PHEV Conversion

mrbigh · 09-16-2007, 01:36 AM

My 2004 Prius was successfully converted to PHEV with PbA (lead acid) batteries by December 2006 and presented in our regular Long Island group meeting on Dec 16 2006.

As a first not commercially equip packaged conversion is the first Toyota Prius converted to Plug-In in the northeastern part of the USA known and running daily as a commuter car.

I had the support of Manufacturers as Sponsors donating their merchandise to help make this project a working piece, and with great gratitude I would like to mention that :Panasonic Industrial donate 20 x 28AH batteries, Carol cables all the interconnects wires, Xantrex their digital battery gauges including their new version of the E-meter, DeeZee industries donated an aluminum truck toolbox enclosure as batteries insulated container, Anderson Controls all their famous interconnects matching connectors,Helmar Electrical parts with all contactors used and Jayso Electronic's from Bronx, NY all the related electronic parts supporting this great work.

Couldn't be possible with out the hardware of Manzanita Micro and finally the outstanding support of Norm D. from Hybridinterfaces with CAN-View micro-controller to CAN bus.

By the last 10 months of driving and testing this prototype and research vehicle converted to PHEV in a daily basis I can comment with great satisfaction that is fulfilling my expectations of a basic drawing concept on a paper napkin to the final conception, including of the last underrated fuse.

Through the past 10 month I refined the PHEV conversion, I kept charts of every kind and tweaked to the point of maximum efficiency rendering the most of what I hand built.

The final test was the trip made from Long Island, New York to Madison, Wisconsin to attend Hybridfest 2007, almost 2000 miles (actually 2036) round Trip where I had an extra weight of 720 Lbs to Madison and returning with 860 lbs plus a passenger (my wife as a co-pilot). My converted Prius was driven by max permitted speed almost all the time, and A/C on when necessary, and consumed 23 gl total, rendering an averaged 88Mpg of EV assisted driving. At Hybridfest 2007 I was awarder with the BEST CAR IN SHOW, including best PHEV conversion, appearance and performance.

I stoped 15 times along the way to refuel, yes to refull..... electricity to keep my EV pack at full power, that was my ever best EV assist, 88Mpg in 2000 miles, not the CAL Cars claimed 100 Mpg for 5 miles, actually this type of conversions can be made better with longer range results.

With an economical mind set, average cost is $5200.00 for a "you get dirty" on my type of electrical conversion with products out of the distributors shelf and NOT a pre-manufactured KIT from others.

Well, now is a time for a change, I will improve my conversion for even better............

I'm changing the batteries powering the PHEV from Lead Acid (PbA) to NiMH........what will I gain?, from an existing weight of 485Lbs maybe a half of it with NiMH batteries, my rear seat bench back and probably2 to 3 time more power range.

I'm working with 3 original Prii Hybrid Battery packs, 2 of these kindly donated, combining these to 2 extra identical power sources, all connections merge to and are handled by a central interlock control box.

Batteries array will take location on the spare wheel well and storage compartment area as other's concept are. ......and for the ones asking for the "spare".....I do not care, for $2.00 I have a fix-a-flat can, call Toyota road side assistance or I will pay for a Tow trux if necessary.
This upgrade has to coexist with my original design and fully working equipment without disturbing and disabling anything, so I have to be extreme careful.
Being that this will be a work in progress I will be adding pictures as things go along, but for now I'm posting some ...........

Few questions are allowed, so by kind......

Interlock and control box in assembly progress</span>

[attachmentid=11808]
CAN-View<span style="color:#cc0000"> 4+ in Dash installation.

[attachmentid=11809]
I'm so happy for the final finish and the great information in front of my eyes. Perfect for me.

MPG > HP · 09-16-2007, 02:51 AM

Congratulations on the amazing innovation! Any chance of your jumping past NiMH and going straight to LiPo? Seems like the 12-18 months or so of additional planning that it may take would be well worth avoiding having to do it right after the NiMH conversion. Is safety of the currently available A123s that much of a concern or is their cost compared to NiMHs the issue? I ask, because I could be a customer of yours for the DIY, but only with a LiPo chemistry (which ever one of those "wins").

Cheap! · 09-16-2007, 04:24 AM

VERY COOL!!! That dash is fantastic too.

SureValla · 09-16-2007, 11:10 AM

question: ever gotten pulled over in that? I can only imagine the cops face when he sees all your gadgets lol

Godiva · 09-16-2007, 01:29 PM

That new array? Looks kinda big. Will that completely replace the back seats as well, or just fill up the cargo area.

And what about weight? Seems that's going to add a lot of weight. Are you going to have to modify the suspension in the rear to compensate for all of that weight?

brick · 09-16-2007, 02:02 PM

Since he's replacing the existing lead-acid array he should be just fine on weight. Can't wait to see how this works out!

