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Discussion in 'Generation 1 Prius Discussion' started by bwilson4web, Mar 21, 2010.

  1. w2co

    w2co Member

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    I connected to the 06 again today, and here is a shot of all the systems supported at this time. Like I mentioned b4 they will have a new version very soon which he highly suggested getting.

    [​IMG]
     
  2. w2co

    w2co Member

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    Also visited the "HV ECU CAN" and selected these items to plot.

    [​IMG]
     
  3. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Thanks for providing these details, I'd like to buy that soon. I understand that it is necessary to order the basic unit plus the Toyota interface, total cost ~$400?
     
  4. w2co

    w2co Member

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    Here's a plot of just the MG1 & MG2 Torques.

    [​IMG]
     
  5. w2co

    w2co Member

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    Here's the most interesting one today, this was from a cold start, notice how the MG1's motor temp rises well above what MG2 is doing. Is this because MG2 has better cooling? It also indicates that both inverter circuit temps are well cooled. The 03 Prius is next.

    [​IMG]
     
  6. w2co

    w2co Member

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    You're very welcome Patrick. Yes it is the Proline hardware connector with ver 8.2 scantool software ($249), then also the Toyota Enhanced Interface option at $150. There is a wealth of useful information to be had about this car, and with this system you can be creative in how you plot things too. Only wish it could plot more than 4 things at a time, (I haven't figured out how to do that yet). Anyhow I think it's worth it especially for the GEN1 owners with weak batteries to monitor them. Better get used to it now and know what "normal" is, then when something happens you can compare.
     
  7. bwilson4web

    bwilson4web BMW i3 and Model 3

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    MG2 is on the end of the transmission, nothing but air around the end and all sides. In contrast, MG1 is between the engine block and gears. MG1 normally running pretty close to engine coolant temperature and seems to be happy there.

    What we find is when MG2 develops a fatal short in the stator coils, its temperature rises above MG1. It can sort of continue to run for a little while and there will be a speed related "humming" but it is burning itself up at that point. Time to find a salvage transmission.

    Now the torque data combined with rpm gives you the power. Also, you should be able to see MG1 rpm reversal, sometimes called "heretical mode." Having MG1 torque, ICE rpm and MG2 rpm, you can calculate the ICE shaft output. Combine that with the fuel consumption, either injector timing or mass air flow, and you can calculate the brake specific fuel consumption.

    I used those data from my Graham scanner to plot the most fuel efficient rpm/power ranges:
    [​IMG]
    The "red dots" are the most fuel efficient power ranges which also correspond to well defined power bands. Neat Stuff!

    What I'm hoping to see is if I can read anything of the ZVW30 data with the Autoenginuity. If so, it will have been money well spent!

    Bob Wilson
     
  8. w2co

    w2co Member

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    Thanks Bob, very interesting indeed. And it makes sense that MG1 would get hotter in the beginning because it's right next to the ICE and also less air flow in the middle of the transaxle/engine. MG2 is towards the outside of the transaxle and therefore gets good air flow. Did you get your scantool yet? Tom
     
  9. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Tracking shows it arrived in Montgomery Friday, 6:11 PM. It should be here either Saturday or Monday.

    Bob Wilson
     
  10. jk450

    jk450 New Member

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    That's not why MG1 often gets hotter than MG2 during a cold start and warmup. The engine in the Prius produces less waste heat than a typical passenger car engine, and contributes little to MG1 temperatures.

    You can find out why MG1 is heating up during this time by observing motor data, if you like.
     
  11. jk450

    jk450 New Member

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    That will be a problem if a module has four or more codes.

    Almost all scanners utilize scrolling, including OEM scanners.
     
  12. statultra

    statultra uber-Senior Member

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    would it be because the engine is starting up requiring the MG1 to spin up to ~3600 rpm-3900 rpm to spin the engine to like ~ 1200 rpm?

    im not sure if this belongs here, but maybe someone can shine some light on this. I have a USB CAN232 adapter that supports OBD2 and CAN interfaces, and all the protocols ( kwp2000,9141-2,14230 etc ) and the issue im having is getting it to be detected with autoenginuity and/or techstream
     
  13. bwilson4web

    bwilson4web BMW i3 and Model 3

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    In one respect, MG1 will be running anytime the ICE is producing power. MG1 provides the counter torque needed to pass ICE torque on to the ring gear:
    [​IMG]
    But the easiest reason is to observe that the engine coolant will be between 82-90C depending and is firmly mounted on one side of the transaxle housing next to MG1. The other side of MG1 has MG2, which has only the circumference as well as the end plate to dissipate heat. The Dept. of Energy report from UT Battelle identified the surface as being the primary cooling mechanism followed by the coolant channels.

