A complete beginner setup

[electric_sheep]

I've been really wanting to build an EV for ages and until I'd seen Damien's videos I thought the best budget way was with a forklift motor mated to the transmission. Now I've been convinced that Toyota hybrid parts are the best way to go.

I literally have no stuff at all. The most I've done is electrify a mountain bike.

Eventually I want to electrify a small FWD econobox. But my first aim is to just have a prius transaxle spinning on the bench. I have some very basic questions about what I need to get the ball rolling...

* When I visit breaker's yards to find Prius parts, should I aim for Gen2 or Gen3, or just whatever's cheapest and available? On evbmw.com I notice they're currently only selling boards for Gen3, if that has any bearing on the choice?

* Aside from the transaxle and inverter, what other parts should I try to salvage from the scrap Prius if possible? In the Lexus tutorials, he mentions some oil pump but I'm not sure if the Prius has the same thing.

* I notice that in some of Damien's videos he powers his bench test transaxles with some kind of battery, and other times using some transformers and stuff plugged into his workshop mains. What should I do? If I get a battery, what kind of battery is sufficient for these slow-speed bench tests (i.e not the actual battery I will end up using to power the finished EV), and what kind of charger do I need to get for it?

Thanks

[johu]

Both Gen2 and Gen3 will work. Gen2 controller is sold here on openinverter.org and will use one inverter for driving a motor. Gen3 controller exists in a two motor flavour which is good for using both motors in a Prius transaxle.

Always salvage as many connectors as possible, they are hard to get afterwards.

You best start the test with some 50V of battery with a light bulb in series, to limit current should you mess something up. You can bypass the light bulb as you gain experience.

Watch this:

[electric_sheep]

Thanks for that advice and informative video. I was a bit confused by this statement:

Gen3 controller exists in a two motor flavour which is good for using both motors in a Prius transaxle.

Does that mean if I buy a Gen2 transaxle and Gen2 inverter (and consequently get the "Toyota Prius™ Gen2 inverter controller - community edition"), I will only be able to use one of the two MotorGenerators inside for traction to drive the car?

Right now I have the opportunity to get a Gen2 transaxle and Gen2 inverter for a very good price. The equivalent Gen3 parts are costing quite a lot more but I could be tempted to choose the Gen3 (and associated "Prius Gen 3 Inverter Logic Board Kit" from EVBMW.com) if that's the only way to make use of both MotorGenerators inside.

But maybe I've totally misunderstood the situation.

[Isaac96]

Yes, you are limited to one motor if you only have one controller.
Maybe you could get two controllers? Or if you're real clever, align the two motors perfectly and run them both from the same controller.

[arber333]

Right now I have the opportunity to get a Gen2 transaxle and Gen2 inverter for a very good price. The equivalent Gen3 parts are costing quite a lot more but I could be tempted to choose the Gen3 (and associated "Prius Gen 3 Inverter Logic Board Kit" from EVBMW.com) if that's the only way to make use of both MotorGenerators inside.

Maybe you could look at prof. Kelly Prius transaxle videos and eventually you will come to a conclusion what you really need is Gen2/Gen3 inverter and Gen3/Gen4 transaxle to drive EV at 100km/h and beyond. You should however bypass buck/boost part of inverter so you can run field weakening for more power at high rev.
I am not sure if you should use MG1 at all. But with Gen3 tx you would need to use aux electric oil pump to keep motor lubricated.

Gen 3 transaxle P410
MG2 should have plenty of power at 60kW


Gen 4 transaxle P610
MG2 is at 70kW
Here you cold actually use BOTH motors to drive your car!

[electric_sheep]

Thanks for these responses.

What I perhaps failed to grasp before is that the MotorGenerator2 is much bigger than MG1, and should be OK to propel the car at decent speed. So it's not a catastrophe to only use one MG.

With that in mind, I am hoping to use the Gen3 inverter, Gen2 transaxle, and Gen3 control logic board. If that's a combination that will work then I'll happily go to the breaker's yard to collect the parts ASAP!

[ZooKeeper]

One would need to weld the power split device.