Remove the ICE from a Prius Gen 2 ⚡️and roll on battery only ⚡️

[Bassmobile]

This little car rolled off a truck and into our shop over the weekend.
Has a golf-ball size hole in the engine block. Catastrophic failure @ 90K Miles. Who knows how it happened.
Cut the valuable California Spec. catalytic converters off of it this afternoon and sold them to a recycler for a cool $500 to break even on the deal.

Mission now is to pull the dead ICE, and make it roll again as an around town vehicle on only electrons

Is this crazy impossible, or crazy cool?

[celeron55]

I was considering doing that to a gen2 Prius, but the cheapest one I could find was 3500€.

I would have gone the "out-of-gas-mode + talk the same bms protocol" route myself. What's your plan?

[Jack Bauer]

My advice would be to weld up the planet gear and use the Johannes controller.

[Bassmobile]

I was considering doing that to a gen2 Prius, but the cheapest one I could find was 3500€.

Sheesh. There are dozens in my neck of the woods for around that same price, but there are also many that have ICE or NiMH problems, or both for much much less.

I would have gone the "out-of-gas-mode + talk the same bms protocol" route myself. What's your plan?

That blown motor is quite a bit more than out of gas. As far as the BMS goes, we might as well be comparing English to Mandarin.
The NiMH system only monitors the 'blocks' which are composed of 12 cells in series. There is no active balance going on with the 12S blocks. NiMH have been a Toyota favorite for a long time it is assumed due in part to their simplicity and resilience to this type of pack construction. Toyota was largely able to make good on that warranty of the Prius battery that was good for 8 years or 100,000 miles. By that time the NiMH is well abused and time to go to the recyclers. Some still keep working well into the 150K mark or more. But I don't know how much credit the BMS deserves for this. Long of the short. The Stock / OEM BMS isn't going to cut it for any other purpose.

Will install in the next few days the 13.25kw LTO replacement pack. Constructed using Toshiba modules, blasphemously bearing 'Honda' trademarks. Occupies roughly 2* the space as the original NiMH pack, in the back. Runs at 240V nominal. 10C all day long. Love those LTOs.

My advice would be to weld up the planet gear and use the Johannes controller.

If the design files for that route were available, it would be done. Have inquired about that today.
But as it is, we have three Gen 3 Prius inverters with your boards fully assembled, programmed and on the ready. Been watching your Capacitor follies like it's the Game of Thrones. The thinking is that a Gen 3 inverter would sit quite nice under the hood of this Gen 2, and offer some nice benefits too. Going to see about a second Gen 2 tomorrow. This one also in a similar state of ICE death. Should be had for pretty cheap. Will be tearing one down and firing up the TIG soon.

HA! Yes, remember this video from way back. Thanks for reminding about it. That empty engine block?! wow.

[RetroZero]

FYI , I am trying to get a lock-up solution for planet gear made up. As soon as there is an update, will post in Transaxle Mod thread...

[Jack Bauer]

Sounds like you are well on the way.

[Bassmobile]

FYI , I am trying to get a lock-up solution for planet gear made up. As soon as there is an update, will post in Transaxle Mod thread...

Yeah? The method has already been established. TIG weld planetary gears to lock MG1 MG2.
a la;


Trying to understand the context of your comments, and assume that you must be stressing about this under some sort of Governmentally imposed QMS?
Here in the USA, a land where ISO90xx, or TÜV standards have little to do with life in the EV swap auto shop. One simply walks up to a motor vehicle department counter, with a box on a form field for fuel ticked "Electric", pay the $15.00 and walk out with a new designation on the vehicles registration. Establishing an approved protocol for welding the gear set isn't part of the rational here. Much less buying an aftermarket gear-set. For the Euro brethren, one would imagine that welding can be performed by a certified operator, and /or it can be further scrutinized by x-ray or other methods to satisfy the official imposition. Really feel for the fellows whom lives are under such bureaucratic scrutiny. Would think it be enough to drive a man to seek refuge in a new land.. hehe.

[RetroZero]

Many have done just that, but where do you move to now that everyone is in lock down ? . Bureaucrats think ev conversions are bodge jobs done by unprofessional DIY people. Our regulations does its best to keep DIY illegal... I hope to get my 'gen 2 kit' approved hence the more 'fancy' approach to lock up gear is under way.... Bureaucracy

[Bassmobile]

Bureaucracy

Watched some video about French regulatory boards and now I understand more why you have to go to such great effort to design a solution other than simply welding. But it seems that if the welds are done by a certified welder. It should be fine. No?

