Prius Gen2 adapter board development thread

[arber333]

I recommend you search for them, but in the meantime you find some PVC material and cut and file it to shape. Then drill holes for bolts and two centraly positioned holes for two cables you intend to use. You glue/seal DC cables onto this plate by means of black auto glass sealant, of course on the inside. You get nice flat grommet secure from moisture etc.
I have done this many times and it can only be removed intentionally.

[johu]

Ah but you mean for the HV DC bus? I meant the little 12V input.

[SciroccoEV]

It's not exactly an expensive connector to replace, I'd just buy a matching plug and socket.

[konstantin8818]

It's not exactly an expensive connector to replace, I'd just buy a matching plug and socket.

My first thought exactly Why bother with OEM when you can replace it with any aftermarket. I consider I'm lucky to have piece of OEM harness with sealant.
Anyway I've got number 11717 on my connector, so google shows it correctly: 90980-11717

[ZooKeeper]

post deleted

[RetroZero]

Good find Konstantin8818.

[RetroZero]

Easy, easy will get some made at JLC and test them, then will publish the design.

Will leave you to it then. Just let me know when I too can become a proud member of an openinverter board ..

[konstantin8818]

Easy, easy will get some made at JLC and test them, then will publish the design.

It's going to be a loooong waiting. My blue pills ordered from China lie somewhere for over one and a half month already

[RetroZero]

I have located another company, in my Town that does prototype pcb's. I know it will be 'expensive' compared with JLC, but I could ask around? However, if Johu prefers to have them built and tested through known channels, I understand too.

[Jack Bauer]

I have encountered no delays with JLC. about ten days for smd board builds.

[RetroZero]

Thanks for info.

[konstantin8818]

I have encountered no delays with JLC. about ten days for smd board builds.

Oh, that is a good news. We'll hope for the best.

[RetroZero]

I might have to go locking up a planet gear set whilst I await 'the cure'. Will post in the transaxle post as I go....

[konstantin8818]

I might have to go locking up a planet gear set whilst I await 'the cure'. Will post in the transaxle post as I go....

"the cure" is a simple chunk of metal produced with the lathe. All you need is do some measurements maybe with a micrometer, and a good lathe operator. Unfortunately, I went by the way of MGR, and have got no free money to purchase prius gearabox to disassmle it. Yet I've got micrometer and a good lathe operator=)

[johu]

Order at JLCPCB placed
I have made some small changes: solder jumpers for optional encoder pull-up resistors (thanks Damien) and corrected inverter fault detection.
EDIT: and I created a logo

[EVs4Coluche]

Thanks, so many Gen2 out there, siting on shelf, waiting for new home..

[ZooKeeper]

Order at JLCPCB placed
I have made some small changes: solder jumpers for optional encoder pull-up resistors (thanks Damien) and corrected inverter fault detection.
EDIT: and I created a logo

I can hardly wait! Thanks for your efforts!

[MattsAwesomeStuff]

Wait, it's done? Huh? What?

Great success.

[RetroZero]

Awesome news! Can't wait to test it out ...

[johu]

Wait, it's done? Huh? What?

Great success.

It's done when it's tested - this is Germany, there are procedures to follow (James May)

EDIT: found it

[ZooKeeper]

LOL! Capt. SLOW!

[konstantin8818]

It's done when it's tested - this is Germany, there are procedures to follow

it was last time, I promise

[MattsAwesomeStuff]

I'm trying to describe the current state of affairs for the Prius boards to some others on the DIY EV forums. But I'm not sure I understand everything that's been done.

I think what Johannes has done here is create an add-on board for his Open Inverter control board, with some Prius-specific stuff to re-use that inverter. Upgrades over Damien's Gen2 Blue-Pill based board are:
- No Blue Pill, which was a kind of downgrade.
- Current sensing using onboard sensors (Damien's board needs some add-on circuitry to work properly with this).

Damien has recently incorporated twinning the power inverter outputs for MG1 and MG2, or re-using one of them as a charger. I don't think this Gen 2 board from Johannes will do that?

What I'm aiming at is, development is proceeding at a good pace, what might happen next? Integrated charger would be nice, as would boost-converter control. One of the limits of the budget EV scene is that there's not budget (or room) to get a full OEM EV's worth of cells, but 200v-ish is a more attainable target. Another limit is perhaps speed or performance. So, the boost converter would be something nice to have control over. In terms of planning a build, I'm guessing people could start shopping for inverters, but maybe hold off on buying control hardware? Would these be on other add-on boards or tertiary boards if they were developed in the future?

[johu]

it was last time, I promise

Haha, no matter what brilliant things you do, it's always the stupid things that stick

I'm trying to describe the current state of affairs for the Prius boards to some others on the DIY EV forums. But I'm not sure I understand everything that's been done.

Thanks for putting it out there.

I think what Johannes has done here is create an add-on board for his Open Inverter control board, with some Prius-specific stuff to re-use that inverter.

That was the original plan but now it has become a bespoke SMD board for the Prius that will live in its own enclosure and connect to the Prius inverter via a 12-pole cable.

Upgrades over Damien's Gen2 Blue-Pill based board are:
- No Blue Pill, which was a kind of downgrade.
- Current sensing using onboard sensors (Damien's board needs some add-on circuitry to work properly with this).

Yes, and:
- Resolver excitation
- Control of buck converter while NOT running in drive mode, i.e. just for charging

Damien has recently incorporated twinning the power inverter outputs for MG1 and MG2, or re-using one of them as a charger. I don't think this Gen 2 board from Johannes will do that?

Using as charger: see above. Twinning outputs: by default no, you could however route the PWM control signals to both inverters and thereby parallel them. You could however not run two motors independently as there is only one control core.

What I'm aiming at is, development is proceeding at a good pace, what might happen next? Integrated charger would be nice, as would boost-converter control. One of the limits of the budget EV scene is that there's not budget (or room) to get a full OEM EV's worth of cells, but 200v-ish is a more attainable target. Another limit is perhaps speed or performance. So, the boost converter would be something nice to have control over. In terms of planning a build, I'm guessing people could start shopping for inverters, but maybe hold off on buying control hardware? Would these be on other add-on boards or tertiary boards if they were developed in the future?

Boosting while driving is indeed not gonna happen with this controller, as the buck/boost PWM channel does not run off an independent hardware timer. Since the boost converter only sports 20kW and it is easier to just use field weakening, I would not consider this option necessary.

[RetroZero]

Can't wait to get Mg2 spinning and then trying your parallel circuit... People here are very dubious about possibilities with used OEM parts. Hope to prove them wrong
Teams of 5 to 15 people working on kits that fit within norms being put in place... Don't know how it will look with a one man band driving a prius propulsed... (maybe golf mk1?.) bring on V3 Gen2!