Toyota Prius Gen2 EVBMW Throughhole Board

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Prius Board v1

The EV BMW Throughhole Board is a now-deprecated open-source board designed to repurpose Toyota Prius Gen2 Inverter by replacing the essential components of the Prius wiring harness and electronics. It runs the OpenInverter.org software for vehicle control. It was an early prototype and is deprecated in favor of a new SMD Kit from OpenInverter.org.

This is archived here for recordkeeping purposes.

History

This board was designed by Damien McGuire and sold on his EVBMW.com webstore.

While Damien had several Prius control boards designed and available, he felt they were intimidating and inaccessible at low cost to beginners because of the surface-mount components. This meant EV converters would have to buy a pre-assembled board from him at higher cost, or, already have intermediate soldering equipment and skills to tackle tiny SMD components.

The purpose of this through-hole board was to be beginner-friendly - with no surface-mount components - so that all soldering could be done by a novice at an affordable price where they would order their own components and build the board themselves using only the circuitboard from EVBMW.

An initial challenge was that the STM32 microcontroller that runs the OpenInverter software is itself a surface-mount component. The solution was the "Blue Pill" board, a popular and cheap through-hole breakout board with an onboard STM32 that could be purchased on Amazon/Ebay/etc for only a few dollars. This would be soldered onto the EVBMW board same as any other component.

After some testing, some users ran into problems with the BluePill. Perhaps the STM32 chip installed on some BluePills were non-standard knockoffs, or perhaps the board design itself didn't give full access to all the pins on the STM32 microcontroller, but for some types of motors or some things required by the software, this was a critical obstacle. (More detail needed - is this design dead, or just restricted to certain motor types, if so, which?).

Rather than find another through-hole STM32 alternative to the BluePill, several new circuitboard manufacturers at the time made it so cost effective to also populate circuitboards with SMD components that it became not only cheaper but easier for novices to just order a board with the components already mounted than to solder through-hole components themselves. So, the design was deprecated.

The first person to build a replacement design/kit for the Gen2 Prius was Johannes of OpenInverter.org, which he sells in his webstore. Damien has encouraged people to use that design, does not sell these circuitboards anymore, and considers the design a deprecated dead end.

Some people have got motors spinning and EV conversions driving with this design. (Konstantin, links?)

Old Description

The Toyota Prius Gen2 Board is an open source project to repurpose 2004-2009 Toyota Prius inverters for DIY EV use. It consists of a circuit board and programming that replaces the original logic board, connected to the inverter and allows independent control of it without communicating with a Prius ECU.

Note that there is also a Toyota Prius Gen3 Board for the 2010-2015 model years.

As designed by Damien Maguire, the open source hardware for the control board can be purchased as blank, unpopulated boards on his website: Prius Gen2 Logic Board on EVBMW's Webshop

How To Use

The Prius Gen2 Board is suitable to control any (please add: motor types here) motors.

Note: There is a mistake in the printing on the v1 circuit board. The parts labelled T1, T2, and T3 - which are the small black transistors in the upper right of the board - are all drawn backwards to how they need to be inserted. These parts should be installed with the flat side of the component facing the opposite direction as the printing shows. The flat side should be to the right.

Schematics, Bill of Materials, and other documentation are available on Damien's Project Github (note: flesh out bill of materials here, or post changes to Damien to update his documentation directly?)

The control board utilizes the Blue Pill (link?) micro controller, and takes advantage of the OpenInverter.org software (link?) for control. It is also connected from the outside via the main (32 pin white) OEM connector - try to retrieve this connector and part of wiring loom when sourcing your inverter. Picture of connector further down in wiki.

The control board design incorporates the use of the existing inverter Current Sensors - if FOC option is to be used (Gen 2 Transaxle MG2), bandwidth should be a multiple of control loop frequency which is 8.8kHz. (link to how to modify original setup?)

Functionality of the existing resolver is integrated as well.

Assembly notes? Blue Pill programming notes or just links to Blue Pill section?

Try to get all the wiring harness bits that plug into the inverter when you purchase it. Else, the 32-pin connector inside the inverter part number is: 1318747-1, and the pins to wire it are: 1123343-1

Terminal Block Connection list (rough, in-progress):

Wire Connections

Prius Control Board - Wiring Map (click to see fullsize details)

Control Board Pin mapping:

Pin # Designation Description
TB1-1 12v-in Primary 12v supply from ignition on
TB1-2 GND Primary ground connection to 12v negative. All grounds are common
TB1-3 5v VCC 5V supply from board for use with throttle pot or hall pedal
TB1-4 Throttle In 0-5v variable voltage input from throttle pedal or pot
TB1-5 Regen In 0-5v variable voltage input. Can be used as second throttle channel or control regen from a brake pressure sensor
TB1-6 GND
TB1-7 Brake In 12v digital input from brake light switch.
TB1-8 Start In 12v digital input from "Start" position on a traditional ignition switch. Momentary action push button can be used.
TB1-9 For In 12v digital input commands motor to run in forward direction
TB1-10 Rev In 12v digital input commands motor to run in reverse direction
TB3-1 +12v VCC 12v output to inverter IGCT terminal (Not on the 32-pin connector, the red wire on the 2-pin connector next to it).
TB3-2 GND Common ground, but used to connect to inverter GND terminal (Not on the 32-pin connector, the black wire on 2-pin connector next to it).
TB3-3 Phase U

Phase U output. Connect to Inverter MUU terminal for MG2 inverter drive or GUU for MG1 inverter drive

TB3-4 Phase Y Phase V output. Connect to Inverter MVU terminal for MG2 inverter drive or GVU for MG1 inverter drive
TB3-5 Phase W Phase W output. Connect to Inverter MWU terminal for MG2 inverter drive or GWU for MG1 inverter drive
TB3-6 Current U Phase currents from inverter. Requires external divider circuit. Not required to run motor or inverter.
TB3-7 Current Y Phase currents from inverter. Requires external divider circuit. Not required to run motor or inverter.
TB3-8 MG2 Enable Connect to Inverter MSDN to run MG2 inverter or GSDN to run MG1 inverter
TB3-9 MG2 Fault Connect to MFIV for MG2 or GFIV for MG1
TB3-10 DC Bus Connect to inverter VH to measure DC link voltage
TB2-1 +5V VCC 5v output to encoder for induction motor
TB2-2 ENCA In Encoder input A
TB2-3 ENCB In Encoder input B
TB2-4 GND Encoder ground
TB2-5 HS Temp Heatsink temp sensor input
TB2-6 MOT Temp Motor temp sensor input
TB4-1 GND Common ground
TB4-2 Main Con Main HV contactor control low side switch
TB4-3 Precharge HV precharge contactor control low side switch
TB4-4 +12 V VCC Spare 12v output
TB4-5 CAN L Can bus low signal
TB4-6 CAN H Can bus high signal