And I love the CV display...absolutely the best installation of an extra screen that I've seen.

**TonyPSchaefer** · 09-16-2007, 06:17 PM

Horacio,
There was and is clearly no doubt why you were awarded "Best in Show" at Hybridfest. Your Pius is truly impressive.

Best of luck, thanks for the awesome write-up, and keep us posted.
Or, if you want, post a lot of pictures on the LIPOG site and provide links; that way you won't have to post the same pictures twice.

mrbigh · 09-16-2007, 08:02 PM

<div class='quotetop'>QUOTE(TonyPSchaefer @ Sep 16 2007, 06:17 PM) [snapback]513403[/snapback]</div>

Quote:

Horacio,
There was and is clearly no doubt why you were awarded "Best in Show" at Hybridfest. Your Pius is truly impressive.

Best of luck, thanks for the awesome write-up, and keep us posted.
Or, if you want, post a lot of pictures on the LIPOG site and provide links; that way you won't have to post the same pictures twice. [/b]

Thanks Tony, I'll do my best to keep all of you up to date in the progress.

mrbigh · 09-16-2007, 08:14 PM

<div class='quotetop'>QUOTE(MPG > HP @ Sep 16 2007, 02:51 AM) [snapback]513236[/snapback]</div>

Quote:

Is safety of the currently available A123s that much of a concern or is their cost compared to NiMH the issue?[/b]

At this point and in my case is merely economics, used good quality Toyo OEM NiMH from dismantled vehicles runs average $650.00 a piece, x3 about $2,000.00.

For very cheap Chinese Lion about $8,700.00 and A123 I imagine $12,000.00.In top of this to prices we have to add a quality Battery Management System for around $5,000.00 and even more $$, make your numbers and compare.

The electrical interface in between any chemistry is basically the same.

Thank you for asking.

galaxee · 09-16-2007, 08:34 PM

wow- you earned that name "mr big h!"

you might consider upgrading to the touring struts in the rear. they're much bigger, physically, than the standard prius struts. DH isn't sure of the damping rate on them but they will probably control that bounce a little better in the back. you may also think about stiffer springs.

and adjust your headlights a bit.

good luck!!

(ps. wanna, cough, get rid of that old setup? cough cough

)

09-16-2007, 01:36 AM	#1
mrbigh Prius Absolutum Dominium Join Date: Sep 2005 Location: Long Island, NY Posts: 802 My Car: 2004 Prius Model: Package: Base Thanks: 29 Thanked 93 Times in 78 Posts Friends: 10	My 2004 Prius was successfully converted to PHEV with PbA (lead acid) batteries by December 2006 and presented in our regular Long Island group meeting on Dec 16 2006. As a first not commercially equip packaged conversion is the first Toyota Prius converted to Plug-In in the northeastern part of the USA known and running daily as a commuter car. I had the support of Manufacturers as Sponsors donating their merchandise to help make this project a working piece, and with great gratitude I would like to mention that :Panasonic Industrial donate 20 x 28AH batteries, Carol cables all the interconnects wires, Xantrex their digital battery gauges including their new version of the E-meter, DeeZee industries donated an aluminum truck toolbox enclosure as batteries insulated container, Anderson Controls all their famous interconnects matching connectors,Helmar Electrical parts with all contactors used and Jayso Electronic's from Bronx, NY all the related electronic parts supporting this great work. Couldn't be possible with out the hardware of Manzanita Micro and finally the outstanding support of Norm D. from Hybridinterfaces with CAN-View micro-controller to CAN bus. By the last 10 months of driving and testing this prototype and research vehicle converted to PHEV in a daily basis I can comment with great satisfaction that is fulfilling my expectations of a basic drawing concept on a paper napkin to the final conception, including of the last underrated fuse. Through the past 10 month I refined the PHEV conversion, I kept charts of every kind and tweaked to the point of maximum efficiency rendering the most of what I hand built. The final test was the trip made from Long Island, New York to Madison, Wisconsin to attend Hybridfest 2007, almost 2000 miles (actually 2036) round Trip where I had an extra weight of 720 Lbs to Madison and returning with 860 lbs plus a passenger (my wife as a co-pilot). My converted Prius was driven by max permitted speed almost all the time, and A/C on when necessary, and consumed 23 gl total, rendering an averaged *88Mpg of EV assisted driving.* At Hybridfest 2007 I was awarder with the BEST CAR IN SHOW, including best PHEV conversion, appearance and performance. I stoped 15 times along the way to refuel, yes to refull..... electricity to keep my EV pack at full power, that was my ever best EV assist, *88Mpg in 2000 miles, not the CAL Cars claimed 100 Mpg for 5 miles, actually this type of conversions can be made better with longer range results. With an economical mind set, average cost is $5200.00 for a "you get dirty" on my type of electrical conversion with products out of the distributors shelf and NOT a pre-manufactured KIT from others. Well, now is a time for a change, I will improve my conversion for even better............ I'm changing the batteries powering the PHEV from Lead Acid (PbA) to NiMH........what will I gain?, from an existing weight of 485Lbs maybe a half of it with NiMH batteries, my rear seat bench back and probably2 to 3 time more power range. I'm working with 3 original Prii Hybrid Battery packs, 2 of these kindly donated, combining these to 2 extra identical power sources, all connections merge to and are handled by a central interlock control box. Batteries array will take location on the spare wheel well and storage compartment area as other's concept are. ......and for the ones asking for the "spare".....I do not care, for $2.00 I have a fix-a-flat can, call Toyota road side assistance or I will pay for a Tow trux if necessary. This upgrade has to coexist with my original design and fully working equipment without disturbing and disabling anything, so I have to be extreme careful. Being that this will be a work in progress I will be adding pictures as things go along, but for now I'm posting some ........... Few questions are allowed, so by kind...... Interlock and control box in assembly progress</span>* [attachmentid=11808] CAN-View<span style="color:#cc0000"> 4+ in Dash installation. [attachmentid=11809] I'm so happy for the final finish and the great information in front of my eyes. Perfect for me. Attached Thumbnails __________________ PHEV conversion (rolling since Dec '06)

