2011 Automobile Maintenance Advanced Course for the

Industrial Technical Instructors

Instructor : Lin, Jen-liano

~ Hybrid Electric Vehicles <7{uto

Jfy6ritf P,fectric 'Veliicfes

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W Hybrid Electric Vehicle <7{uto

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draft: 2001107106

Revision: 2004107106

)lutowin Indust ria { Corp.

COPYqu(]Jff 2001

Introdu·ction • What is a Hybrid Electric Vehicle?

• Background • Introduction of Hybrid Electric

System ~ Advantage/Defect, Construct and

Operation

• Conclusion • Re f erences

P1

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Number of Hybrid Vehicles Sold • Toyota:

• Till the release in August of the year 2003, the global sales volume of Hybrid Vehicles has been exceeding 140,000 units, it occupies a share of 90% in the global market.

.; ~. >

• Honda:

Prius, Estima Hybrid

Crown Royal with mild hybrid system Crown Sedan with mild hybrid system

Coaster Hybrid

• Till 2002, the sales volume of Insight in US has accumulated to an amount of 10,730 units, it amounts to more than 1/3 of Prius sold in US.

3

Global Sales Volume of Toyota Hybrid

• Global Shares: 900/0 Cumulative Toyota hybrid vehicle sales (unit = one vehicle)

1997-Model \ Period 1997 1998 1999 2000 2001 2002/1 -3 2002/3

Prius 323 17,653 15,243 19,011 29,459 7,402 89 ,091

Estima Hybrid - - - - 5,886 5,840 11 ,726

Crown wI mild 1,574 520 2,094 hybrid system - - - -

Coaster hybrid 9 3 12 15 9 8 56 (bus)

Total by year! 332 17,656 15,255 19,026 36,928 13,770 102,967 month

Cumulative total 332 17,988 33,243 52,269 89,197 102,967

4

YLHybrid Electric Vehicle (jl{uto

What is a Hybrid Electric Vehicle?

• Hybrid System: • A system that is constructed by integrating

two (or above) types of dynamic sources with different features is called the Hybrid System.

• Hybrid Vehicles • A hybrid vehicle is a vehicle that adopts

hybrid system as the dynamics, abbreviated as HV.

W Hybrid Electric Vehicles (jl{uto

Hybrid Electric Vehicles· .

• Hybrid Electric Vehicles • The hybrid dynamic system usually adopted in a vehicle

means a system that integrates the usage of two types of dynamic sources, one is internal combustion engine that uses fuel (Gasoline, Diesel, CNG engine .. ) and the other is electrical motor (DC, AC) that uses battery power.

• A vehicle that adopts the above-mentioned hybrid electric system as the dynamics source is called a Hybrid Electric Vehicle, abbreviated HEV.

• The generally-meant hybrid electric vehicle is exactly HEV.

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Fundamental Background • H EV Releases

• TOYOTA _'-• THS, THS-II ",,08'(; I,~;J/\.

PRIUS: October, 1997; PRIUS II: September, 2003. • THS-C (C=CVT)

ESTIMA (i.e., HV-M4) August, 2001 • THS-M (M= Mild) - 42V Electric System

CROWN

• HONDA IMA • INSIGHT: November, 1999 • HONDA CIVIC: December, 2001

• NISSAN NEO HS • TINO: April, 2000

W Hybrid Electric Vehicle

~m The Developing Background of H brid Electric Vehicles

• Energy Exhaustion

~ Reservation Issue of Petroleum

• Air Pollution

~ Environmental Protection Regulations

• Global Warming ~ C02 Emission

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Emissions Legislation

Now Now

Source: Honda, 1999

W Hybrid Electric Vehicle Wiuto A Solid Goal of Reducing Vehicle CO2

Emissions Volume set by Japan

~ 20 !!!. n g 15 lit c: 3 "0 a: \0 o :::J

'" ~ CD

25

."

