Prius G3 gearbox in a performance vehicle?

[stoff]

Hey there. I've gotten a bit obsessed with the Toyota Hybrid Synergy Drive Wikipedia page lately. The way the system operates reminds me of those new LMDh cars, and I think it would be interesting to repurpose a HSD drivetrain and instead control it to operate in a manner that maximizes performance and responsiveness instead of efficiency. The idea of using MG1 to always keep an engine in its peak power band and using MG2 as a power assist sounds very appealing.
I understand that functionality similar to this is afforded by the "ZombieVerter" project, and I've decided on the Prius G3 drivetrain which should be well-supported. (I'll think about what chassis to put it in later, and swapping in a different gas engine might be on the cards too.) My MSEE was in control systems, so I'm aware of what I'd be getting into here, and I recently came across Damien Maguire's work which should greatly reduce the amount of hardware I imagined I would have to make myself.
Is there anything I'm missing here from an applied POV? Can the Prius G3 MG2 motor and battery run at the "rated" 60kW for long or am I going to have issues? Has anyone actually destructively tested the gears and/or motors (which, if robust enough, could allow for use with more powerful or higher-revving gas engines)? Is it a bad idea overall? Hope to hear your thoughts.

Thanks.
stoff

[tom91]

The Gen 3 Prius control via Zombie is limited to stock toyota speeds. We have yet to unlock anything above what has been seen in this build thread: viewtopic.php?t=4484&hilit=gen+3+prius+rabbit&start=575

You could of course unlock this all by swapping the logic boards and tuning the system with those for more then factory power.

You will always need to write your own control code for the lot to function correctly.

[jrbe]

I think we need to sticky something for this. It comes up about once every month or 3.

Short version, yes it's cool and a great concept. The reality is it's a ton of work for coding, fabrication, integration of the ice engine & controls, troubleshooting, etc. ..Even if you had specialists for each and excellent communicators between the disciplines it would be a huge undertaking.

[stoff]

Tom91, the way I see it is that that only limits the angular top speed of the transfer case "output"; there is still the final drive and the diameter of the wheels to enable a higher vehicle top speed. Of course if any other engine mated to this has a redline significantly higher than the 2ZR-FXE's then it would matter like you said.

Unless I'm wrong, ZombieVerter reanimates the inverters alone and the stock BMS should still work, so I would really only need one other board that controls both the gas engine and the ZombieVerter in the manner that I want. (I'm aware of the difficulty of its necessary software)

[tom91]

Unless I'm wrong

Guess who been working on the Zombie and Prius Gen 3 reverse engineering work in that topic, Me. I would say at the moment I am the largest contributor to any Zombie Development work going on over the past year or so.

Stock inverter firmware/hardware is yet not bypassed, there are severe limitations.

Also Hardware limits, using the boost converter limits power draw to 30kw burst, alot lower for higher rates. Also Toyota battery is garbage and wont last in stock configuration let alone asking 60kW, which is roughly 3x stock configuration.

[stoff]

I'm only going off of stated ratings for MG2 itself which are 60kW; now I know the rest of the system isn't up for that, thank you Tom. Seems like a battery swap is in order as well, maybe something with 400-600V and bypassing the DCDC.

What limitations exactly are in the stock firmware that you were talking about? I'm not averse to developing my own inverter control stage (i.e. gates and back), I've done stuff of the sort before, but would be nice not to have to if stock isn't that bad.

[tom91]

What limitations exactly are in the stock firmware that you were talking about?

If I knew I could have bypassed them in the serial comms like I done on the GS450h and IS300h. Tried almost all positions as listed and documented in the build thread I posted.

You for sure need to by pass the DCDC and a suitable battery.

Here the designed replacement control board for the Gen3 Prius inverter https://openinverter.org/wiki/Toyota_Prius_Gen3_Board