1. Attachments are working again! Check out this thread for more details and to report any other bugs.

PHEV mod under way, Bristol, UK.

Discussion in 'Gen 2 Prius Accessories & Modifications' started by aminorjourney, Jun 7, 2008.

  1. Flying White Dutchman

    Flying White Dutchman Senior Member

    Joined:
    Dec 29, 2007
    4,374
    313
    0
    Vehicle:
    Other Non-Hybrid
    Model:
    N/A
    yes sure he will
    bob is the guy to take apart the 2010:D without us even needing to ask for it.;)
     
  2. hobbit

    hobbit Senior Member

    Joined:
    Mar 23, 2005
    4,089
    468
    0
    Location:
    Bahstahn
    Vehicle:
    2004 Prius
    Model:
    N/A
    Heh, maybe. It's his wife's car at the moment...
    .
    "here, honey, hold these two wires for a sec"
    .
    _H*
     
  3. aminorjourney

    aminorjourney Mum to two prius!

    Joined:
    Jan 29, 2007
    335
    27
    0
    Location:
    Bristol, UK
    Vehicle:
    2007 Prius
    Model:
    N/A
    One week since the battery boxes were finished....

    Everything is working just great. I headed up to London on Thursday - a 230+ mile round trip. I got the chance to charge in central London and had a fairly good trip there and back.

    On returning to Bristol, all the batteries had got up to 30 degrees C. (Tested immediately on parking, using an infra-red thermometer).

    The ambient temperature this week has been in the mid 20s, between 24 and 25 degrees C. A few extra degrees don't seem to have been all that bad at all.

    When it comes to charging the heat I'm getting is coming from the charger, not the batteries warming up through charging, if that makes any sense.

    I'm finding that if I move the charger while charging the batteries stay a lot cooler.

    I'd be interested to hear/see what other NiMH pioneers are using to keep the battery charger heat away from the batteries.

    Nikki.
     
  4. F8L

    F8L Protecting Habitat & AG Lands

    Joined:
    Aug 14, 2006
    19,011
    4,081
    50
    Location:
    Grass Valley, CA.
    Vehicle:
    Other Non-Hybrid
    Model:
    N/A
    That is so awesome Nikki!

    I've dreamed of getting such great mileage with a plug-in conversion but they are so bloody expensive at the moment and even a DIY kit is just not viable/justifiable for me at the moment.

    Congrats on your success and I applaud your willingness to help others achieve the same goal.
     
  5. Flying White Dutchman

    Flying White Dutchman Senior Member

    Joined:
    Dec 29, 2007
    4,374
    313
    0
    Vehicle:
    Other Non-Hybrid
    Model:
    N/A
    hi nikki
    so if i am correct you do not monitor the battery cells when driving?

    only the OEM pack i guess using canview.
    but nog the add packs.

    i also monitor those during driving
    and i use OEM fans to cool during charging and driving if needed.

    a picture that i will attach to this post shows a impression of my current setup ( picture is from the before moment not yet finisched but give's a good picture of the setup )
     

    Attached Files:

  6. aminorjourney

    aminorjourney Mum to two prius!

    Joined:
    Jan 29, 2007
    335
    27
    0
    Location:
    Bristol, UK
    Vehicle:
    2007 Prius
    Model:
    N/A
    Aaaah!

    Okay. You're using the entire boot space? Is that a permanent solution, or are you planning to put them under the floor?

    I'm planning on using PC fans to finish things off. I'm also researching becoming a UK based installer for the Plug In Supply kits. I did my own conversion using second hand parts, but if we want more plug in conversions in the UK new kit is the only safe way to go.

    Nikki.
     
