Converting Prius G3 to all Electric removing ICE

Prodigyplace oh the memories....
I think I built my first micro-controller project
around 81 or was it 79.
I want all those decades back
wasted on computers
...where do i line up?

The reverse clutch (I think) was introduced in the G3 transaxtial
however both motors were not enabled in the firmware,
and regardless ICE is being removed in my project, and Primes
aren't so common as wrecks in 2020
but I sure am looking forward to that extra HP with those motors
on a Prime with my conversion ready in the future.


Rmay635703
RE UMC is interesting Thank you
but I am Not Interested in other peoples Inverters or Controllers all.

I will be designing my own.
My current passion is firmly planted on the Panasonic IGBT Inverter in G3
and learning it and no other.

Now Can bus communication I have my own equipment and will design my own
emulators and controllers and expect I may need help restoring some basic systems
from this community.

 

Hi Maarten28

(from 3.6 in G3 not 2.4 like G2 ...oops thanks)

The G2 planetary gears weld video
was posted to answer a questions
and I hope is relevant to future readers in this discussion.

So this project is for G3, so I hope its in the right forum.

I am aware of these limitations with G3 its in
Toyota's firmware.
The limit in G3 is 61.2 MPH
The top mph is Governed by Toyota and limited to one motor
it can go much much faster.

The weak power problem in G3 is gone if you use both motors
as we can control both motors with our own logic
in almost the same ratio
1 to 1.14 (I Think in G3)
close enough so one doesn't over rev (like G2 would have)
and G3 can now drive the vehicle with MG1 and MG2 at similar speeds.
(assuming controller logic bypass)

On a P410 transaxle if i (use MG1 as a motor) and turn MG1 in reverse at a greater ratio of 1.14
of the speed that I am turning MG2 Both MG1 and MG2 will drive the vehicle.
(with no ice)

 

My Project


The whole idea of this project is to replace
the inverter logic while retaining the existing
(state of the art) Panasonic Inverter and IGBT drivers
with its built in safety features.
You CANNOT buy this quality separately.
And it becoming my go to inverter for my other solar projects.

I will be replacing the logic function of
the Toyota firmware and associated controller hardware .
Also I want to learn about the Inverter for other projects.
Since I am into quality and like what I
can do with those inverters like :
-fully programmable dc to dc inverter,
-fully programmable buck inverter,
-3 fully programmable ac controllers.

Additionally I will be creating a new "board" with
my micro to "take over" from Toyota
and control the car.
I will also restore or duplicate basic car functionality that i need to.
(I've done that a few times and know what I am getting into)

Thank you Toyota for re-engineering G3
so we can use both motors for driving the wheels
without a nasty weld in the trans-axle like G2.!
(and extra hp too, and smaller too, and lighter too)

 

A Engineer in Ireland just recently Nov 2019
created a replacement
G3 inverter controller Logic board
and has released it as public domain at GitHub

Its a prototype (Dec 2019)
but good enough for me
it saves me weeks
and I can start to play around
with the next steps sooner.
Thank You Damien Maguire.

I'm will not be focusing on the battery for long range at this time.
I will use the existing battery, replicate some basic safety,
and add a quick plug in charging to facilitate my project.
Latter I will need to decide (I expect around summer of 2020)
my battery solution.

I think my only question at this time is
Has anyone ever seen a Prius ICE motor removed project
with Bypassed ECU?

 

I cant post links now, so i will update links above when my account status returns

 

Here is a video of the logic board replacement
https://youtu.be/CXKlsYRqZ7E


Prius Gen 3 Inverter Logic Board
http://www.evbmw.com/index.php/evbmw-webshop/toyota-built-and-tested-boards

project at GitHub
GitHub - damienmaguire/Prius-Gen3-Inverter: Open source logic board to control the Toyota Prius Gen 3 Inverter

 

"The reverse clutch (I think) was introduced in the G3 transaxtial"

oops I see it its a damper , there's no reverse clutch in P410 in a G3 sorry

 

The Prius 3 is best for this conversion

I earlier mentioned a Prime would be faster
for my Conversion but since then I learned
it would be slower.

In the a Prime
with the introduction
of the one-way-clutch
the Prime's new firmware
is now able to control
both M1 and M2 motors at the same time
to drive the car.
(since it could disconnect from the engine)
(and still the speed is governed)

In so doing however
they dropped the power of M2
from 60 k watts to 53 k watts
and
they dropped the power of M1
from 42 k watts to 23 k watts

while still increasing overall power output
since now the Prime could tap MG1 as M1
and it could combine both motors to drive the car
now possible with the one way clutch
as the engine wont spin ICE backward.

Therefore if I apply my "HomeMadeECU"
that uses both M1 and M2 to drive the car in EV only
in a Prime it would be SLOWER!!!
then the Prius G3.

so:
not the G2 cause of the weld!
not the Prime because the electric motor got smaller so the modification
would be less powerful (its already an ev too, and no wrecks are available)
the G3 is "just right"

 

thanks
ChapmanF
Ive updated the post

In so doing however
they dropped the power of MG2
from 60 k watts to 53 k watts
and
they dropped the power of MG1
from 42 k watts to 23 k watts

All while still increasing overall power output
since now the Prime could tap MG1 as M1
and it could combine both motors to drive the car
now possible with the one way clutch
since MG1 when engaged as a motor
now cant spin ICE backward.

 

Maarten28
Attila Fekete

thank you