[DRIVING] Audi A2 /w Prius Gen2 Transaxle & Inverter [FINISHED]

[Ev8]

Not trying to go off thread here, so delete if this is, but to be fair anyone who’s taken the time to stay up to date with the firmware development threads should have a good understanding of what any new parameters function is, most new releases also tend to have a description of any changes also. Remember this is a open source product so don’t go expecting an owners manual and quick start guide! Maybe someone will update the wiki, if I wasn’t away from a computer for the next 10 days I’d get on it. Will taken a look when I’m back

[johu]

Audi is now delivered
It was a 350 km drive, 5 charge stops (not 6 as stated in the video), 45 kWh spent.
Makeshift CCS held up just long enough to make the trip except a short tow from my dad 10 km before we touched base

Early forum release

[Proton]

That is 4.8 mile/kw. Really good. with the electricity price here would be about $3.8

[johu]

Just found that I'd taken a picture of the modified A/C inverter, here it is

[johu]

That connection wasn't up to the job

[Ev8]

Which connection has died? The smaller gauge wire soldered to the rectifier leg?

[johu]

The connection with the heat shrink. It was actually crimped to the leg, not soldered. Maybe that was not so clever, I don't know.
I always charged at 2kW but before delivering the car I raised this to 2.8kW for more reasonable charging time. That must have killed it.

[TRWIKI]

Hello everyone.
I am new here.
My name is Carsten, from North West Germany.
My background: I am a mechanical engineer with little knowledge of electrical engineering. I am a 60 year old petrol head. I have already rebuilt/replaced motors and also used a new motor controller (Megasquirt). I also have a little experience with Arduino programming, but no knowledge of C, C++ etc.
Now I want to get away from the combustion engine. I started with a book by Johannes Hübner.
(https://openinverter.org/shop/index.php ... duct_id=76)
It was a Christmas present from my three children

First of all, many thanks for all the pioneering work in this forum and the documentation here!
I've read a lot over the last few weeks, but unfortunately I haven't understood everything yet.
That's why I'm trying to reproduce this conversion (Audi A2). I would like to stick as closely as possible to the components used here, because a lot has already been documented. Many thanks for that!
In the Wiki (https://openinverter.org/wiki/Audi_A2_Conversion)
it says "Toyota Prius Gen 2 (2004-2009) transaxle with matching inverter"
In my search here
https://a2-freun.de/forum/forums/topic/ ... ent-980118
and on youtube
I have unfortunately not been able to find the converter actually used (?) for which the conversion was so well documented.

In my research on this component I get at least these different variants:
G9200-47100
G9200-47111
G9200-47120
G9200-47121
...

May I politely ask which component was used in this conversion?
many thanks and best regards
Carsten

[johu]

Welcome
The inverter has part number G9200-47121 but any that looks like this will work: https://openinverter.org/wiki/Toyota_Pr ... 2_Inverter

[crasbe]

Hey Carsten,

where in "North West Germany" are you located? I have a Prius Gen2 Inverter laying around that I won't use, so you could have that for little money. I'm located ~50km southeast of Hamburg, but I commute to Hamburg every day.

Maybe you're interested. I'll have to look up which part number it is exactly.

Best Regards,
Chris

[Gregski]

did I miss the part about oil pump control, I swear I skimmed every page and did not see how you are handling the oil pump pumping

[TRWIKI]

Hello
thanks for the quick reply Johannes!
And many thanks for your offer, Chris.
I live near Oldenburg/Bremen.
And I already ordered Prius Gen 2 inverter and transmissin yesterday morning here:

https://www.partan.de/de/car/toyota/#q= ... ype=type_a

I found the offers there comparatively favourable. They are within my budget.
While the parts will arrive, my first goal is to experiment with them on the workbench. That will probably take much longer than I would like. Working with the CAN bus, STM32, for example, are completely new topics for me. But there is good advice here in the forum: AUDI A2, VW Touran, VW Beetle (CAN bus)
and in the future perhaps also good documentation from "Gregski" , if you'll choose Prius components for your Golf MK1

And I'll always keep an eye on this thread too:
viewtopic.php?t=4162


I see project durations of several years in this forum. But that doesn't matter, because for me it's just a hobby for now. And before this hobby, there is always my job, family, house, dog and garden. I'm sure some of you know that

Best Regards
Carsten

[johu]

did I miss the part about oil pump control, I swear I skimmed every page and did not see how you are handling the oil pump pumping

Not much to do, thats why As soon as more than 600 rpm are put on CAN bus it starts pumping

[Bigpie]

Isn't the transmission oil pump mechanically driven from MG1?

[johu]

Oh transmission oil pump. Yes that is driven mechanically *somehow*

[Gregski]

Oh transmission oil pump. Yes that is driven mechanically *somehow*

as per Professor John D. Kelly of Weber Auto the engine when running would spin the input shaft which then connects to an extension oil pump shaft and spins the mechanical oil pump, this would pump the oil to a few strategical places such us on top of the MG1 stator via a little faucet drip like system



2004 - 2009 Prius Transaxle - P112 Deep Dive video queued to the Oil Pump section




in addition to the oil pump the transaxle's final drive ring gear "self lubricates \ self cools" by simply splashing the oil around

[johu]

So quick update from Thomas.
He has moisture problems, I think 2 of them.
- At one point he drove in the rain and the CAN bus died. I told him which connection it probably is and he sealed it better. Need to see if that helps
- Also after rain the GFCI or even the breaker trips when he plugs in for charging. When he waits a few hours the problem is gone and he can charge again. Need to find the root cause for this. Current theory: I folded the rear carpet over the battery and it might touch HV. Thomas said it was a bit moist so this could be it

Apart from that car runs fine, he has driven 4500 km so far.

[TRWIKI]

Hello Johannes,
thank you very much for the report on your experiences with the car!

If it's not too much trouble, a short video about the acceleration would be helpful (dashboard). That would be nice, because you wrote elsewhere that the acceleration is poor from 50 km/h upwards. I will also need a car like this on the motorway and a minimum acceleration from 50 km/h is necessary.
I think many others will also be interested in this.
However, this is not urgent. Only on occasion.
Many thanks in advance and best regards

[arber333]

the GFCI or even the breaker trips when he plugs in for charging

I had the same problem on Mazda a long time ago. A lump of mud formed at the back of my charging connector. In wet weather this tripped many EVSE protection before i figured it out.

[johu]

I will also need a car like this on the motorway and a minimum acceleration from 50 km/h is necessary.

Just saw this. Not sure if I get a chance to do that as the car is now far away. Thomas uses it on the motor way every day so and never reported it was too slow on the ramp. It is slow in EV terms but compared to 60 hp estate it is quick,

Anyway, unfortunately more issues to report. The vacuum pumps drops out. Hard to get to the bottom of it without being physically present. Apparently even the power steering pump drops out occasionally. Need to visit to find out more about this.

[TRWIKI]

No problem with the answer now.
You had already answered me on YouTube.

Thank you for the further information.
The other problems (pump) can certainly be fixed.
I had also read that you don't necessarily need power steering on such a light vehicle....