I'm still messing around with the 650 amp controller. It operates well but the DC-DC converter, which powers the PWM circuit board, emits energy in the Megahertz region like an AM radio station, which messes up the current feedback from the current sensor. Ordered a different DC-DC from Mouser this evening.
Working on the controller in the picture below helps me gain an insight into the Prius Inverter. I have not taken a boat trip to the mud lake at the local Pick 'n Pull yet, but they have lots of gen 1,2, and 3 Prius cars on hand. I have done a lot of self education on the Prius inverter on-line and learned a lot.
The gen 1 inverter is constructed much like a home brewer like myself would make a controller. It uses parts with manufacturers part numbers marked on each part. The IGBT modules are most unlike "normal" units at all. They are a IPM, or Intellegent Power Module, I believe, which packages all 6 or 12 IGBT's in one case. Besides the 6 or 12 IGBT'S, there is a circuit board inside each modules case which has the gate drive, overcurrent alarm, over voltage alarm, temp sensors and temperature over-
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temperature alarm and more. So each module has dozen of small wires leaving each module going to the circuit board mounted above. Highly unconventional, but very popular in automobile use.
This makes it hard for a regular person to figure out, especially without any documentation. I believe the gen 1 may use 600 volt IGBT's since it has just a 270 or whatever volt pack. Six-hundred volt IGBT's are desired for a DC motor controller, due it their lower Vce drop. The generation 1 also has many more individual components than the later Prius inverters, again making the gen 1 easier to figure out.
I don't really care for the gen 2 inverter. This uses the step up booster to raise the 200 volt pack up to five or six hundred volts. This requires 1200 volt IGBT's, which have a higher "on" voltage drop, This wastes hundreds of watts more power than the previous generation 1 inverter, I'm hoping. The generation 2 has the Toyota part numbers on the components instead of the manufacturer's part number, like the first generation.
I see no usage of the gen 2 buck/boost converter as a battery charger since that concept would not be isolated from the utility line.
I'll eventually get a gen 1 and 2 inverter and mess with them. It will probably be easiest to just gut the IGBT's and circuit board and mount two 600 amp, 600 volt Powerex CM600's, using the Prius buss capacitors and current transformers.
Thanks for the interest.