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Difference between revisions of "Prius PHEV"

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(Original CalCars Method)
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At this time there are two common conversion methods for the Prius.
 
At this time there are two common conversion methods for the Prius.
The '''[[#CalCars Method]]''' used in Rons [[PriusPlus]] and [[EDrive]]s conversions replace the stock battery with a new [[Battery Pack Configurations#Simple|simple string]].
+
The '''[[#Original CalCars Method]]''' used in Rons [[PriusPlus]] and [[EDrive]]s conversions replace the stock battery with a new [[Battery Pack Configurations#Simple|simple string]].
 
The second '''[[#Hybrid-Pack Method]]''' which is believed to be used by the [[Hymotion]] kits for the [[Toyota Prius|Prius]] and [[Ford Escape Hybrid|Escape]]  use a [[Battery_Pack_Configurations#Hybrid|hybrid battery pack configuration]] which uses both a new simple string and the original stock batteries.  Other upcoming conversion projects for ''Classic'' 2000-2003 Prii and Ford Escape might also use this method.
 
The second '''[[#Hybrid-Pack Method]]''' which is believed to be used by the [[Hymotion]] kits for the [[Toyota Prius|Prius]] and [[Ford Escape Hybrid|Escape]]  use a [[Battery_Pack_Configurations#Hybrid|hybrid battery pack configuration]] which uses both a new simple string and the original stock batteries.  Other upcoming conversion projects for ''Classic'' 2000-2003 Prii and Ford Escape might also use this method.
 
Both types of course use a [[Battery Chargers]] to refuel from the grid.
 
Both types of course use a [[Battery Chargers]] to refuel from the grid.

Revision as of 08:18, 28 May 2006

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There have already been a number of successfull Prius PHEV conversions such as Ron of CalCars PriusPlus and a similar EDrive consumer conversion, which is expected to become available in 2006. The tenth conversion was undertaken in public at the Inaugural Maker Faire to help enhance the documentation and help promote PHEVs in the pacific northwest and midwest. A company called Hymotion will be offering conversion kits to fleets and eventually consumers. Recently CalCars has begun working to perfect various #Hybrid-Pack Method techniques to remedy the CCL Conundrum.

See the Terms page is you aren't familure with some of the acronyms used throught the documentation. Also be aware of the Disclaimer should you be considering a conversion yourself. This PriusDisMan.pdf copy might be handy for its dismantle and safety warnings

At this time there are two common conversion methods for the Prius. The #Original CalCars Method used in Rons PriusPlus and EDrives conversions replace the stock battery with a new simple string. The second #Hybrid-Pack Method which is believed to be used by the Hymotion kits for the Prius and Escape use a hybrid battery pack configuration which uses both a new simple string and the original stock batteries. Other upcoming conversion projects for Classic 2000-2003 Prii and Ford Escape might also use this method. Both types of course use a Battery Chargers to refuel from the grid. Toyota has stated that such a conversions will affect your Warranty.


Original CalCars Method

Further development of the Original CalCars method has been postponed to persue the #Hybrid-Pack Method:

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 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 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.

Prius PHEV Schematics-CalCars are Dormant.
EAA-PHEV-PRIUS-Combined.png

Navigation Image

Hybrid-Pack Method

The Hybrid-Pack method:

As of yet un-implemented except perhaps by Hymotion, till 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 implamenting this type of configuration in three Prii with much success thus far, stay tuned...

Contactor Based

Ron is refining a contactor and resistor based setup in his car and has provided these documents from 2004 which have information and considerations regarding these configurations.

PFC Based

Rich Rudman of manzanitamicro, and Ryan are working on an implamentation using an upgraded PFC-30 as a DC-DC converter and charger, and Rich is hoping to develop and offer conversion kits.

Electro Energy has successfully demonstrated a PFC based setup with NiMH durring CalCars trip to DC.

Kits and Conversions

This div does not appear withing the page but is used to define the references used below. If multiple ref tags were to appear within the table only the text from the first would be displayed. Thus we pre-define them here, the only side effect being that the first "a" backlink does nothing.

<ref name=ev_range> EV range [mi] or All Electric Range (AER) Assuming <35 mph, 210 Wh/mile (260 Wh/mi from grid) per http://www.greencarcongress.com/2005/08/solarpoweraugme.html, 1.5 miles is approximately the range with a fully charged stock battery pack</ref>

<ref name=phev_range> PHEV range [mi] or Blended mode Range (BMR) During which the mileage is on the order of 100 mpg. Shows range as stated by organization.</ref>

<ref name=safety> Safety in case of major accident

  1. Many Lithium cells will burst in flames if penetrated. However, phosphate cathode LiIon cells (such as Valence and A123) are flame-proof.
  2. SLA batteries contain lead and sulphuric acid but are spill-proof</ref>

<ref name=charge_time> Charge time [hours] From discharged to the point the pack will no longer be used in PHEV, to fully charged.