~20 n o ii: 15 c: 3 "0 go 10 :::J

'" ~ CD

o

Basis Value of Gasoline Vehide Fuel Consumption Goal (Average Increase 22.8%)

212 ml Practical Performance Value in Year of 1995

R-------------O Goal Value for Year of 2010

-702 703-827 828-1015 1016-1265 1266-1515 1516-1765 1766-2!l15 2016-2265 22ti6-

Vehide Weight

Basis Value of Gasoline Vehide Fuel Consumption Goal (Average Increase 14.9%)

-1015

IllI Practical Performance Value in Year of 1995 _______________ Eil Goal Value for Year of 2010

10\6-1265 12ti6-1515 1516-1765 1766-2015 2!l16- 2265

Vehide Weight

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...;!LHybrid Electric Vehicle Cilluto

Countermeasure of the Vehicle Plant • TOYOTA Countermeasure to Reduce CO2

Emissions Volume

W Hybrid Electric Vehicles Cilluto

Electric Vehicle Types • PEV (Pure Electric Vehicle)

• Also named BEV (Battery Electric Vehicle,)

• HEV (Hybrid Electric Vehicle) • HEV : Internal (External) Combustion +

Electric Power

• FCEV (Fuel Cell Electric Vehicle, FCEV) • The final goal of Electric Vehicle

• FCEV~FCHV

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Goal of Developing Electric Vehicle

• An electric vehicle should have the following advantages:

1) Cleanness

2) High efficiency

3) Energy diversity

~m The Advantage/Disadvantage of a Pure Electric Vehicle

• Advantage • Using electric power, therefore, no waste gas

emissions while in driving; causing no air pollution (Reducing environmental pollution)

• Driven by drive motor, it will not produce the vibration and noise caused by vehicle engine (Reducing environmental pollution»

• Different from the vehicle that uses an engine; it could retrieve the energy while decelerating (Energy Saving)

• Gasoline, diesel oil and the likes cold only be produced from petroleum; however, electric power cold be produced from all kinds of energy sources other than the petroleum (Energy Source Diversity)

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W HEV (illuto The Advantage/Disadvantage of a

Pure Electric Vehicle • Disadvantages:

WHEV Cilluto

• Short PEV endurance/ less passenger load capacity; so with limited applications

• High battery price, vehicle price higher • Charging is time-consuming and tediousv

• I nsufficient charging facility • Long FCEV fuel battery start-up charging

time· • Onboard Reformer: about 30min • Direct hydrogen: 3-5min

The Advantage/Disadvantage of a Hybrid Electric Vehicle

• Advantage • Effective in fuel-consumption saving and is able to

reduce the air pollution • No problem regarding the endurance of the vehicle

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• Required battery capacity is smaller than that of an electric vehicle; storage battery could be made small in size and light in weight (it weights about 1/5-1/10 of an electric vehicle), the management of charging status is easier and the price cheaper.

• Without the issues regarding charging consumption time and insufficient facilities.

• Like an electric vehicle, the energy could be retrieved when decelerating

• Possessing the pause function of engine idle running

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WHEV ~ The Advantage/Disadvantage of a

WHEV (jl{uto

Hybrid Electric Vehicle

• Disadvantage • Complicated construct for a hybrid

electric vehicle and difficult in maintenance

• Its price is higher than that of a gasoline vehicle

• Comparing an electric vehicle, the waste­gas emission issue still exists.

Types of Hybrid Electric Systems

1. Serial Hybrid System • Using engine to drive the generator for operation, then driving the

wheels by using the generator-produced power to supply to the motor; at the same time, storage battery could be charged. The reason it is called serial is because that there is only a single route of transmission for the dynamics by which the wheels are driven.

2. Parallel Hybrid System • The parallel driving dynamics could be acquired from the dynamic

sources of the paralleled engine and motor; it could be operated alone or together at the same time depending on the driving conditions, the two compliment each other. Of course, while using engine to drive the vehicle for running, it is in the mean time allowable using the engine to drive the motor for power generating (generator function) to charge the storage battery.

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Serial Hybrid System

Motor

Engine

(Storage) Battery

Engine

(Storage) Battery

G) CD :::J CD OJ 8" .....

