (driver’s side).

  • Drilling the hole for the box.

Day 3

  • bolting the battery box by the muffler.

  • The heat shield removed and the battery bolt holes exposed.

  • The heat shield installed. Notice the battery box bolt.

  • The CAN-View installed. It is a very simple installation process (more images to follow). Main read out screen and change of PHEV controls are all done on the Prius display screen.

  • Rich Rudman doesn’t want to be bothered! CAN-View installation.

  • Removing the protective cover of the Prius HV battery box. Underneath are the main contactors.

  • The orange cables are the most positive and most negative of the Prius HV system.

  • The Rudman kit – cables come off of the HV battery. A couple of installation points inside.

  • John working on the sharp edges of the HV cover.

  • Inside the PHEV HV box where the main contactors are and cables. The black-coated cables represent our installation.

  • tapping into the NAV system 12V wire to install the CAN-View.

Day 4

  • Rich standing by his charger. The charger is bolted into a cavity on the driver’s side. It also acts as a DC-DC converter for the PHEV system.

  • The CAN-View is on top of the NAV and underneath the driver’s seat.

  • The battery box, charger, and relay box (with contactors) are shown here. All are part of the kit.

  • The batteries have now been installed!

  • The inside of the relay box. Notice the contactors. This controls the AC charging and the DC-DC function. It also has a safety so the DC-DC switches off when the car is charging or inactive completely.

  • Another view of the charger when it’s on.

  • Rich is testing the voltage of the batteries.

  • The job is done! Everyone smiling in front of the completed car on Saturday. Everybody there helped out that day.

Day 5

  • Day 5 Image 1.jpg

    The kit installed with carpeting put back in. Lots of cables and wires to be hidden yet!

  • Day 5 Image 2.jpg

    testing some of the regs – the readout of the computer program. Only 6 are in the kit now and they all don’t quite work. Must make sure not to drain the batteries too much until all the regs arrive, are installed, and properly set. The computer program sets the reg specifications. Flash on!

  • Day 5 Image 3.jpg

    The computer and the PC to test the regs.

  • Day 5 Image 4.jpg

    The reg rails on top of the battery box and 4 regs installed.

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