LiBSU - Redesigning the "Battery Support Unit" to Support Lithium

Not yet... I'll release it eventually, but not anytime soon. For now you'll need to reverse engineer the data structure yourself. My color coding in that image is quite helpful as you begin your journey.

 

Here's what 12 square inches of cross sectional airflow looks like from the pack bottom:


LiBSU's pack has 40% more cross sectional airflow than OEM.
In fact, the OEM air plenum's cross section is only 8 square inches, so that'll be the limiting airflow factor.

 

Great questions, Mike!

Several reasons:
-I wanted to retain the wire harnesses, connectors, and mechanical enclosure in their OEM locations.
-Simplifies installation and reduces cost.
-I didn't need additional space.
-Fun challenge.

I think you're suggesting placing the BMS computer inside one of the blade widths?
I didn't explore this idea, primarily because it would require lengthening the OEM wire harness.

Yes, the 'LiBlade' lithium modules I designed form a pack that is shorter than the OEM blade length, while also delivering more energy than OEM. Specifically, replicating the OEM voltage range leaves QTY7 OEM blade widths empty (~14 cm).
However, we might as well fill that empty space to increase pack voltage, which will increase power output if we spoof the voltage lower... QTY9 LiBlades yields 72S, but I don't yet know how well the inverter hardware will tolerate that voltage. Certainly the car tolerates 60S and 64S in my testing so far.

I'm having a good time... can't wait to share more.

 

I like the concept of a complete pack that doesn't require a separate computer and cable (in the BSU's OEM enclosure). This streamlines some of the annoyances involved with the existing BSU enclosure.
Probably (edit: no, definitely) worth re-investigating on my end.

Thanks for the tip/concept.

With a "BMS blade" in slot 1, I could change from:
-"external modular expansion via ribbon cables", to;
-"internal modular cards that insert into said BMS blade".

This is probably due to high NiMH pack ESR. For example, a pack with 500 mOhm ESR would increase 30 volts during 60 amp regen. In general, the Gen3 Prius tries to keep the pack below 240 volts.