[RetroZero]

Every modification has to validated by a scientific / engineering validating enterprise.
So questions start being asked like,
how much rotational force will be applied?
will a welded up unit, with 3 teeth per plantet gear in contact with carrier suffice for said rotational force?
What type of strengthened steel is being used?
OH and it goes on and on.

So, output of MG2 is coupled via "connecting gear" to carrier, and transfers its 50kw to wheels without ICE or MG1.
If we use the same gear for MG1, there shouldn't be a problem - it's less powerful.

You would swear I'm building a spaceship or something, but you need to understand that the authorities look at this from the "who do we point a finger at when this goes wrong" angle....
Who will pay? Who is liable? Can you 'guarantee' it for 5 years? With what 'proof'? Think of your worst insurance broker and double it.
Bureaucracy very or over cautious. In a way that's good, only space for safe conversions on public roads. That's what Openinverter is trying to achieve from what I understand.

[imwoody36]

52mph is max speed without spinning the input shaft ( like the I.C.E. would be doing)
here is a link to a nice animation you may fiddle with the rpms yourself
http://eahart.com/prius/psd/

Im the guy who did the youtube video back in 2008.

reach out to me if you like

[arber333]

So, output of MG2 is coupled via "connecting gear" to carrier, and transfers its 50kw to wheels without ICE or MG1.
If we use the same gear for MG1, there shouldn't be a problem - it's less powerful.

What about if you state a declaration that you use ONLY OEM components and dont touch the transaxle. You lock the input shaft by means of torque rods or plate and use MG1 to fight MG2 torque electricaly? Like constant speed matching. How much speed would you get out of it then?

A

[Matthew100]

13.25kw LTO replacement pack. Constructed using Toshiba modules, blasphemously bearing 'Honda' trademarks. Occupies roughly 2* the space as the original NiMH pack, in the back. Runs at 240V nominal. 10C all day long. Love those LTOs.

How is this battery configuration working out for you?

I saw the same batteries and was considering this myself.

What BMS are you using?

[Pcstreet]

Any updates?

[ZooKeeper]

I'd suggest making a plate to cover the engine side opening and a clutch disc on the input shaft bolted to said plate to prevent MG1 from spinning. That way, only OEM parts are used for the conversion.

[SciroccoEV]

I'd suggest making a plate to cover the engine side opening and a clutch disc on the input shaft bolted to said plate to prevent MG1 from spinning. That way, only OEM parts are used for the conversion.

Locking the input shaft results in MG1 spinning faster than MG2. Locking the power split device results in MG1 and MG2 spinning at the same rpm.

[slow67]

I'd suggest making a plate to cover the engine side opening and a clutch disc on the input shaft bolted to said plate to prevent MG1 from spinning. That way, only OEM parts are used for the conversion.

Locking the input shaft results in MG1 spinning faster than MG2. Locking the power split device results in MG1 and MG2 spinning at the same rpm.

X2. Locking it on a gen 3 would be ok (might need external oil pump to keep it cool though).

[ZooKeeper]

Locking the input shaft results in MG1 spinning faster than MG2. Locking the power split device results in MG1 and MG2 spinning at the same rpm.

Recorded MG2 speeds are about 4k @ 68mph, and MG1 can spin to 10k, so while "high speed" driving could certainly pose a concern... completely doable at posted speeds.

[Nexgen2.l]

Lads hope u are well ... lads am going to build a boat thinking of auris inverter converter an battery a gs450h gearbox an about 300hp am I mad .
Wylie

[slow67]

Lads hope u are well ... lads am going to build a boat thinking of auris inverter converter an battery a gs450h gearbox an about 300hp am I mad .
Wylie

The only issue I see is the continuous duty nature of boats. Its worth a shot though! You have an unlimited supply of
cool water to help out!

[Bassmobile]

13.25kw LTO replacement pack. Constructed using Toshiba modules, blasphemously bearing 'Honda' trademarks. Occupies roughly 2* the space as the original NiMH pack, in the back. Runs at 240V nominal. 10C all day long. Love those LTOs.

How is this battery configuration working out for you?

I saw the same batteries and was considering this myself.

What BMS are you using?

Working great! LTO batteries are so awesome. So much so, that had to buy the remaining stock from the distributor.

Using the "Micro-BMS" from Teknømadix.