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Difference between revisions of "Prius PHEV Schematics"

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(LV Schematics.)
(→‎PFC Based: Added simplified relay layout (no regen))
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)
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