(per Orbital, SLA require 8 hr taper -- done at least once every 3 days -- after near full charge, to reach 100% and prevent sulfation)</ref>

<ref name=energy> Available energy [KWh] Because the DOD of the stock pack is limited by the Prius, only about 0.3 KWh of its energy is available (used). It is assumed that additional batteries are limited to a DOD range of:

  1. SLA: 0% down to 50%, due to Wikipedia:Peukert's law much of the nameplate capacity is unavailable.
  2. Lithium: 0% down to 90%, has far less Peukert losses and can be safely deep discharged.</ref>

<ref name=spare_tire> Spare Tire access

  • No the original tire well is covered or occupied by the new battery pack and must be secured and stowed in the rear cargo space.
  • Yes the original tire well is accessible.
  • Opt Optionally the battery box may be implemented in such a way to preserve access.</ref>

<ref name=convert_service> Conversion service: done by the PHEV conversion company, at their location. Conversion kit: done by the owners in their hometown.</ref>

<ref name=status> Project Status:

  • Doc: Open Source Documentation in progress.
  • Dev: Development: Working vehicles on the road but some features still under development.
  • Unknown: Unknown: No public news the last 12 months
  • Prod: Production: Working vehicles on the road, performing conversions or supplying kits.</ref>

<ref name=topology_type> Topology Type:

  • New New Battery Pack and BMS, the OEM NiMH battery and BMS are replaced with a simple string.
  • Hyb OEM NiMH battery and additional battery are both utilized in a hybrid battery pack configuration, OEM BMS continues to manage OEM battery.
    • Con Contactors are used to parallel the OEM and PHEV batteries.
    • DC A DC to DC converter is used to move power forward from the PHEV to the OEM Battery.
    • CV The CAN-View is used to manage the PHEV systems operation.</ref>
Comparison table: PHEV conversion and kit options for the Toyota Prius
Organization :Location Websites (Products)
Conv. service
<ref name=convert_service/>

Conv. kit
<ref name=convert_service/>

Status
<ref name=status/>

# done so far
EV range [mi]
<ref name=ev_range/>

PHEV range [mi]
<ref name=phev_range/>

AC power
Charge time [hours]
<ref name=charge_time/>

Safety
<ref name=safety/>

Added weight [kg]
Spare Tire
<ref name=spare_tire/>

Cost [US$]
Warr. [years]
Type
<ref name=topology_type/>
Pack energy [KWh]
DOD energy [KWh]
<ref name=energy/>