    Bob Wilson
     
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  14. jk450

    jk450 New Member

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    Not entirely; that takes less than a second. But MG1 continues to spin for during cold start and warmup for a variety of reasons, while MG2 is not doing much of anything. Basically, MG1 is usually working harder than MG2 during this time. That's really all there is to it.

    Contact the cable manufacturers and see what they say.
     
  15. jk450

    jk450 New Member

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    Sure that's not 82º-90ºC?

    If MG1 temperature was significantly affected by engine temperature, it would not fluctuate as much as it does during a typical drive cycle, which it does even though it's almost always spinning.
     
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  16. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Thanks, fixed.
    This is a partial fractions question with part from the motor losses and part from the thermal transfer of heat through the cases. The rapid MG1 temperature changes come from the motor resistance losses which will be proportional to the ICE power. Roughly:
    ICE_power * 28% ~= MG1_power
    MG1_power * (100 - 97) ~= MG1_waste_heat
    This assumes a 97% efficiency in the motor although in reality it is a non-linear function. The resistance heating will be proportional to the current squared so higher power settings will significantly, rapidly increase MG1 temperature. However, MG1 power is mostly provided to or received from MG2. This load dependent, heat load will apply to both MG1 and MG2. So this leave the case transfer heat load.

    This winter, I used my block heater at temperatures near freezing and recorded this data before starting the engine:
    Column 1 Column 2 Column 3 Column 4
    0 block C MG1 C MG2 C Battery C
    1 36 18 13 5
    2 31 13 8 7
    3 23 6 3 2
    variable block heater times, 2 hr to 30 min.

    The block heater uses ~450W and I was curious about the thermal lag. You can clearly see there is a net transfer of heat from the engine, through MG1, and MG2. We can use the traction battery as the 'cold soak' ambient.

    This data can help construct a heat transfer model if we look at the temperature differences:
    Column 1 Column 2 Column 3 Column 4
    0 block dC MG1 dC MG2 dC ambient
    1 31 13 8 0
    2 24 6 1 0
    3 21 4 1 0
    variable 2 hour to 30 minute heating

    This static, thermal data shows roughly a 5C difference between MG1 and MG2. It doesn't change rapidly but the pattern is clear.

    Bob Wilson
     
  17. w2co

    w2co Member

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    Also I would guess that because of all the above and the fact that MG1 almost immediately becomes a generator the first time you let up on the gas and coast or brake it is pumping a few amps into the battery pack as well. So the temp will rise from a cold start faster than MG2. Now the thing I want to see is what happens after driving a longtime, like maybe an hour. Have yet to do that. Now below I have a screenshot of all GEN1 systems covered...This one is an 03 Prius w/ low miles.
    [​IMG]
     
  18. w2co

    w2co Member

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    And here is a shot of the "High Block vs Low Block voltage" and two of the four battery temps on the 03 Prius under "BattECU" during a short ride across town. I am really interested in the low blk voltage sag just 1/3 way from the beginning. There seems to be a delta there of over 1V however the overall delta throughout trip is reasonable (.2-.4v). Maybe this large delta during a hard accel indicates a cell or two is weak. But the overall delta is relatively small so the system doesn't yet log a code?
    [​IMG]
     
  19. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Part of it is sampling error. Although we see a single graph, the Graham scanner time-stamps each sample and there is typically a 100 ms. difference between each data point. Many of our vehicle operations happen in shorter intervals.

    What I do is record the time-stamped data and then require consecutive samples to be within 10% of each other. Don't get fooled by sampling error, single points, that might look worse than they really are. <grins>

    Bob Wilson
     
  20. w2co

    w2co Member

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    Yes I am looking at the raw .csv file and the timestamp is around .3sec ticks between data samples. Here is one cycle of batt blocks 1-19 and the 4 batt temps at the end. The 10th value is blk max V, and the 11th is blk min V.

    01:05:08.109, 15.18, 01:05:08.484, 15.19, 01:05:08.812, 15.16, 01:05:09.140, 15.12, 01:05:09.468, 15.15, 01:05:09.796, 15.15, 01:05:10.125, 15.15, 01:05:10.453, 15.22, 01:05:10.781, 15.19, 01:05:11.109, 15.28, 01:05:11.421, 15.12, 01:05:11.734, 15.15, 01:05:12.062, 15.20, 01:05:12.390, 15.17, 01:05:12.718, 15.28, 01:05:13.046, 15.14, 01:05:13.375, 15.15, 01:05:13.703, 15.11, 01:05:14.031, 15.14, 01:05:14.359, 15.17, 01:05:14.671, 46, 01:05:15.000, 48, 01:05:15.312, 48, 01:05:15.625, 46,

    I don't have Excel on this compuker so can't plot them all at once yet.. The scantool software can only plot 4 at a time, as you can see from the screenshots. But it can capture in a .csv file many more. You can see just by this first string that the two middle batt temps are higher than the ends. Also judging from the time to make one string of data, it was updating ea. value every 7 seconds or so.
     
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