PHEV Conversion

<div class='quotetop'>QUOTE(efusco @ Sep 30 2007, 11:02 PM) [snapback]519646[/snapback]</div>

Let me tell you that it is a tight squeeze .....

 

Answers to fallow

 

<div class='quotetop'>QUOTE(TheForce @ Oct 1 2007, 12:15 AM) [snapback]519677[/snapback]</div>

1. How are you going to cool the batteries during charging and discharging?

Already though about it and it is in the works, I installed an electronic thermometer (with adjustable settings) to trigger some blowers and /or recirculating fans wile the lid of the cargo area is closed.

2. Are you going to baby the batteries like Toyota does with the stock battery? Are you going to keep it in the 40-80 range or are you going to try to max it out in the 10-90 range or do you plan to run them dry?

A MUST, but not as Toyo complexity. Will use the extra pack up to usable voltage to the MM charger.

3. What is your expected range on electric only?

I guesstimate an add on 7.5 KWh, wait until I start driving....................

4. Would there be enough room to group these batteries into smaller bricks for easy removal? Something like a cinder block size box with connectors to daisy chain the boxes?

This NiMH cells can be combined and distributed in the car in any imaginable way but these need to be interconnected, requiring extra wiring and interconnects, adding impedance and hence, loss. The right way to do it is as shorter and closer is better.

In this case, each pack or battery cluster is 102Lb average. The concept of this prototype design is once installed , removal is not necessary until maintenance requirements but yes, these can be split for easier removal.

5. Is there enough room there to sink the charger below somewhere out of the way?.

This MM charger is large ( all of the other brands also) and requires open ventilation for better performance and life span.

6. When you get this rig fully tested and post great results will you help me build a pack?

No problem!! The project I started is open source. If you are handy with mechanical tools is a plus.

That's if Hymotion does not come out with a ~30 mile pack for around $5k.

KEEP DREAMING and all the others PHEV's enthusiasts to be too.

If they have a pack for that price I'm going to get their pack instead of building one.

ME 2.

 

<div class='quotetop'>QUOTE(Cheap! @ Oct 2 2007, 03:16 PM) [snapback]520442[/snapback]</div>

My first intention on the newest NiMH conversion was to replace my existing PbA box on the rear seat area, I have the mechanical design drawings of the Al box with sliding batteries trays but became costly and time consuming for a prototype of this kind.

My second though was the cargo area; after exchanging few ideas with Norm D ( eflier ) I asked him if I can use his battery array concept for my new install with a variation and a twist. All steel frame with welded tabs and a hanging structure for the lower battery array. Support to the car body and frame is by means of Stainless Steel fasteners and spot welded reinforcing pieces. Yes, I had to retrain myself on the Arc Welder for this project.

After taking in consideration some dimensions, electrical necessities and "safety requirements", I drew a basic idea up to the final conception of the completed project in several note pads

I'm planning to use this prototype conversion for a while, this layout have an open area for rework and testing as needed without complications and back breaking stories, this is the beauty of it and already I have plans for more than one version of power source configuration.

First testings will be demanding.

 

<div class='quotetop'>QUOTE(nwprius @ Oct 3 2007, 09:55 PM) [snapback]520963[/snapback]</div>

Thank you for the comments.

In my long introduction it is explained but nerveless, a second time is not an effort.

Thanks to the generosity of rest stops and gas stations mechanics/attendants along our way. People that we ask for a power source to recharge the PHEV never denied use of it, in some instances of our return trip we stopped in the same places and we left some money in tips as token of appreciation plus a lengthly explanation of the mechanical and electrical conversion of the "Pluggin Yorkers".

Until a business adventure capital shows-up to implement electricity on demand meters for a fee next to the gas pumps.... friendship and good will is only necessary.

 

<div class='quotetop'>QUOTE(sub3marathonman @ Oct 8 2007, 01:45 PM) [snapback]522789[/snapback]</div>

As Rob Smith explained it in a very mathematical, easy to understand and correct way, I can only add that my current and "future to be completed " NiMH PHEV conversion pack is NOT parallel tied to the OEM like others do.

I'm using a sort of expensive AC-DC / DC converter, featuring Power Factor Correction ( do a wiki on this at your leisure), with it I obtain a constant current and regulated voltage output manipulated in such a way that make an efficient PHEV conversion.

This same device serve the purpose of battery charger and more for pennies at night.

I'm far away to have this conversion completed; as a refresher, so far all mechanical's are done, almost all signal, low voltage and HV wiring completed and rechecked 3 times. I just started the task and very time consuming of checking, balancing and equalizing the NiMH modules, piece by piece......before putting these to use.

Meanwhile, developing and building my own BMS for the NiMH's.

And trying to check and answer PM from the PC site when it is NOT down or out of service.....at home in the night time.

I'm sorry, I'm not the type of guy that jumps into the board to tell everyone that today I went to the electrical supply shack, bough a length of cable and I splice it from here to there or glued some PVC tubing to "invent" a ventilation apparatus to amuse the crowd and hundreds of board hits.

I think that when a real improvement in this project is made, it will be share it in a timely maner for those who are interested and fallowing this unique thread at a higher technical level than novice or apprentice. I know that certain generated questions will be self answer by other members willing to participate in good fate and to all of them I thank you for supporting Prius Chat.

 

<div class='quotetop'>QUOTE(claytonsuch @ Oct 6 2007, 01:12 AM) [snapback]522090[/snapback]</div>

My name is Clayton, I am a mechanical engineering student at the University of Texas at Austin, and I am currently converting my uncle's 2004 Prius to a PHEV. Your car looks incredible! This forum has been an excellent source for "how to" information for a PHEV conversion process.

Welcome to the Prius Chat community, hope you learn a lot through these pages filled with very useful information on Prii.
Your local support in Texas will be Cheap!, an excellent person and willing to help at any time, hope you have a great time with him at the Maker Fair in Austin, a great place to get your feet wet in building and modding .

I have purchased: the EV button/kit, CAN-View V4+, Lilliput screen GL701-NPCT. I am in the process of installing these items. I plan on creating a website documenting my conversion process.

You just bought the right kind of stuff to start playing with the Prius.
Take you time, document as much as possible and take notorious pictures to insert in the web pages, people like that.

I am planning on purchasing 3 used Prius NiMH batteries and stringing the modules together the way you and Norm have done. I would like to hear your thoughts on using the Manzanita Micro charger for this type of conversion. I'm using a PFC40HM from them and basically is the power horse of the system. Also do you know what type of charger Norm is using in his car? It is his proper design and built, a 10KW inverter. And finally, do you have a schematic your interlock box that you are willing to share with me?

The basic electrical wiring of the PHEV I built is open source and can be found here ,today and now. The completed block diagram and circuitry of operation of my PHEV " will be" posted in our local Prius group (LIPOG) when finished and fully operational, as it is my current PHEV conversion.</span>

<span style="color:#999999">For the time been, is a project under research and development and may/will incure revisions or changes as necessary.