General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

Difference between revisions of "Conversion Interest"

From My wiki
Jump to navigation Jump to search
(Categories)
Line 70: Line 70:
 
[[Category:Prius PHEV]]
 
[[Category:Prius PHEV]]
 
[[Category:CalCars]]
 
[[Category:CalCars]]
 +
[[Category:PriusPlus]]

Revision as of 03:06, 7 October 2006

Per EAA-PHEV_Maillist:2006./7./5 or Y!

Request for Show of Interest in Converting Prius to PHEV Instructions

Calcars, in collaboration with the EAA’s Eaa-Phev SIG, intends to assemble and publish public domain instructions for converting a 2004-5<ref>The 2006 Prius’ multi-function display is incompatible with the current CAN-View electronics that is used in this conversion. This limitation may be eliminated in the future. If you are interested in converting a 2006 Prius, please let us know so we can asses this demand.</ref> into a PRIUS+ plug-in hybrid. The first versions of this conversion will use 20 BB Battery EVP20-12B1 AGM PbA batteries <ref>BB Battery EVP20-12B1 AGM PbA batteries http://www.electricrider.com/batteries/specsheets/evp20-12.pdf</ref>, along with the OEM hybrid battery, because of their cost and easy availability. They will provide a 10+ mile pure electric range in EV-only mode (at up to 34 mph), or assist the ICE for the first 20+ miles of Mixed-mode driving at around double the Prius’ normal mileage. This battery pack costs about $800 and can be expected to deliver 200-400 full (80% DOD) cycles. The added weight is around 300 lbs, which existing conversions have been handling without upgraded springs. We aren’t removing the OEM battery or changing the HSD system, but the spare tire space will not be accessible.

A li-ion and/or NiMH battery pack may become available within a year, probably capable of 20-25 EV-only miles, weighing 100-200 lb, lasting 2000-4000 cycles, and selling for in the ballpark of $6000. Such a pack should be retrofitable into either version (below) of the conversion.

Two versions, both with similar performance and using Hybrid Interfaces’ CAN-View device <ref>Hybrid Interfaces’ CAN-View device http://www.hybridinterfaces.ca</ref>, are anticipated:

  • The first version is the cheapest, using contactors and a homemade wirewound power resistor for control of the current between the OEM and PHEV battery, and a Delta-Q <ref>Delta-Q charger http://www.delta-q.com/products/quiq.shtml</ref> overnight charger.
  • In the second, more sophisticated, version, the Delta-Q charger is replaced with a high-power (PFC-40) charger from Manzanita Micro <ref>Manzanita Micro PFC-40 (40 Amps peek, 30 Amps continuous, input or output limit) charger http://manzanitamicro.com/chargers3.htm</ref>, which doubles as a DC:DC converter, used, in place of the resistor, to more carefully control current into and out of the PHEV battery while driving.

The total cost in materials (all commonly available), including batteries, is around $3,000 for the resistor/Delta-Q version or $4500 for the Manzanita Micro version. The time for two skilled people to assemble and install it (not including gathering parts) is probably at least 80 hours, though this is bound to decrease if and when kits become available with all parts included and some of the pieces pre-cut and drilled. A printed circuit board is anticipated becoming available either for a modest donation to Calcars or from a third party. That board is being designed to be usable with various battery packs and modifications. EXPERIENCE IN SAFELY WORKING WITH HIGH VOLTAGES IS MANDATORY. If you do not have this experience yourself, hire an electrician.

These changes will void Toyota’s warranty on affected components (no doubt the OEM hybrid battery and battery management computer; anything else is debatable). A modified Prius will operate as before the conversion when the PHEV battery pack is depleted. Slightly higher mileage than before is even possible despite the extra weight, due to the decreased internal resistance and larger capacity of the then-paralleled battery packs.

It will be valuable for us to learn how many DIYers actually intend to convert a Prius into a PRIUS+ using the plans we are currently working on. Therefore, please send me an email if you do intend to do so. Include answers to the following questions:

  1. Do you already have a 2004-5 Prius available to convert?
  2. If not, do you have or expect to get 2006 Prius that you would like to convert?
  3. If a conversion kit -- probably costing a little more than the retail parts costs but saving much parts-gathering and some assembly time -- becomes available, would you buy it?
  4. When do you plan to begin your conversion, once the plans or a kit is available?
  5. If an NiMH or li-ion battery pack, as described above, were to become available, how much would you be willing to pay for it (in place of the $800 PbA pack)?

To respond please mail to: tdriscoll@calcars.org.

References

<references/>

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General disclaimer