Prius Gen3 Inverter Hacking

[Jack Bauer]

Just pickup on on the Prius Gen 3 inverter hacking. My little breakout board works great. Soon we will transplant a Johannes brain into this baby.
https://github.com/damienmaguire/Prius-Gen3-Inverter

[sonachan1]

Great news Damien!

[Jack Bauer]

Thanks:) Going to try spinning a motor open loop at the weekend to make sure the drivers are working correctly.

[Jack Bauer]

The Prius Gen 3 inverter is now responding to gate drive signals.

[Jack Bauer]

Motor spinning with the Prius inverter. Will get some video done in the next few days.

[Jack Bauer]

More progress on the Prius :

[johu]

Nice!
Maybe this is a silly question: the package includes 2 3-phase inverters and one HV to 12V DC/DC converter? And none of that HV to HV boost rubbish?

[Jack Bauer]

It has 2 3 phase inverters, a dc dc converter for 12v and a buck boost module comprised of an igbt half bridge and inductor. This can either be ignored or possibly used for hv battery charging.

[Jack Bauer]

Got started on the logic board design today. Three micros in total

[arber333]

Can you tell how would you distribute logic units? Are they full blown Johannes units?

I recommend adding Lebowski brain as MG2 to have sensorless BLDC generator or rear motor application possibility.
Also i wonder if it wouldnt be good to account for buck/boost module as EMW charger? Hm... my mad scientist brain is thinking of charge pump application for charging from different sources like 3phase AC, single phase generator, DC solar source, DC battery extender etc...

[Jack Bauer]

i think the design should handle most applications. There are two complete Johannes brains and an atmega 328 to handle the buck/boost and 12v dcdc converter control. I'll be uploading everything to github in a few days.

[Jack Bauer]

V1 logic board design schematic :
https://github.com/damienmaguire/Prius- ... ematic.pdf
Would appreciate it if people could throw an eye over this before I screw up too badly. PCB design in progress.

[sonachan1]

I can take a look over the weekend. The base Johannes design you've used is mainboardv1.1 from his GitHub page here?https://github.com/jsphuebner/inverter-hardware

[johu]

Very nice!
Only thing is the bypass caps of the resolver (C47, C78). 10µF proved a bit to small when I tested. I got power supply oscillations. I'd recommend at least 100µ.

[Jack Bauer]

Thanks guys. I'm going to call this one HSD : Heubner Synergy Drive

[sonachan1]

Damien, I've just emailed over some notes to your evbmw address.

[Jack Bauer]

Go that. Thanks a lot

Making progress ....

[dima]

Why not make "Expansion Board" just like Leaf, standardized v3 can be dropped instead of another custom design.

[Jack Bauer]

The board space would be a problem. Also the pcb skyline has to be low as the current sensors bracket sit on the top. If it was just a single inverter I could probably get away with it but this being the Heubner Synergy Drive it's a very tight layout especially as I'm trying to keep it single side surface mount to ease assembly.

[arber333]

Go that. Thanks a lot

Making progress ....

So you are convinced that you can supply 3ph power to one 6bridge (use only diodes) with second 6bridge connected to a motor and DClink will see 600V. Then you buck 600Vdc down to healthy 380Vdc with some overhead and supply the battery. That was also my plan .

I was considering using Ampera inverter as rectifier to get 600V, but IGBTs are on the edge. And Prius gives the benefit of built in halfh bridge and inductor.

[Jack Bauer]

Done

[johu]

Wow, that looks like a lot of work, great achievement!

[Jack Bauer]

Thanks Johannes:) I can't wait to see two leds blinking on the one board. Initial release of design files over on Github for those interested :
https://github.com/damienmaguire/Prius-Gen3-Inverter

Expect updates before I order prototype boards.

[Jack Bauer]

Final test fit with a cardboard template to check size and hole location before ordering prototypes.

[Jack Bauer]

Pcbs have arrived and they fit. Hurdle one passed:)