Motor

.. Parallel Hybrid System

Engine

Generator

Single-Axis Allocation

Engine

(Storage) Battery

Double-Axis Allocation

Engine (Storage) Battery

Separate Allocation

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W HEV ~ Hybrid Electric System nomenclatures

and models of Japan Major Makers

Maker Brand Hybrid Electric System

Major Equipped Name Model Vehicle

TOYOTA THS Parallel Double-Axis PRIUS, PRIUS II Allocation

THS-C Parallel Separate ESTIMA Allocation

THS-M Parallel Double-Axis CROWN Allocation

NISSAN NEO-HS ' .:.. .• Dou ... ··A~;; < ::~e":: -'" , TINO ,

, ' / .... '" "-

HONDA IMA Parallel Single-Axis INSIGHT, CIVIC Allocation

MITSUBISHI GDI-H~V: ' Parallel Double-Axis: AllOCation

0 SUWADVANCE

DIHATSU EV-H Parallel Double-Axis MOVE Allocation

SUBURU SHPS Parallel Double-Axis ELTEN CUSTOM AllOCation

g[~to;;g~b77-Construct of a Hybrid Electric Vehicle

_._ Dynamics

Transmission ,------,

I

c-:-:-:-:-:-:-:. Electric Transmission

Generator :':'.':':':':':':':':':

\(\H'.-\., \~ Converter

High-voltage h":.~:.:."-'!'d:.: Storage

Engine

0000 Dynamics Separating Mechanism

I I

I I I I

Decelerator

---I I I

Motor I I

• ........ _--' I ,--------

Gear Box Unit I I

, .... ----------~ Toyota Prius (THS)

Battery

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Dynamics Device---THS

I Prius I

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(j' .

Dynamics Device ---IMA ~.

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Engine Fuel-Saving Technology • Countermeasure adopted regarding the

Engine • Adopting Low-fuel-Consumption Engine

• Atkinson Cycle Gasoline Engine: Toyota • Thin Combustion Engine: Honda • GDI Engine: Mitsubishi

• Reducing Engine Exhaustion Volume

• TOYOTA PRIUS: 1.5L

• HONDA INSIGHT: 1.1L

• MITSUBISHI SUW ADVANCE: 1.5L

• Idling stop function: It is also named as Auto Stop & Go(ASG)

W Hybrid Electric Vehides 9iuto

tkinson Cycle and Otto Cycle Otto Cyde

Intake Stroke Compression Ignition Stroke Exhaustion Stroke Stroke

Atkinson Cycle

Intake Stroke Not Compression Ignition Stroke Exhaustion Stroke Compressed Stroke

Yet

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~ Advantage/Disadvantage of Atkinson Cycle

---------~=,~.'"".,.' ''.'''.,.,.,

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• Advantage: • Combustion Vibration is avoidable • Reducing the pump pressure loss • Less exhaustion loss, high thermal

efficiency and fuel-saving

• Disadvantage: • When operating in low speed, efficiency

will be pretty worse • When in high-speed operation, it is hard

to produce high horse power.

Atkinson Cycle Applications on Hybrid Electric Vehicles

• Operation in Low Speed

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• Stopping engine operation, using motor to . drive the vehicle

• When High Output Horsepower is required • The highest revolution speed is limited at

4000rpm

• Using motor to supplement the insufficiency of engine horsepower

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Why GDI Engine has not been widely accepted by Hybrid Electric Vehicle

1. Under same exhaustion volume, engine fuel­saving is no better than that of Atkinson Cycle

2. Dynamics insufficiency could be supplemented by Motor

3.GDI Engine costs more

4. It is required to have GDI engine technology of small exhaustion volume

Rem: Mitsubishi Motor has already developed a GDI engine of l.ll exhaustion.

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High Voltage Storage Battery • Rated Voltage

• TOYOTA PRIUS(THS) : 288V ~ 273.6V

• TOYOTA PRIUS-II (THS-II) : 201.6V

• HONDA INSIGHT (IMA) : 144V

• Models }"" Ll

1.Lead-sealed Battery: Bus, Electr(

2. Nickel Hydrogen Battery: THS ' i "-

Cylindrical Type

Corner-Post Type

3. Lithium Battery: NEO-HS

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-l:t!V High Voltage Storage Battery --Nickel Hydrogen Battery

• Sub-battery Assembly

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Cylindrical Type Corner-Post Type

7.2V 7.2V

High-Voltage Storage Battery ---Lithium Battery

• Sub-battery Assembly

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Motor (1)

• Functions • Key function

• Driving Motor (Driving the Vehicle)