Bat type
PriusPlus:CA<ref>CalCars is based in California, however locations where progress is being made and help is available now include CA, CT, CO, IL, and TX.</ref> CalCars (Pb
NiMH)
No Yes Dev Doc 5
<ref>CalCars completed the 1st ever Prius PHEV conversion 11/04, With six by 5/07 (One which became the test bed for the PiPrius project, two of which uses NiMH, and the latest which retains the spare tire.)</ref>
10-12
20-25
20+
40+
100 to 240 Vac 4+
5
<ref name=charge_time/>
Flame Spill proof 130
100
Opt $3-$9K +Labor
<ref>CalCars Batteries: ~$1K ($3-$5K for NiMH) Charger: $0.9-$2K Total: $3-$4K + labor for PbA conversions and an additional $3 to $5K for NiMH</ref>
0 Hyb Con CV 4.8
6.5
2.4-3.8 +0.3 stock
5
PbA (Ni, Li)
<ref>CalCars uses 20 * BB Battery EVP20-12B SLA (Sealed Lead-Acid). Have used Electroenergy NiMH in EEEI Prius and Nilar NiMH in Nilar Prius, evaluating Lithium.</ref>
PiPrius:WA Manzanita Micro, PiPrius, AVI, Green Car Co. No Yes Unknown 4
<ref>PiPrius vehicles include PriusBlue, WhiteBird, and GrayPearl.</ref>
10 20-30 90 to 300 Vac Vdc 0.4-3+
<ref>PiPrius Charges in about 3 hours @ 120v & 15a or can be charged in as little as 0.4 hours (24 minutes) @ 240v & up to 40amps with manual current control from 0 to 40amps.</ref><ref name=charge_time/>
Flame Spill proof 150 no $10K +Labor
<ref>PiPrius Batteries: $0.8K~$1.2K Charger/DC-DC: $3K Target: ~$10K</ref>
0 Hyb DC CV <ref>PiPrius notes:
  1. The PiPrius PFC40H charger doubles at the DC-DC converter between the OEM and added battery packs.
  2. BMS consists of a Mk 3 Reg on every battery, which fully protected each battery on charge and discharge mode.
  3. The BMS is programmable with a laptop, with no security locks (open source).</ref>
4.7 4+0.3 stock PbA (Ni, Li)
<ref>PiPrius uses 15 * Hawker EP26 SLA (Sealed Lead-Acid), 24 * 20Ah SLA., Evaluating Lithium, or users choice of chemistry, voltage and capacity.</ref>
EnergyCS:CA EnergyCS Yes No Unknown 11 30 50 120 Vac 9.0 Flame Spill proof 83 no $40K 0 New 9
<ref>EnergyCS has 9kWh of battery capacity from a 230v 40Ah pack</ref>
8 Li
<ref>EnergyCS uses Valence Saphion phosphate cathode LiIon cells extracted from U-Charge packs</ref>
Amberjac:UK Amberjac EnergyCS partner <ref>Amberjac uses the EnergyCS system electronics but a different battery manufacturer.</ref> Yes No Dev 7 30 60-70 110 to 230 Vac 9.0 Flame Spill proof 83 yes $40K 0 New 9
<ref>Amberjac has 9kWh of battery capacity from a 230v 40Ah pack</ref>
8 Li
<ref>Amberjac works closely with EnergyCS but uses a different battery system and manufacturer though the same (LiFePO4) chemistry</ref>
EDrive:CA EDrive Systems ? ? Unknown 0 32? 60? 100 to 240 Vac 9.0 via cell sep
<ref>EDrive Through cell separation</ref>
? yes $12K 0 New 9.5 8.5? Li
<ref>EDrive uses Laptop Cobalt LiIon 18650 cells</ref>
Hymotion:ON Canada Hymotion /A123 (PHEV-L5) Yes, fleets No Prod 18 15
<ref>In the past, Hymotion has stated 50 km (30 miles) pure EV range. Yet 4.3 KWh calculates out to 15 miles. The specs on their new website say "Up to 100 mpg for 30-40 miles", which means blended mode, and is indeed consistent with the energy stored in the battery</ref>
30 100 to 240 Vac 5.5 / 4.0 Spill proof 72 no $10K
<ref>Hymotion $10K may or may not include installation, depending on source</ref>
3 Hyb 5.0 4+0.3 stock Li
<ref>Hymotion uses Lithium polymer (future: A123 LiIon)</ref>
Plug-In Conversions:CA Plug-In Conversions Yes Yes Prod 15 25 50 120/240 Vac 6/2 Flame Spill proof 100 no $12.5K<ref>Plug-In Conversions High capacity chargers extra</ref> 3 New CV 6.1 5.1 NiMH
<ref>Plug-In Conversions Uses Gold Peak NiMH 10GP30EVH</ref>
Plug-In Supply:CA Plug-In Supply Yes Yes Prod 140 40-50 80-100 110 Vac 8 Flame Spill proof 220 Yes $13K 3 Hyb 10 10.6 LiFePO4
OEMtek:CA OEMtek Yes No Unknown ? 30 50 100/240 Vac 4/6 Flameproof 95 Yes $12K 0 Hyb 9 8 Li
3Prong Power:CA 3Prong Power Yes No Prod 12 10-12 20+ 110 Vac 4 Flame Spill proof 130 Yes $6.7K 1 Hyb 4.8 2.4 PbA
Enginer:MI Enginer No Yes Prod 795 10-20 20-40 110 Vac 3-5 Flame Spill proof 75-90 Yes $2-3K 2 Hyb 2-4 1.6-3.2 LiFePO4
MD-Tech:China MD-Tech No Yes Prod 200 25-30 35-40 110/230 Vac 3-5 Flame Spill proof 75-90 Yes $3K 2 Hyb 4 1.6-3.2 LiFePO4


Notes: <references/>


Prius Conversions Chronology

  1. Fall 2004 - CalCars PRIUS+/Ron Gremban by Ron Gremban, EnergyCS and CalCars team
  2. March 2005 - EnergyCS by Greg Hanssen, Pete Nortman and team
  3. May 2005 - Energy CS/Clean-Tech by EnergyCS
  4. Sept. 2005 - Amberjac Projects Ltd UK, by EnergyCS/Amberjac
  5. Feb. 2006 - Hymotion by Hymotion
  6. March 2006 - Electro Energy by CalCars and Electro Energy
  7. March 2006 - South Coast Air Quality Management District by EnergyCS
  8. April 2006 - CalCars/Felix Kramer by EnergyCS
  9. April 2006 - Sacramento Municipal Utility District by EnergyCS
  10. April 22-24 - Ryan Fulcher of Seattle EAA by CalCars and Maker Faire team
  11. Coming soon - City of Santa Monica by EnergyCS

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General disclaimer