Converting Prius G3 to all Electric removing ICE

oops
earlier I stated MG1 to MG2 ratio was 1.14
its 1.014 on G3 in EV Mode NOT 1.14


My Prius Motor/Generator Specifications List
(only electric specifications)

Classic

MG2 44 hp 33 KW/273ac max 5600 RPM 350 N·m (258 lbf·ft)
MG1 20 hp 15 KW/273ac max 6500 RPM 400 N·m (295 lbf·ft)

G2 P112

MG2 67 hp 50 KW/500ac max 6700 RPM
MG1 41 hp 30 KW/500ac max 10000 RPM
-MG1 2.4 ratio to MG2 both M1/M2 Torquing
-MG1 2.4 ratio to MG2 ICE
-MG2 xx ratio to Drive Shaft (help)

G3 P412

MG2 80 hp 60 KW/650ac max 13500 RPM (403 lbf·f)
MG1 57 hp 42 KW/650ac max 13500 RPM
-MG1 1.014 ratio to MG2 both M1/M2 Torquing
-MG1 3.6 ratio to MG2 ICE
-MG2 8.6 ratio to Drive Shaft

G4

MG2 72 hp 53 KW/650ac max17000 RPM
MG1 31 hp 23 KW/650ac max 17000 RPM

 

For the record my mod
could reach a theoretical speed of

103 MPH



Theoretical Maximum
MPH of G3 P410 all Electric Conversion is 103 MPH

1)
M2 to shaft ratio in G3 P410 is 8.6 to 1
according to professor Kelly of Weber State.
reff

2)
195r15 is approx 1.81 meters or so circumference


3)
13500 rpm / 1.014 ratio MG1 to MG2 = 13130 max rpm not to over-spin MG1
The rpm of MG2 must be governed to max 13130 rpm
so maxing out MG2 at 13130 revs instead of 13500
because we cant over rev MG1 limit of 13500
It will cost us a little HP that we cannot tap in M2
If we use M1 as well
13500 rpm / 1.014 ratio MG1 to MG2 = 13130 max rpm not to over-spin MG1



therefore:

13130 rpm / 8.6 ratio to wheel shaft = 1,527 wheel turns per minute
1,527 wheel turns per minute * 1.81 meters approx wheel circumference = 2,763 meters / minute
2763 meters / minute * 60 minutes = 165,780 meters / hour
165,780 meters / hour / 1000 meters = 165.8 Kilometers / hour
165.8 Kilometers / hour / 1.609344= 103 MPH




accessible HP is not 80
13500 rpm / 13313 max rpm = 97.2 Percent of Capacity
.972 * 80hp = 77.6 hp from MG2
After governing M2's 80 hp
we can have available 77.6 hp from M2 AND 57 hp from M1
for a total 129.6 HP ALL ELECTRIC
if MG1 spinning at max 13500 and MG2 spinning at max 13130 rpm

(Assuming my updated battery pack has the power)
that is
129.6 HP all electric from a G3 folks!


Interestingly this mod if applied to G4 could
ONLY yield 103 hp from MG1 and MG2
(72hp mg2 and 31hp mg1)


that's right
you heard heard it here first
103 MPH Possible AND 129.6 HP Electric HIDDEN in G3


this G3 project is:

129.6 HP all Electric in a Prius G3 Conversion
REMOVING ICE or cutting drive to ICE
using EXISTING electric motor(s) and EXISTING inverter(s)
(Better) Batteries required

Kit to come

 

thread summary

I looked into this some time ago when
G2 started showing up as scrap
but with the G2 and the 2.4 ratio problem
when joining M1 and M2 the opportunity was not there

Then came the weld on G2
but it was not practical
for any type of kit for the masses
and a little under powered for an EV
I calculated approx 91 hp since
we cant access all of M1 Hp since
we need to sync at max 6500 RPM of M2
so even with a weld
the opportunity was just not there


The G3 was available
with an acceptable ratio to join M1 and M2
but because we have to disconnect the ICE
it would have been uneconomical destroying a
otherwise fine Hybrid.No market.


So I waited for the markets to start to
produce G3 as scrap.


2020 time is now up
you need a donor G3 car,
blown ICE engine or eg 780 km engine or just a good cheap G3
then remove ICE or ICE shaft cut
swap couple of Toyoda ecus with my replacements
a couple of Toyoda computer tricks
my battery controller
its a fairly easy mod then for an end DIY user
it will be basic car, many features will be lost.


Batteries not included.

 

Maarten28
yes i am designing programing a few ecus. it will replace toyodas.

The 13500 RPM it in the Weber Video on P410 above
from professor Kelly
I seen it here and there in Toyoda's literature too.