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09-16-2007, 02:51 AM	#2
MPG > HP Member Join Date: Feb 2006 Posts: 55 My Car: Model: Package: Thanks: 0 Thanked 0 Times in 0 Posts Friends: 0	Congratulations on the amazing innovation! Any chance of your jumping past NiMH and going straight to LiPo? Seems like the 12-18 months or so of additional planning that it may take would be well worth avoiding having to do it right after the NiMH conversion. Is safety of the currently available A123s that much of a concern or is their cost compared to NiMHs the issue? I ask, because I could be a customer of yours for the DIY, but only with a LiPo chemistry (which ever one of those "wins").

09-16-2007, 04:24 AM	#3
Cheap! Senior Member Join Date: Apr 2006 Posts: 1,157 My Car: Model: Package: Thanks: 0 Thanked 1 Time in 1 Post Friends: 4	VERY COOL!!! That dash is fantastic too.

09-16-2007, 11:10 AM	#4
SureValla Senior Member Join Date: Jul 2007 Location: White Plains, NY Posts: 505 My Car: 2007 Prius Model: Package: #3 Thanks: 17 Thanked 9 Times in 7 Posts Friends: 0	question: ever gotten pulled over in that? I can only imagine the cops face when he sees all your gadgets lol

09-16-2007, 01:29 PM	#5
Godiva AmeriKan Citizen Join Date: Apr 2005 Location: San Diego, CA Posts: 10,342 My Car: 2005 Prius Model: Package: #1 Thanks: 0 Thanked 1 Time in 1 Post Friends: 7	That new array? Looks kinda big. Will that completely replace the back seats as well, or just fill up the cargo area. And what about weight? Seems that's going to add a lot of weight. Are you going to have to modify the suspension in the rear to compensate for all of that weight?

09-16-2007, 02:02 PM	#6
brick Senior Member Join Date: Dec 2006 Location: Columbia, SC Posts: 895 My Car: 2007 Prius Model: Package: #2 Thanks: 10 Thanked 21 Times in 15 Posts Friends: 0	Since he's replacing the existing lead-acid array he should be just fine on weight. Can't wait to see how this works out! And I love the CV display...absolutely the best installation of an extra screen that I've seen.

09-16-2007, 06:17 PM	#7
TonyPSchaefer Your Friendly Moderator Join Date: May 2004 Location: Far-North Chicagoland Posts: 10,503 My Car: 2004 Prius Model: Package: #9 Thanks: 39 Thanked 168 Times in 109 Posts Friends: 23	Horacio, There was and is clearly no doubt why you were awarded "Best in Show" at Hybridfest. Your Pius is truly impressive. Best of luck, thanks for the awesome write-up, and keep us posted. Or, if you want, post a lot of pictures on the LIPOG site and provide links; that way you won't have to post the same pictures twice.

09-16-2007, 08:34 PM	#10
galaxee resident lab rat Join Date: Mar 2005 Location: boilermaker territory Posts: 9,675 My Car: 2005 Prius Model: N/A Package: #5 Thanks: 0 Thanked 94 Times in 37 Posts Friends: 26	wow- you earned that name "mr big h!" you might consider upgrading to the touring struts in the rear. they're much bigger, physically, than the standard prius struts. DH isn't sure of the damping rate on them but they will probably control that bounce a little better in the back. you may also think about stiffer springs. and adjust your headlights a bit. good luck!! (ps. wanna, cough, get rid of that old setup? cough cough )