Toyota Prius Gen2 Board: Difference between revisions

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[[File:Prius Board v1.jpg|thumb|Prius Board v1]]


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 Prius' original ECU.
This page is now deprecated in favor of the following new pages:


== Prius Inverter ==
* [[Toyota Prius Gen2 Inverter]] - General knowledge about the Toyota inverter itself, how it functions, pinouts, etc.
[[File:Prius Gen 2 Inverter.jpg|thumb|Prius Gen 2 Inverter Montage]]
* [[Toyota Prius Gen2 EVBMW Throughhole Board]] - Details on the now-deprecated EVBMW "Blue Pill"-based easy-to-solder controller board, diagrams, instructions, pinouts, etc.
[[File:Prius Gen2 Inverter - Internal.jpg|thumb|Internal look at the Prius Gen2 Inverter]]
* [[Toyota Prius Gen2 Inverter Controller]] - Details on the newer OpenInverter controller board and kits to repurpose the Gen 2 Prius inverter.
The Toyota Prius is a hybrid vehicle. Their inverters are suitable and attractive for DIY EVs because of:
[[Category:OpenInverter]] [[Category:Toyota]] [[Category:Obsolete]]
* Large part availability. Priuses have been made in large numbers for 20 years.
* High affordability. Prius inverters are available for around $150 from scrapyards everywhere.
* Durability. Toyota engineers appear to have made the inverters foolproof, many inputs and outputs gracefully handle fault conditions.
* Respectable performance. Rated for 50kW output, but tests indicate they can tolerate as much as 300kW
* Ease of repurposing. Emulating the original ECU seems reasonably feasible.
 
The Gen2 Prius (2004-2009 model years) has a variety of useful components inside the inverter package:
* 2 high power inverters, for the 2 motors MG1 (starter) capable of handling X(?) amps, and MG2 (drive motor) capable of handling Y(?) amps.
* A DC-DC converter to provide 12v power supply to the automotive systems and accessories.
* A boost module to boost the 200v battery pack up to 500v, which looks to be able to function as a battery charger (wish list for future development)
* See this video for a thorough disassembly and explanation of the Gen2 Inverter (Timestamp 1:15:30): https://www.youtube.com/watch?v=Y7Vm-C4MsW8&t=4531
 
== Control Board ==
 
As designed by Damien Maguire, the open source hardware for the control board can be purchased as blank, unpopulated boards on his website: [https://evbmw.com/index.php/evbmw-webshop/toyota-bare-boards/prius-gen-2-inverter-bare-logic-board 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 circuitboard. 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 [https://github.com/damienmaguire/Prius-Gen-2-Inverter 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?) microcontroller, and takes advantage of the OpenInverter.org software (link?) for control.
 
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 ==
[[File:Prius Control Board - Wiring Map.png|thumb|700x700px|Prius Control Board - Wiring Map (click to see fullsize details)]]
Control Board Pinout:
 
{| class="wikitable"
! 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
|}
 
32-pin Prius Inverter Pinout:
[[File:Prius Inverter - Pin Numbering.png|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
{| class="wikitable"
|-
! Pin # !! Designation !! Description!!Wire Color
|-
|1|| NC ||Not connected||
|-
|2||GIVA||MG1 Phase Current V|| Example
|-
|3|| GIVB ||MG1 Phase Current V|| Example
|-
|4|| GUU ||MG1 PWM U - Speed Signal Wave|| Example
|-
|5|| GVU ||MG1 PWM V - Speed Signal Wave|| Example
|-
|6|| GWU ||MG1 PWM W - Speed Signal Wave|| Example
|-
|7|| MIVA || MG2 Phase Current V || Example
|-
|8|| MIVB ||MG2 Phase Current V|| Example
|-
|9|| MUU ||MG2 PWM U - Speed Signal Wave|| Example
|-
|10|| MVU ||MG2 PWM V - Speed SIgnal Wave|| Example
|-
|11|| MWU ||MG2 PWM W - Speed Signal Wave|| Example
|-
|12|| VH ||Inverter Capacitor Voltage|| Example
|-
|13|| CPWM ||????|| Example
|-
|14|| GSDN ||MG1 Shutdown|| Example
|-
|15|| VL ||????|| Example
|-
|16|| GINV || Inverter Ground || Example
|-
|17|| NC || Not connected ||
|-
|18|| GIWA ||MG1 Phase Current W|| Example
|-
|19|| GIWB || MG1 Phase Current W || Example
|-
|20|| CT ||????|| Example
|-
|21|| GIVT ||MG1 Inverter Temperature|| Example
|-
|22|| GFIV ||MG1 Inverter Fail|| Example
|-
|23|| MIWA ||MG2 Phase Current W|| Example
|-
|24|| MIWB ||MG2 Phase Current W|| Example
|-
|25|| MSDN ||MG2 Shutdown|| Example
|-
|26|| MIVT ||MG2 Inverter Temperature|| Example
|-
|27|| MFIV ||MG2 Inverter Fail|| Example
|-
|28|| OVH ||Overvoltage|| Example
|-
|29|| CSDN ||????|| Example
|-
|30|| FCV ||????|| Example
|-
|31|| OVL ||????|| Example
|-
|32|| GCNV ||????|| Example
|}

Latest revision as of 17:42, 20 December 2024

This page is now deprecated in favor of the following new pages:

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