  7. Flying White Dutchman

    Flying White Dutchman Senior Member

    Joined:
    Dec 29, 2007
    4,374
    313
    0
    Vehicle:
    Other Non-Hybrid
    Model:
    N/A
    wy not use norms bms+ system? and go for the plugin supl system..
    you can also get the casing from them only if you want.

    only second hand where the battery packs the rest is al new just like the bms+

    do you want to go without the bms+ in the future?

    i dont want to put then beneed the floor
    i used see tru plastic for demontration to poeple and i have noticed that only these strong fans will cool the pack fast en good.
    i used pc fans and that did noting ( to weak )

    there is not good enough space under the floor to do this.

    and i dont use any boot space.. what that matters i never drive my care anyway:p just take the bike.:D
     
  8. patsparks

    patsparks An Aussie perspective

    Joined:
    Jul 12, 2007
    10,664
    567
    0
    Location:
    Adelaide South Australia
    Vehicle:
    2004 Prius
    Model:
    N/A
    For cooling when driving why not use a powerful 220 volt fan which runs whenever the power is supplied from the mains? That would be easy and cheap to install. You could most likely use a fan from a compact fan heater or something like that. You need a way to vent the warm air out of the car, maybe duct a 220v fan in the interior exhaust vent which is behind the rear bumper cover. Is there an exhaust vent in the left corner and could you put the fan in the space taken by the bin in the corner?
     
  9. Orf

    Orf New Member

    Joined:
    Mar 11, 2006
    414
    4
    0
    Location:
    Devonport, Tasmania
    Vehicle:
    2009 Prius
    Model:
    N/A
    In your first sentence "For cooling when driving why not use a powerful 220 volt fan...." do you mean charging not driving?
    Also, In winter it would be beneficial use the ducted heat to pre warm the car?
     
  10. Mesuge

    Mesuge New Member

    Joined:
    Jun 5, 2009
    53
    11
    0
    Location:
    undercover
    Vehicle:
    Other Hybrid
    Model:
    N/A
    It takes some time to go through A-Z of this interesting thread, but I'm glad there is some documentation available on the internets beyond hybridinterfaces "beta" pages on this BMS+ system/approach..

    Tip for NG3 charger users, you can utilize its AUX1,2 contacts to enable several features such as remote visual signaling of mains/charger activity and/or control additional cooling system during the charge cycle in the batt. bay either powering fan directly or by connecting to other relay/board logic etc..

    It has been discussed in detail at this EV conversion blog (bottom of the page):

    volt914 - Electric Porsche 914

    Btw. also can't wait for the first practical confirmation of the rumors that 2010 Prius model has plugin capability ready/friendly ECU and other related systems..
     
  11. Orf

    Orf New Member

    Joined:
    Mar 11, 2006
    414
    4
    0
    Location:
    Devonport, Tasmania
    Vehicle:
    2009 Prius
    Model:
    N/A
    I hope that rumour is correct but I have my doubts.
    Toyota stands to sell more cars if 2010 owners have to buy another car to get the plug-in.
     
  12. Mesuge

    Mesuge New Member

    Joined:
    Jun 5, 2009
    53
    11
    0
    Location:
    undercover
    Vehicle:
    Other Hybrid
    Model:
    N/A
    My impression is that even if true, there will be several diy hacking steps involved anyway, like connecting cables, preparing the batt. tray, adding force cooling etc. And obviously installing and managing the batt. pack itself! So, this will scare many people anyway, Toyota is not worried about this, but perhaps more about the fact that such functionality inside 2010 model could make the situation much easier for 3rd party plugin kits..
     
  13. Mesuge

    Mesuge New Member

    Joined:
    Jun 5, 2009
    53
    11
    0
    Location:
    undercover
    Vehicle:
    Other Hybrid
    Model:
    N/A
  14. Orf

    Orf New Member

    Joined:
    Mar 11, 2006
    414
    4
    0
    Location:
    Devonport, Tasmania
    Vehicle:
    2009 Prius
    Model:
    N/A
    On thinking about it, Toyota are releasing 500 PHEVs at the end of the year so perhap they have put in all the looms. Wouldn't it be marvelous if all we had to do is put in the new battery pack, plug and associated electronics.
     
  15. aminorjourney

    aminorjourney Mum to two prius!

    Joined:
    Jan 29, 2007
    335
    27
    0
    Location:
    Bristol, UK
    Vehicle:
    2007 Prius
    Model:
    N/A
    Talking of the PHEV mods...

    I do know that several places are working on 2010 PHEV conversions :) But i can't say any more at the moment!

    Nikki.
     