• Generator (Regenerative Bra ke)

• Sub-functions: it depends on the system • Start-up Motor (Start-up Engine)

c HONDA IMA

Motor (2)

• Models: 1. Permanent Magnet AC Synchronous Motor

• AC Servo Motor: i"il TOYOTA PRIUS (THS)

:] NISSAN TINO (HEO-HS)

• DC Brushless Motor: Suitable for small power ,] HONDA INSIGHT (lMA)

;;; Electric Motorbike: Tse-Mon( l-M.), Kimco

2. AC Sensing Motor: EVs or FCEVs

3. DC Motor: Electric Bicycle

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W HEV -Q'llltO

g{uto

Generator

• Function: • Key Function: Generator • Sub-function: Start-up Motor (It depends on the

system) • TOYOTA PRIUS (THS) • NISSAN TINO (HEO-HS)

• Model Types: Same as the Motor

• Remarks: • Whether it will be equipped with a generator shall

depend on the hybrid electric system

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Electric Power-Conversion Device

• Rectifier: AC to DC • Inverter:

• Specific-defined Inverter: Changing DC into AC power source and providing the motor with required power­conversion device, i.e., DC-AC Converter

• Broadly-defined Inverter: AC-DC-AC Converter

• Transformer: : AC to AC (f : not changed)

• Cycloconverter: AC to AC (f : Changeable)

• DC-DC Converter ~c

• Chopper: Driver for DC Servo Motor ~ ~

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Inverter (1)

• Function: Motor Driver • Construct:

• Internal basic construct circuit of an inverter

• Different from an industrial frequency-changer, a vehicle-based inverter does not contain motor controller

Rectifier or DC cf Power

Current Controller

PWM Inverter

u v

Base (Gate) Pole Drive Signal

W IfEV g[uto

Ig

I High-

Voltage Storage Battery

I

nition Signal

Grounding -

Motor Controller

L......:....:..~.......::..._j-_---lic

Inverter (2) ~int~ r- ----------------------------------------------, I Motor-specific Bridge Circuit

I I Current

:d: OJ~ lJJ~ ~ [1J~' Sensor

i k' i'\

~ I -X

: T . on:; ~ []Jt1 r-[]1~ r-'

[

I I I Voltage I I Detection I Circuit I -Signal Processing I I -

e Hybrid

- ECU I -Circuit ProtHiion Function PrOQ-llNng I Voltage - - - . - - . - I (Motor ECU) I

. I Detection

I I Jr Circuit I

I I I

OlK on;:. ~ []~ I I

~ I I --X I

L.....X . . I I

on~ . on:; OJt;~ v-

I Current I I Sensor I - - - -: Charging-spedfic Bridge arml: I ~ _______________________________________________ J

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(I.

F.L MAIN

"I" 34Bl9 •

DC-DC Converter

12V+ Output

F.LDCDC

Frequency Changer

Converter DC/AC

..I. Aux Storage Battery

112V

DC288V

15A

IG

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Dynamics Separating Mechanism

• Definition: • A mechanism that connects the separate engine dynamics

and motor dynamics • Some models possesses the function of allocating the

engine and motor dynamics outputs

• Application Situations: • Applied only on the parallel hybrid electric system of double­

axis allocation model

• Model: • EM clutch: NED -HS, THS-M, GDI-HEV

• Planet Gear Mechanism: THS • Possessing the function of allocating dynamics loading

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~ Planet Gear

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Dynamics Separating Mechanism

Generator Motor

Ring gear (motor/power shaft)

Planetary gear

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Actions of Planet Gear Dynamics Separating Mechanism

Genenllor rpm

o

- .rpm En!joe rpm (1IIlI1ic1e speed)

"'0 (; c) .. , S ... ~ar C«rrler Ri/'lg gew

Engine Stop

Start

GMe<ator rpm . ' 811:1"* :

-rpm etlgine rpm (1IIlI1ide (;peed)

• =

Genemlor .rpm Motor rpm

El9ne rpm (1IIlI11de speed)

L"----. ', . , ;, . ~. . , . (3 , '~; I

-.."., '-- . Sungelll carrier Ring goor

Acceleration

Genenilorrpm -rpm

Engine rpm (1IIlI1lde $peed)

