Unlocking the power/torque of Prius gen 3 drive train?

[Ghia66]

Hi, in my shed is;
ZombieVerter VCU, software V2.15A running the following;
Toyota Prius gen 3 drive train and inverter
Mitsubishi Outlander onboard charger and DC/DC converter
BMW hybrid 330e 7.6 kWh gen 1 battery pack
Toyota Yaris accelerator pedal
Tesla model S water pump connected to skirting board radiators

Logs (speed, torque). Spot values screenshot. Params attached

Possible to unlock power/torque of the Prius gen 3 drive train?
I have a similar bench setup as The Greg RabbitMyster (my teacher) and much like him I would love to see the Prius smash the 52mph barrier!

Really want to fit this Gen 3 Prius setup (because I have one and it will be different) in my 1966 Karmann Ghia which I have just de iced from a Subaru N/A 2litre 92kW 184Nm engine that I fitted in 2019.

Have converted the Ghia from Swingarm rear suspension to IRS to facilitate the fitting of an EV drive train.

I have not welded the Prius Power split device (as ably demonstrated by Damien) but am prepared to do so and anything else that may help to unlock the power!

Thanks
Les

[tom91]

So at the moment there seems to be a firmware limited power limit on using MG2 only. As found in testing by greg viewtopic.php?p=73007#p73007 with the support of myself.

Your speed limit is likely due to the revlim of 6000, please raise this to 8000 and see if it will reach that.

I would strongly recommend welding the power split and seeing what changes, since there can be a limit due to only sending torque requests for 1 motor.

[Ghia66]

Thanks Tom, I will raise the revlim to 8000 and retest.

I will weld the power split after this

[Ghia66]

Set revlim to 8000...see log
set revlim to 10000...see log

[tom91]

So this is not the limit right now. Best get this into a vehicle with a welded PSD and then start tweaking things.

[Ghia66]

Thanks, I will start stripping it down and weld up the power split.

Just wanted to see if it was worth my while installing it into the Ghia

[Ghia66]

Just had to chance my arm with a revlim 13000 run before the teardown!

[Ghia66]

Have just welded the Prius Power split device and reassembled.

Did a quick test using MG2 only with revlim set to 13000

Is there anything else I can do?

Thanks

[tom91]

Run MG1, I would not run it to that high a speed without oil or load.

This is just to check it runs alright and no strange noises. Please check the output rotates in the correct direction.

No idea if we have to invert the torque for MG1 or not.

[Ghia66]

Thanks Tom, will do tomorrow when I get some oil

[Ghia66]

Oil in and MG1 running on revlim5000 no unusual noises.

Runs forward and reverse with output shaft matching.

[tom91]

Runs forward and reverse with output shaft matching.

And this matches MG2? Then we can proceed to get to loading it up, which needs a vehicle.

[Ghia66]

Thanks Tom, anything else I can try in the interim?

I have a crude resistance rope setup on each drive hub that I could use to increase the load.

Any point in trying MG1 & MG2 together for a spin?

I am currently fabricating the drivetrain mounts to fit on the Ghia pan.

[tom91]

Any point in trying MG1 & MG2 together for a spin?

No the limit Greg's rabit hit was 20kW, this is not something to simply absorb in a "DIY" setup.

[Ghia66]

Thank you

[Ghia66]

Well I couldn’t resist spinning the drive with MG 1 and MG 2 now the power shift is welded.

The mounts are sorted on my test chassis so now to the next challenge…the driveshafts!

[Ghia66]

New Independent rear suspension and air bags are in

Engine mounts fitted to drive train

Drive shafts measured and sent off to the machine shop

Planning locations

[arber333]

Thanks Tom, anything else I can try in the interim?

I have a crude resistance rope setup on each drive hub that I could use to increase the load.

Any point in trying MG1 & MG2 together for a spin?

You may break things, so dont...
On the other hand you may try to rotate assembly by MG2 and then put the MG1 in regen . This should be interesting...

[Ghia66]

So I hit 86 kph on my third test run in the Karmann Ghia.
I reckon it will go faster when I have enough open road and have corrected the massive toe in on the rear wheels…so maybe the 52 mph Rabbit limit will be broken
ZombieVerter VCU, software V2.15A
Toyota Prius gen 3 motor and inverter welded power split device
BMW hybrid 530e 12kWh gen2 battery pack
BMW Safety box

What do I need to try now?

[tom91]

Can you get a log showing, speed? A log showing udc and idc would be useful too so see how much power she draws.

Be good to go out to a strech of road where you can do 60mph and see how fast it goes.

How does the acceleration feel?

[Ghia66]

Thanks Tom, will attach a log.

I am battling to get enough granny charging time for the battery pack so I can venture to a good road but will do!

It seems to accelerate quicker off the line in reverse (this may be due to the massive toe in on the rear wheels) When in drive it really needs the pedal nearly to the floor and then it gets moving quickly.

log (12).csv

(5.86 KiB) Downloaded 19 times

log (11).csv

(4.94 KiB) Downloaded 11 times

[Ghia66]

log (17).csv

(37.05 KiB) Downloaded 12 times

Whet for a test run in the Ghia and reached 103kph (64mph) but no faster. So the 52mph barrier has been passed!
It drives smoothly but the throttle needs to be pushed down a long way to get really motoring.
It spun up to 7959 rpm should I do a test run with revlim set to 13000 now?
Any suggestions would be most appreciated.

[tom91]

Can you please next time add
"idc" and "potnom" instead or "KWh" or "AMPh"

Please post your params.

[Ghia66]

Thanks Tom, will do.
Worth trying 13000 rev lim?

[tom91]

I do not see your Params, so who knows what is going on.

I need data to make conclusions and recommendations