siai47 wrote:When I did this I was messing around with my first attempts at getting into the HV battery. . . . BTW--both packs could be charged in this configuration by the internal charger but there was no cell balancing available to the external pack so this wasn't a real solution for a long term range extender.
Thanks so much for the valuable details. I'm looking at using the bolted main cable connections just inside the battery pack to piggy back another set of power cables. They would have their own contactor actuated by whether the genset was running, or not. That way the whole thing is disconnected from the main pack inside or directly outside the main pack if the genset is off. As with stock, all of high voltage would be terminated inside the pack by the main contactor when the vehicle is parked .
The current sensors inside the pack that talk to the system are battery bank side of the high voltage cable connections (at the battery pack) to the inverter aren't they? It looked that way from Martins pack cell replacement video. Is that correct from your experience?
I can use smaller cables since they will only carry genset amperage so waterproofing should be attainable. The car should see the whole thing much like it did your extra paralleled battery pack experiment. As reduced demand by the motor system and regen when genset output exceeds motor and systems power usage.
Of course the same type of connection could be done for a trailered XR battery (or smaller onboard one) with the XR battery contactors (one at each end) run by the presents or absence of system power from the cars existing system.
I've collected quite a bit of freeway cruising Canion data suggesting that as a serial hybrid the "i" should get between 50 and 58 MPG. Again, for EV purists the unit would likely be used two or three times per year burning less than 25 gallons of gas per year and replace the current need for a gasoline car in the household, burning hundreds of gallons per year. The rest of the time would be pure EV driving charged with in house solar. Sometimes the genset would be taken along for piece of mind but not needed and hence not used.