, :-~

m_,~').m. S ... ~ar C«,nier Ring gear

Gene<ator rpm

Start up

Cruise

Molot .rpm Engine rpm (VIlIllele speed)

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W HEV (illuto

WHEV (illuto

Computer Controlled System(l) Frequency Changer Revolution Speed, Current

Gear Position 1----'-"'--'----+1 Sensor Motor

ECU Acceleration Pedal Sensor /-----1 Hybrid /4----'----f

:=========. ECU Voltage '----' Brake

Computer SMRControI

....... m :::J

......... 10 , - 5- :

Sl\.ffi

Dynamics II) : '--__ ../

Separating : Mechanism ~

Frequency Changer

: SMR: . System Master Relay • TIre TIre : l' ~' _ ...... __ .... ..,.._""' .... ""''''''..,. .... '''' ""' .... .... "" ... " •• """ ... -" ..,; .;<.."'" ... _,... ..... .0;.-. .... ,"" ""' ""' .0; ............. "'" ;.. ..... _ .... ;00"" .,..,,.. ........ "',#

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Computer Controlled System (2) :

• Control Computer

• Hybrid Electric ECU .

- Control Center; integrating the functioning of all ECUs

• Engine ECU: EFI

• Motor ECU : Motor, Generator

• Storage Battery ECU : Charging Storage Battery

• Clutch (antral ECU (if necessary)

• Brake ECU

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Computer Controlled System (3)

• Signal Input Sensor

• Gear Position Sensor 1 k, {)-ft\{

• Air-Saving Gate Sensor

• Current Sensor

• Storage Battery Temperature Sensor

• EFI System Sensor

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Computer Controlled System (4)

II Signal Output: Activator nY~ tll.o..

• Engine : Electronic Control Air-Saving Gate VO-\\jt,

• Motor : Driven by Inverter

• Generator (if equipped)

• EM Clutch (if equipped)

• Brake Oil Pressure Regulitor

?/ 46

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WHEY (illuto

Battery ECU

Hybrid Dynamics

ECU <l>----.t Storage Battery

Current ECU

~ '~'; .:,.~, " ' . '. " ', ' ,', ,', ••• 0 · .... ' ,'. ,t. ' ,<, <. " :::~~

;: . ~~~~. ~; Temperature

; ; ; ; ; ; .' "----r--J Cooling Fan

000000 II r ___ :~ ,_,t

.' High-Voltage :: ~ :: Storage Battery i: V, :::~!_;" ;" :':_;'>~_:':':': ':':_:':':' :_:'~':";XA:':~:::::

Battery ECU Fu.nctions 1. Status of Charging (SOC) Detection

2. Maintenance of the High-Voltage Battery Performance ~'

~ (

• Uniform Charging fo ·)

• Temperature Manag Storage Battery ECU

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3. Detection of Battery Voltage Sensing

• Battery Abnormality Det

• Leakage Detection

• Voltage Abnormality De1

• Storage Battery Temper

• Storage Battery CUrl -

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Maintenance of High-Voltage Circuit

MainFrame Supportive I I (...!m~-Rela-y)---i"-!--$

:: S:MR 1 Resistor :: Storage Battery Module

Sea:::=t s;;:::~. __ ~ ·~O ~I T (7.2VX 20)

I I

High-Voltage Storage Battery P

~ Highvoltage Fuse

:: Storage Battery Module

~ (7.2VX 20) , S:MR.3

Maintenance Plug

'-----0--0--------+---<8

IntemalLock Guidance

Switch

Operation Modes

Fuse

of the Hybrid Electric System

• Driving Mode

• Regenerative Brake Mode

• Auto Stop / Start Mode

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Driving Mode

• Five Basic Driving Modes

1. Battery Mode

2. Serial Mode

3. Engine Mode

4. Parallel Mode

5. Serial-Parallel Mode

Battery Mode

* Motor Driver AC: Inverter

DC: Chopper

...-------,

I 1

~ I I I II

I Engine I- - -II- - - Motor I I II 1 _______ 1

__ t

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W IIEV <iJluto

Engine

-f' }

3 J\

Engine

Serial Mode

-~

Motor ---(7

Engine Mode

~

~

.---------, I I I High-Voltage Battery I L ___ , ____ I

.----_._---,

: Motor Driver : L ___ , ____ I

I I .---------,

I I

L ________ I

Motor

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Parallel Mode

- f'

Engine ~ Motor

Serial-Parallel Mode

Engine Motor

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Regenerative Brake Mode(l)

• Electric Brake:

• Regarding the motor revolving speed control, the motor speed could be reduced by controlling the electric power; in this way, it is called Electrical Braking.

