When you look at the gen2 hybrid pack, you see that it has the service disconnect with 9 modules on one side and 19 on the other side. Reason is that they simply chopped 10 modules out of one side of the original 38 module pack of the gen1 to create the 28 module gen2. Apparently that was less work than making 2 changes, one on each side of the disconnect. The resulting 270V pack gave the gen1 about 15kW of electrical power, if I am not mistaken it reaches the redline of the MG1 at 42MPH and it needs to turn the engine in order to downrev the motor. Reason for the breakdowns in the armature of the MG2 predominantly is the insulation which is not designed for the high frequent switching of the inverter and (I heard) contamination of the splash-cooling oil of the MGs which causes small magnetized metal parts to settle on windings, making the fields concentrate on spots and/or the fast mechanical movement of the wires due to the forces in the magnetic fields that rub wires together until the insulation is worn through and short circuits between windings occur. I have replaced a handful of the MG2 which is a rather challenging task with the vehicle on the ground and the weight of the motor. I am in a similar situation as Lee, although I no longer have a gen1 because all 3 that I had, were robbed of their catalytic converters when those became unobtanium, so I sold all cheap for parts. but I do have a pristine 2006 gen2 with 200,000 miles so the hybrid battery was no longer repairable. I replaced it with a set of used modules and it works again, but still has a weak hybrid pack. Hence my interest in newpriusbatteries.com
On Tue, Jun 18, 2024 at 5:07 PM (-Phil-) via EV <ev@lists.evdl.org> wrote: > > I don't have a lot of familiarity with the Gen1's, but my understanding is > that it's a larger and higher-voltage pack, because it doesn't have the > SEPIC converter. > > I reverse-engineered the Gen2 Battery control module with only a week's > worth of work and was able to completely replace it in my Gen2's PHEV > upgrade with an LFP pack. I'd guess it should be similarly easy on the > Gen1, but it's a lot of work to put into such an old car at this point. > > I don't know what the Gen1's powertrain limits are. I've heard that > insulation breakdown on the windings have killed a lot of them though. > > > On Tue, Jun 18, 2024 at 12:27 PM Lee Hart <leeah...@earthlink.net> wrote: > > > Phil wrote: > > > The older Prius hybrid powertrain makes > > a poor EV, as you can only achieve a top speed of about 50mph/80kph before > > the efficiency is super poor, and you are limited to about 20kW of EV power > > by the boost-converter architecture. I'm really surprised anyone would be > > interested in it today. > > > > Actually, I *am* interested, because I have a low-mileage gen-1 2001 Prius > > that needs batteries. I like the car, and it has a 10-15 mile range as a > > pure EV, and 50-60 mpg as an ICE. > > > > Replacements for the original nimh modules are unobtainium. Modules for > > the later gen-2 Prius almost fit; but are longer and need serious > > modifications to the cover to avoid shorting. > > > > A couple decades ago, I experimented with adding a booster pack with 12v > > 13ah lead-acid batteries. It worked, but added too much weight and I wasn't > > clever enough to fool Toyota's computers. > > > > Lee > > > > > -------------- next part -------------- > An HTML attachment was scrubbed... > URL: > <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20240618/6bad9319/attachment.htm> > _______________________________________________ > Address messages to ev@lists.evdl.org > No other addresses in TO and CC fields > HELP: http://www.evdl.org/help/ > _______________________________________________ Address messages to ev@lists.evdl.org No other addresses in TO and CC fields HELP: http://www.evdl.org/help/
