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Originally Posted by e*clipse
Ok here's some real info (not just my fuzzy memory) 
The papers below go into amazing detail and will require many cups of coffee to help with the short-circuiting brain .... They go into testing stuff that no other testing organization gets remotely close to.
The main thing that is important here is that Toyota made a major improvement in motor technology around 2005. Most of their new hybrids use this technology; this is why I say the controller for all of them can be very similar. The paper about the development of this technology is here:
http://e-mobile.ch/pdf/2005/321.pdf
Here's the ORNL paper about the 2010 Prius:
http://info.ornl.gov/sites/publicati...s/Pub26762.pdf
For your project, it actually seems like the system Toyota developed for the Lexus 600h sedans and the Camry would be a good starting point:
SciTech Connect: Evaluation of the 2008 Lexus LS 600H Hybrid Synergy Drive System
There are others, detailing the 2004, 2007, Camry, etc. available from these links.
I know some folks w/ CNC's. It may take some interesting trades, but I may be able to get some time...
I do have solids modeling software, and CNC code generating software (and know how to use it). I do have a Bridgeport mill w/ a DRO and a Clausing lathe. I could get accurate bearing locations with the DRO. It would require some clever design, because machining it from a solid chunk would require a LOT of $$$.
Oh, regarding output splines, etc: The local driveline shop is extremely good and he just got a CNC and broaching equipment. A custom spool or output shaft is no problem here. I'll check his prices today.
- e*clipse |
WoW!!! so much math... That was an enjoyable read though, Thank You E*clips! I will leave the math to the powers that be. I am interested in that transmission setup. Can the generator rotor be used as a motor as well?
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It would require some clever design, because machining it from a solid chunk would require a LOT of $$$.
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That's why I was leaning towards the 3D printing of a case instead of trying to machine it from billet. Splines would have to be made so your contact would come in handy.
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I do have a Bridgeport mill w/ a DRO and a Clausing lathe. I could get accurate bearing locations with the DRO.
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GAH... you lucky dog. I am working on the mill part. Got a nice lathe already.
I have about 2000 pounds of cast aluminum pieces waiting. I have all the parts for a furnace to melt it and a kiln to process the investment castings. All I need is 48 hours in a day and I may have all this done in a few years!
Well not that long but ya know what I mean, life keeps getting in the way of my fun plans...
Cyruscosmo