 

Leadfoot J. McCoalroller

thanks
I have no idea
suggestions welcome

 

****************************************************************************************

This is not for everyone I know

If anyone/DIY wants no know my plan

or if anyone/DIY with Prius knowledge
who can see what I'm doing here
sees a problem
and is wiling to help


I'm good on electronics
However
I have no Prius experience
and no Prius mechanical experience whatsoever
and very little mechanical experience

1)
a new logic board
that controls the inverter gets replaced
(special thanks to Damien Maguire for creating and placing in Public Domain)


2)
a new ecu controls the new logic board
-inputs safety (6), gas pedal (6) , range sensor prnd (8), Data from new logic board, temp etc (10), Speed (3)

I will not be on using any of Toyodas ecu control logic
(well important ones anyway)


3)
a new ecu will also
use intercept wires from the old
Skid Control ECU / Actuator Assembly
and wires from the old
steering control ecu ()
and restore basic steering and brakes



Brake-Regeneration, Boost , Speed map,
perhaps later,
too much for that on G1
for a proof of concept
"simple stupid" for now


that's the car so far:
"go steer stop"



4)
The power control module ecu
gets a hardware hack inside that
restores a few required systems
nothing fancy on the car will work anymore
and no old display, no ac, no heat

Another way is to replace the pcm ecu
it would be 50 or
so new splices and a new fuse panel
and another ecu, restoring basics.

Yet another way
is to trick the
left over toyoda systems
that
everything is OK

we will see


There is no ICE to deal with
so that's a relief
those of us who have played
with Speeduino or Megasquirt
would know enough said on that
the inverter logic board has been reverse engineered
and boards are available from Damien Maguire as of dec 2019
i will be using his
the new Inverter controller will be mine
and replacing 2 additional toyoda ecus will be mine

It will be a basic car
brakes, steering, shift , lights, signals, speed, a new display panel, doors, windows, wipers, defog
(no heat, no air, no alarm, no keyfob, no fancy features)
(no brake ecu regeneration)
and not much anything else, for now anyway,

I hope other engineers and dyi
will get in on it and spoil my fun
bringing systems back up
and improving the mod

3 toyoda ecus
will be smashed
in a celebration
sorry Toyoda
and bye techstream


I may sell a kit
with the few ecu's to swap out
or post it in public domain
or not
only god knows
we will see


"poor little G3 prius is pushed back to an old pre obd camry "


I think you will see these mods all over shortly
its like dandelions showing up at once
it has to do with conditions being right
its cheap, available (G3 scrap),
and reverse engineered (Damien)
enabling control of MG1 and 2
for enough power 130 HP (125 probably)
the MG1 and 2 trick no ICE is in pubic domain now
for a viable low cost DIY EV
and (kinda) easy


Dec 2019
I cant start this for months,
possibly,
if I've inspired anyone that's great
beat me to it

btw I myself will be charging with solar
min 8 >300 watt panels
Total Panel Cost is $2-3 K

Controller is easy we can almost go straight into the Inverter
(it has great DC-DC regulation)
and Charge away
Cost is only a few hundred dollars
for wires and for safety and controls and first responded disconnects

Car and mod $2-3 K

Batteries are not included


any angels who want to ship me inverters
"Inverter donations wanted G2, G3, G4 or any
would be very appreciated, broken up or not"
message me
and g3 pcm also wanted working or not

******************************************************************************

 

Thanks
That's encouraging
I like uncharted waters and breaking ground

I see this opportunity a Little earlier then most
it will uncloak this year to the masses, I'm sure of it.

 

if your inteested in this you might like my other post

DIY ELECTRONICS A Prius G2 can be a 80 K Watt generator !

DIY ELECTRONICS A Prius G2 can be a 80 K Watt generator ! | PriusChat

 

my understanding of gear difference is wrong above
we can tap the full driving 130 HP rating
at much lower rpm from both electric motors
so any gear difference doesn't matter
this problem does not apply to G3
as it did with G2

as G3 with the new gearing 1.014
and raised rpm
neither motors will ever approach
anywhere near maximum RPM

 

Regarding Batteries correct BYO and your Control

This tread will focus on exploiting the existing G2 inverter
with recent information that is the public domain
for a cheap EV conversion by removing ICE

and How to trick and bypass Toyoda so its feasible


"Batteries not included"



thanks Mithrandrost i love vintage conversions

 

imwoody36 your the coolest
2008 All Electric Prius without a gas engine

this is driven by M2 only
not with M1
of course it would be slow
so limited speed
and with original toyoda ecus
he had his 3 battery of his packs in parallel

 

Wait for it

This guy/guys are awsome
heres his youtube channel
imwoody36 you are very cool
imwoody36 - YouTube

 

proof of concept from 2009
Prius 70 MPH Electric Mode (Second Demo): Ewert Energy Systems