• When using electric braking, the motor will be operated as in a generator mode, it will convert the inertia kinetics stored in motor r­

or in the load into electrical energy.

Regenerative Brake Mode(2)

• The handling method of the electrical energy produced while applying electrical braking:

• Consuming it by using resistor; it is called Dynamic Braking or Generating Braking.

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• After proper converting of the electrical energy, it could be provided to other system for further application.

• Retrieving and storing; e.g., storing to the secondary battery or in a large-scale capacitor (su per-ca pacitor).

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Regenerative Brake Mode (3)

• Regenerative Braking: • That using the above-mentioned second and third

methods to process the electric braking electrical energy are the so-called Regenerative Braking .

• Because the energy-storage capacity of the secondary battery has great impact on the navigation endurance of an electric vehicle, in addition to the huge driving inertia force possessed by the vehicle, so, regenerative braking method is adopted in electric vehicle in order to retrieve part of braking energy when the vehicle is decelerating and braked and convert the energy into electrical energy for recycling.

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Regenerative Brake Mode (3) Regenerative braking

C~J

=/1 depression

\\ ~. Regene.ratlve

\ braking

\'- ~~ Bmktng \ braking

power '._. __ . "_ ,

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W HEV -W{lltO

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Auto Stop and Go (ASG) Mode (1) 1. Automatic Engine Idling Stop

• Operation Timing: • When the vehicle stops

• When vehicle speed becomes lower than certain speed (For double-axis parallel type and the motor itself could drive the vehicle), e.g., TOYOTA THS : 40km/h

• Advantage: Saving fuel consumption ; reducing waste-gas exhaustion

• Effects: Concerning the fuel consumption; MPI: 15% off, '/- / GDI: 10% off

2. Engine Restart • Operation Timing: It will depend on the driving mode

concerning Hybrid Electric System ECU • When a vehicle starts • When the vehicle speed exceeds a certain speed (For double­

axis parallel type and the motor itself could drive the vehicle)

Auto Stop and Go (ASG) Mode (2)

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• Motor ECU will depend on the hybrid dynamic ECU signal to control the inverter to transform the generator (or motor) function into start-up motor to start the motor.

3. Situation under which the ASG mode will not work (Engine keeps running)

(1). When the high-voltage storage battery needs charging (2). When air-conditioner compressor needs to run

• Adopting constant-temperature air-conditioning system • Blower is opened at FULL position

(3). Engine cooling water temperature rises to a level that requires cooling cycle

(4). Engine is still in warming period

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(.

,

---- --- ---- -~.---- -- .. - -- -._-----

WHEV ~ The Operation of

WHEV <:illll to . .

Hybrid Electric System (1)

• System starts up • Same way as a regular vehicle starts

• Engine starts up • The control system will depend on the

necessity to start the engine (e.g., when engine needs to be warmed up or charged)

• To be started up by motor :HONDA IMA

• To be started up by generator: THS ' NEO-HS

The Operation of Hybrid Electric System (2)

• ·When it starts to run

• When driving in low speed

.. Engine Dynamics Transmission

... Charging Storage Battery

Rem : The system operation of HONDA IMA is mainly by engine, motor power is used as an auxiliary solution.

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WHEV ~ The Operation of

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Hybrid Electric System (4)

• Regular Driving

.. Engine Dynamics Transmission

.. OJarging Storage Battery

The Operation of Hybrid ' . Electric System (3)

• Driving under high loading -.. Engine Dynamics Transmission

.. Electric Power Transmission

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The Operation of Hybrid Electric System (5)

• When it decelerates and brakes

.. Charging Storage Battery

The Operat ion of Hybr id Electric System (6)

• When the vehicle" stops: • Automatic Engine Idling Stop

Rem : For the following situations, the engine will keep operating

• When the hi-voltage storage battery needs charging

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• When the air-conditioner compressor needs to operate; the air-conditioner blower is set to FULL position

• Engine Cooling Water Temperature rises to the level that needs cooling cycle.