  16. Mesuge

    Mesuge New Member

    Joined:
    Jun 5, 2009
    53
    11
    0
    Location:
    undercover
    Vehicle:
    Other Hybrid
    Model:
    N/A
    Another must have gadget in the "PHEV garage":

    Electric kWh meter with online capability & datalogging function
    (TCP/IP or serial port), have been looking for something like this in
    one neat package for ages. Has got 230V@50Hz capability ->
    i.e. CE (IEC/EU) certification too!

    www.ekmmetering.com/EKM_Metering/Products.html


    Btw. Nikki, is there at least one true DIYer among these 2010 PHEV
    conversions you know about or is just "big" kit suppliers territory at
    the moment?
     
  17. Flying White Dutchman

    Flying White Dutchman Senior Member

    Joined:
    Dec 29, 2007
    4,374
    313
    0
    Vehicle:
    Other Non-Hybrid
    Model:
    N/A
    nothing new those rail attached meters
    but you have to look into the industry products to find them in the past

    i think those PHEV 2010 are all kit company's but lets wait and see.
     
  18. Mesuge

    Mesuge New Member

    Joined:
    Jun 5, 2009
    53
    11
    0
    Location:
    undercover
    Vehicle:
    Other Hybrid
    Model:
    N/A
    Well, since this is basically BMS+ thread here and I think it has not been referenced often before..
    "Look Ma, no ICE inside my Prius EV !"

    video (more from http://www.youtube.com/user/imwoody36):

    all electric Prius: www.autobeyours.com/All%20electric%20Prius.htm
    PSD Lubrication Issue - bottom page (transaxle oil pump driven by ICE):
    http://www.roperld.com/Science/Prius/priushymotionconversion.htm

    more PHEV projects/info (5-10kWh Li-ion) info: www.autobeyours.com/HighSpeedStealth.htm
    many hacks pictured here:http://www.autobeyours.com/gifs/
    overview of all car's subsystems: http://www.techno-fandom.org/~hobbit/cars/training/prius02.html
    52mph EV thread: http://priuschat.com/forums/prius-p...64-hymotion-52-mph-electric-vehicle-mode.html
    clues to HSS (52mph) hack:
    http://www.greencarcongress.com/2007/05/a123systems_acq.html#comment-68782322
    http://www.techno-fandom.org/~hobbit/cars/ginv/VH.html
    Oak Ridge Report / Efficiency maps, gearbox friction losses:
    http://www.osti.gov/bridge/servlets/purl/890029-WIfqPO/890029.pdf
    http://www.techno-fandom.org/~hobbit/cars/warpstealth.html
    http://www.techno-fandom.org/~hobbit/#prius
    motor pullout, MG2 rebuild, step by step photos:
    http://classic.artsautomotive.com/PriusMG2.htm
    camry hybrid 105kW http://www.hybridsynergydrive.com/en/pcu.html
    '04&'05 shitty inverter box & corrosion/cooling yuck: http://www.techno-fandom.org/~hobbit/cars/ginv/i1mech.html
    detailed disassembly/teardown: http://www.techno-fandom.org/~hobbit/#prius
    http://www.techonline.com/product/underthehood/199201709
    .
    plugin solutions kit install video (case detail) http://www.pluginsupply.com/video.htm
    Pb, *Li-ion cylindrical&prismatic kits: http://www.pluginsupply.com/products.htm | *fastcharge wiring ready (230VAC euro friendly?)

    Ewert Energy/CANTOP:
    http://ewertenergy.com/
    http://www.pluginproject.com/index.html
    youtube.com/watch?v=74Q3qivunE4

    CANTOP CANBUS (Opensource) http://ewertenergy.com/products.php?item=candapter&page=projects
    http://cantop.sourceforge.net/
    partly based on famous CANBUS Talking Prius: http://www.vassfamily.net/ToyotaPrius/CAN/cindex.html
    CanAdapter & sw Suite http://www.uninterruptiblesolutions.com/candapter-can-to-usb-converter-p-224.html


    ==> new "safe" 70mph "Ice-spin" Ewert hack:
    http://priuschat.com/forums/prius-p...-mph-electric-vehicle-only-mode-new-post.html

    -
    complete input data for your Prius simulation spreadsheets
    (drag, wind, rolling resistance/PSI tires, etc.):
    http://privatenrg.com/#Startup

