Prius PHEV Schematics
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
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_]
No new Schematics for these methods yet...
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 Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils) (+)[Grid](-) | | | |====|======================================| | | | | | | | |==================================|========| __|___|____|___|__ | | ! # # # # ! | | ! \ , %%%% \ , ! coil 03 only while RL4=1 | | ! \ coil \ ! | | !___#___03___#___! | | | | | | (+) (-) (+)[PbA](-) (-)[NiMH](+)[NiMH](-)Regen Mode? (no dc|ac inter|lock) | | | | Inverter side of OEM contactor | | | | | | | | | | | | | |====|========#=======|==========|====| | | | | | | | | | | | |=======| #======| | | | | | | | __|____|__ | | | | | | | | | # ,, # ! | | | | __|___|____|___|__ ! ---- ! __|___|____|___|__ ! # # # # ! ! %%%% ! ! # # # # ! ! \ , %%%% \ , ! ! coil ! ! \ , %%%% \ , ! ! \ coil \ ! !___04___! ! \ coil \ ! !___#___01___#___! !___#___02___#___! | | | | |(+) (-)| |(-) (+)| [PFC Input] [PFC Output] Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch? 12 Charge Mode 00 - coil 01&02 open = Grid -> PbA, Charge if AC is present (PFC V set PbA default) 00 - DC immune & AC driven (Drive/coil 01&02&03/RLx lockout) interlock. 01 - nothing changes, can't enguage RL4 without Key On. Power up sequence 10 - coil 01&02 closed = PbA -> NiMH, (PFC V set NiMH) Key On maybe this should lock out AC seperate from coil 03 11 - coil 04 closed = PbA (-)neg input, (PFC powers on) CAN-View Relay RL4 (Stock/PHEV Mode) 11 - CAN-View RL2 drives dither (PFC V set NiMH high). 11 - RL4 locks out AC input so plugging in while on won't change anything. Power down sequence 10 - 1. Drop coil 04, wait (PFC powers off) 00 - 2. Drop coil 01, wait (Grid -> PbA, PFC V set PbA) 123 Regen Mode / Charge PbA Mode / ?Charge external mode? 110- While running regen mode, triggered by CAN-View RL3 Execute power down sequence 100- 1. Drop coil 04, wait (PFC powers off) 000- 2. Drop coil 01, wait (Grid -> PbA, PFC V set PbA) Connect NiMH (via regen points) to Grid input, inside grid lockout contactor. 001- 3. coil 03 closed = NiMH(Regen) -> Grid Regenning When CAN-View RL3 goes from closed to open 000- 1. coil 03 open, wait (PFC powers off) 100- 2. coil 01&02 closed = PbA -> NiMH, (PFC V set NiMH) 110- 3. coil 04 closed = PbA (-)neg input, (PFC powers on) ? Charge external mode ? 123 Potential alternate logic sequence for use with DPDT Grid<->NiMH contactor 000 = 0// (AC locks out coils 04 & 03) 101 (AC is locked out by key on via coil 03) 111 (phev mode enabled and opperational via RL4) 111 (RL2 is SOC driven voltage dither) 110 Regen (RL3 enter regen mode after sane CAN-View timeout) (we can loose grid interlock since we must be at speed? right?) 100 PFC Off 000 Grid->PbA 001 Now Regenning from NiMH -> Grid 000 Nothing->Grid 100 PbA->NiMH 110 (phev mode enabled) 111 (lockout grid again) (One could manually enter external charge mode by safely enguaging stationary regen) (Shut off PFC, manually enable RL3, hyjack PFC output via Andersons, tune and charge) --Rjf 04:45, 9 June 2006 (CDT)
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.