• Engine is still in the vehicle warming period

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The Operation of Hybrid Electric System (7)

• When the high-voltage storage battery is charging

.. Engine Dynamics Transmission . .._. . . . ... ---

.. Charging Storage Battery

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The energy that runs hybrid cars

+ t Supplying required energy

Engine

I Engine off Engine running at

- Ilow-speed maximum efficiency Stationary running Normal running

Source: Toyota

Battery

surplus " Retrieving braking energ1

Braking Stationary

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Hybrid system variations <: Hybrid vehicles :> * Honda IMA * Toyota Prius

* Toyota Crown with mild hybrid system

* Toyota Estima Hybrid

Motor assist

Idling stop

Performance Achieved • Fuel Consumption: Japan 10-15 MODE Testing

Methods

• TOYOTA PRIUS: 28km/L (CVT)

• HONDA INSIGHT: 35km/L (MT Vehicle)

• NISSAN TINO : 23km/L (CVT)

• Waste Gas Exhaustion

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• CO2 volume is about one half of that of a traditional vehicle. And, the exhaustion volumes of CO, HC and NOx are about one tenth of standard formulated in Japan regulations

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I Prius I

THS Assembly

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THS Powertrain

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ATKINSON CYCLE High expansion ratio conceptual diagram

High expansion cycle pumping loss

Conventional pumping

expansion ratio cycle

,CorMmlional cycle

EJ<pansion stroke Exhaust loss

comparison

Planet Gear

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Dynamics Separating Mechanism

Generator Motor

Rlng gear (motor/power shaft)

Planetary gear

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~. ----------------------------------------------------------------------------,

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THS Bra ke Control System

Prius

1+--. - Oil Pressure Brake

Brake ECU

Block Diagram of THS Operation Control

Mokxrpm Engil1e tpITI ("""Ide spooed)

Engine output

Engine rpm

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..

• Poor

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Overall Drive Forces Control of the THS Vehicles