    -
    ~1kW inverter running off 12V system leg (car on in P-gear no drive lights)
    -> EV defrost etc. http://hiwaay.net/~bzwilson/prius/priups.html
    http://priuschat.com/forums/gen-ii-...2-anyone-use-inverter-need-quick-reply-2.html
     
  19. mjv

    mjv Junior Member

    Joined:
    May 13, 2009
    52
    2
    0
    Location:
    Somewhere in Kansas
    Vehicle:
    2010 Prius
    Model:
    IV
    I'm going to try the conversion with the 2010, using Lithium batteries, but it took a while to find a place to help me with it in the Kansas City area. Also going to add the solar panels for the roof, but waiting for them to get these all tested with the 2010 model. Supposedly it will be ready to install in July, but that may be optimistic. My car is supposed to be in this month, so that will give me some time to try it out before the conversions.
     
  20. Mesuge

    Mesuge New Member

    Joined:
    Jun 5, 2009
    53
    11
    0
    Location:
    undercover
    Vehicle:
    Other Hybrid
    Model:
    N/A
    The full EV conversion/hack means you end up with *50kW peak electric motor solely powering ~1.4ton car (but with decent torque). The weight savings from gutting ICE components are offset by added traction batt. pack and stuff. So the car will have its dynamic performance limitations (not exactly a freeway car), but as basic sub 52mph EV this might be very good donor candidate! One has to look for Prius with shot engine/left front damage, add >5kWh batt. pack, bms, charger, some electronics for auto squelching the error codes on start up (is CanView4 fully capable of that?), see Steve's video episode6 and his EV page for it. I'm wondering why this idea of Steve's has not catched up earlier, especially in the U.S. where Prius is plentifull and cheap, and EV conversion popular..

    *also the question is whether the emotor and inverter will survive ongoing operation as the only propulsion system in this upper envelope of <52mph. On the plus side, ditching the ICE alltogether means the diyer can go full monty with the belly pan and other aero mods limited formely by the heat engine presence, so this will help a bit again.

    "Priusight" http://priuschat.com/forums/gen-ii-prius-modifications/50902-review-hybrid-effects-wheel-skirts.html
    Kit (just add bellypan): http://www.hybrideffects.com/

    Full kit, google pic "prius hubcaps", "mooncraft prius", "blade runner prius"
    http://images.google.cz/images?hl=cs&lr=&um=1&q=prius+hubcaps&sa=N&start=0&ndsp=20
    Component pricing (~$6K full) and foto for Aero Prius Yura Style (studio in-house tunnel designed/tested):
    http://priuschat.com/forums/gen-ii-prius-modifications/37756-aero-prius-yurastyle-5.html
    more detailed pic: http://priuschat.com/forums/gen-ii-...acing-ce28-eco-drive-wheels-prius-only-3.html
    (this is also Volk CE28 eco drive -special Prius model- wheel thread, ~2kg less weight!)

    or some minimal compromise combination of both:
    - 4x wheel hubcaps + 2x rear wheel skirts by Hybrideffects
    - front bumper + 2x door mirrors by Yura
    - sharkfin antenna
    - front and side OEM decals out as per Hobbit's tutorial
    - no rear wiper (+ stock or 3rd party rear camera)
    - TaskLED litghts (EVnut)
    - full lexan/alu bellypan with small fins midship and "big" ones NACA type rear end
    - clean and "heavily" waxed & polished for the glide
    - in terms of rolling resistance perhaps 2nd hand racing rare alloy wheels ala eBox
    (see "Volk CE28 Eco drive" for Prius)

    => at the minimum BIG drop in noise and >>5% plus in economy, some more headroom
    for the e-traction, better accel. etc.

    "SightinBeetlePrius" - aka SIBT you saw it here first!
    Basically, it means adding rear skirts and other aeromods, also painting taht black rear bottom black line ala Insight. Plus moving the small spare tire and all the trunk tool-junk to the now empty engine/radiator front space area(like old VW), in addition it will help offset the light front axle load a bit. Moving charger/s and other component (batts.) here as well might not be that benefitial because of wire lenght, lets see. Pic here: http://www.autobeyours.com/gifs/PHEV files for publishing/Empty engine block/all electric 012.jpg