PHEV Project

[vertex]

I bought a salvage Prius last summer and rebuilt it with the idea of doing my own PHEV conversion. My plan is similar to what Nikki did, but I plan on NOT blowing up batteries!
First, let me say that everyone (not here) said I was nuts for rebuilding a salvage Prius, but I have the car running really well now, and have it legally licensed and on the road, which means I got through both the salvage inspection, and the standard safety and emmisions inspections here in NY. In that process I learned a lot about the car, which was my goal in rebuilding it (besides the challange).
Now that I am working on the next phase, PHEV conversion, I am looking for partners to work with me on the development. Others in this forum have mentioned that you need to be a EE to do this, have no fear, I am. As far as the hardware design, custom PCBs etc. I have no conern about getting that done. However, programming is my Achilles heal. I am looking for someone to work with me on that aspect of the project. Of course, anyone else that wants to contribute in any area, is more then welcome to join the effort.
As I said before, I am looking at the general approch that Nikki used, that is adding extra Prius battery packs. The cost, KW/$ is much lower with used Prius NiMH batteries, then with LiO, which of course, I prefer, but can't justify the expense today. I also refuse to use lead acid, not enough bang for the buck.
I plan on only charging, and using 1 pack at a time, and switching packs dynamically. My first task will be to reverse engineer the pack, unless someone has already done that.
I will modify the pack to use more of the battery capacity, but have the Prius think a standard pack is connected. Not only will the packs HV need to be switched ( I think I can use the relays in the packs) but so will the CANBUS. This will need to be done intelligently, so that the switching does not create errors.
I did not see any commercially available chargers that are reasonably priced, so I last year I designed one, which I have yet to prototype. The cost of the material, including the batteries should be under $3000. I have a spare battery pack to start with.
Anyone interested?

Howard

[mrbigh]

You are trying to re-invent the wheel all over again, again.
My advise is, "google" about PHEV conversions and learn wherever had happen in the last 5 years, study past cases of fairlures and advancements, the best source is Cal-Cars.org as a source of information and in PriusChat is full of threads about.
Associate yourself to one of the EAA chapters, here in Long Island is one with bright minds in all electric and Hybrids vehicles.

[vertex]

Originally Posted by mrbigh

You are trying to re-invent the wheel all over again, again.
My advise is, "google" about PHEV conversions and learn wherever had happen in the last 5 years, study past cases of fairlures and advancements, the best source is Cal-Cars.org as a source of information and in PriusChat is full of threads about.
Associate yourself to one of the EAA chapters, here in Long Island is one with bright minds in all electric and Hybrids vehicles.

I already reviewed everything online. Everything I saw seems to be half baked and too expensive, except for the new offering from Enginer in China. For instance, the need to shut the car off, and restart when the battery dies in EV mode. I think ther is a better way. I'll look into EAA, thanks for that tip.

[band]

I would sure look at Norm's BMS+ system. If installed correctly with a proper, fully safe-guarded charging system (temperature and voltage cutoffs, plus timers), it works wonderfully.
Best of luck. b. anderson

[hobbit]

Any of the contactor-based systems I've looked at so far do not
take any cross-pack currents into account. You could be the
first to do it differently, because I probably won't have time to
get that far.
.
NY state, huh? East or west?
.
_H*

[vertex]

Originally Posted by hobbit

Any of the contactor-based systems I've looked at so far do not
take any cross-pack currents into account. You could be the
first to do it differently, because I probably won't have time to
get that far.
.
NY state, huh? East or west?
.
_H*

I'm located in Westchester County. I had another crazy idea. I am thinking of a 4WD system, where the rear propulsion system works as the primary drive system in EV mode. I would pull the accelorator sensor and feed that into my computer and my computer would produce its own output to control the Prius via the accelorator input. (simplified description). Has anyone ever made a 4WD Prius?

[miscrms]

Originally Posted by vertex

I'm located in Westchester County. I had another crazy idea. I am thinking of a 4WD system, where the rear propulsion system works as the primary drive system in EV mode. I would pull the accelorator sensor and feed that into my computer and my computer would produce its own output to control the Prius via the accelorator input. (simplified description). Has anyone ever made a 4WD Prius?

This has actually been done, but I wouldn't think it is particularly well suited to a Prius. Since the Prius already has motors and a very nice control system, you might as well use them. Where this sort of system is employed is usually in converting a non-hybrid vehicle to hybrid.

I actually considered this for a while a year or two back. I was considering a small SUV like a RAV-4 that is available in both FWD and RWD versions. If you bought a used FWD, and a junked rear end from a 4WD you'd pretty much have all the mechanical parts you need. Add a pair of DC motors to drive the rear axle shafts, a pair of DC controllers and a battery pack and you'd be in business for pretty cheap. I was thinking of a return to center style joystick on the console as a simple way to control the electric drive forward and reverse/regen.

Rob

[miscrms]

BTW, nothing crazy about buying a salvaged Prius with the intention of building a PHEV out of it