<A> ---------- -----

Engine Storage Battery

~~~~] Generator

------------ ----------------Engine Drive

Force

<B>

Vehide Speed

Motor

Drive Force

-----

Dr ive Force

f::.::::..lst ~nd

Traditional Gasoline Engine

Vehicle

~3rd

I "' 4th

~ ~

Vehide ~peed

Application Performance of the THS Fuel Energy

Regenerative Brake Power Generation

Power Generated While Vehicle-Driving

Power Generated While Vehicle-Driving

Gear

Motor THS Vehicle

GearBox

Speed-Differential Gear

Regular Gasoline Engine Dynamic

Vehide ~* ~~ O

Fuel Energy

-- - -- -- 50

--=-_-----100

Engine

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Display Panel

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Conclusion • Hybrid Electric Vehicle:

• Demands of Environmental Protection • The sales volume of low pollution vehicles will have to reach up to above a certain

ratio of the overall sales volumes. • The Hybrid Electric Vehicle could effectively save energy source and reduce the

exhaustion volume of CO2 , CO, HC and NOli (one half of the same-class vehicles) ; it could solve the environmental pollution proDlems imposed on earth.

• Admission Impact of WTO: The vehicle is required to reduce energy consumption. • Sales Price Issue • The diversity of Hybrid Electric System

• The combination of different dynamic systems • The diversity of system operation (or the diversification of element functions), e.g.,

• The switching of electrical engineering operation (Motor¢:> Generator)

• The combination of different dynamic systems -Owing to the maturity of electric power conversion, it changes the original model of the DC 12V electric power system of a vehicle, it leads to an electric power system revolution .

• The goal of saving energy has not been changed; under the different function­specified demands, all types of models have been proposed.

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--- -- ----- ----- --- -

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Second generation Prius

Devlping Goal of THS-II Objective:

Compatibility of Environmental & Power Performance

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Item

I Engine

Motor

System

Battery

THS Specifications THSII THS (improved)

Type 1.5 L gasoline (high-expansion ratio cycle) ~

Maximum output in kw (Ps)/rpm 57 (78)/5,000 53 (72)/4,500

Maximum torque in N-m (kg m)lrpm 115 (11 .7)/4,200 115 (11 .7)/4,200

Type Synchronous AC motor ~

Maximum output in IQv (Ps)lrpm SO (68)/1,200-1,540 33 (45)/1,040-5,600

Maximum torque in N-m (kg m)lrpm 400(40.8)/0-1,200 350(35.7)/0-400

Maximum output in kW (Ps)lvehicle speed kmlh 82( 113)/85 or higher 74 (101)/120 or higher

Output at 85kmlh in kW (PS) 82 (113) 65 (88)

Maximum torque in N-m (kg m)lvehicle speed kmlh 478(48.7)/22 or lower 421 (42.9)/11 or lower

Torque at 22kmlh in N-m (kg m) 478 (48.7) 378 (38.5) ."

Type Nickel-metal hydride ~

85

Power-train of THS, THS II

86

I,;; Supply Approach of

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High-Voltage Electricity

Secondary Battery

87

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2nd generation hybrid system THS II

Secondary battery

Power control unit Voltage boost converter

Generator Inverter

Motor (150% Increase In

Power split dewce output)

Drive wheel

Hybrid Synergy Drive

Fuel efficiency Hybrid Synergy Drive

• Conventional HV

III . .. • • • • · • • • • • •

Direction of improvements to conventional engines

.. • •• .,.. 1i'i1 ........ . ...... f------------... Fun to Drive

Combining "environmental performance" with "exciting driving"

- --- ---------

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90

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Drive system output improvement (k~~----------------------------~·

..... ::J C. ...... :J o E (1) 40

! tIJ (J) > ";:: o

o

Prius II

40 .. ;0 . 80 d Vehicle spee

120 (kmlh)

Output performance of the 2nd generation Prius

91

Innovations in running performance (seconds) 7 r------------;-------------,

. ~\e'( Carm1 2.4-1'ter ~.~

Current Prius eVehic1eA

(domestic-make HV) • 5 Allion 2.0-llter C • • • Prius II Acceieratloo peffl)f'Mance ~ vetlicle$

above 2.Q.ltter dass

4 ~----~----~~--~----~~----~--~ 10 (seconds)

Standing start acceleratron: 0·100 kmlh

Standing start and overtaking acceleration performance 92

--~ -~--- - -----_ .- -----------

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Split Mechanism

GASOLINE ENGINE',-,

POWER SPLIT DEVICE

GENERATOR /

/ BATTERY /

MOTOR

Motor

Ring gear (motor/power shaft)

Planetary gear

93

The Actions of a Planet Gear Dynamics Separating Mechanism

Genenitorrpm

o ······,,~)oo-----_r:,..) ----«,.,"

Sun gear C<I/Ifer Ring vo-

Engine Stop

Start & charging at stop -­£ngine rpm '.eI1ido1..-cQ

~ ~ EngIno • -

Colinear graphing of planet~uy gear relationships

~ t :-----J THSI i

I L_~, .. ~, __ !J~ . . : . i / ,?---~ f.. .. THS/" ,

~ ; : , , , .. > > .. .. ..

~-------;--...... ----~' _. Sun gAr Catrler

Acceleration

Motor rpm Engine rpm ("""Ide $peed)

Start Up

Cruise MOIOtrpm

Engine rpm (vehlele spee<f)

£rvne . : Nom\a1

""'''''''

.. ~~~ Sungelll' catrler Ring gear

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The Construct of THS-II Brake System

Regenerative Bra ke·

Improved regene-rQtive braking

...

=11 depression 1/

--+r-----

Staking power

\

~. R~ ,'----­\ ~

\ _. ---. .

/ Brake I

depression pedal /

Braking power

\ Regenerative '., braking

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Deceleration

Genenilor rpm

System Operation Modes

REOUCTION GEAR

Cruise

Control Block Diagram of THS II Operation

McIo< rpm Engine rpm ("""ide ~

THS II SYSTEM CONTROL

Engine output

---'-"~~"",----- -,- .," " " " ""

Enginetpm

! •

97

Poor

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Overall Drive Force Control of THS II

l),rrving power performance THS II drive power (tom:eptuaJ diagram)

Dtive power

VehIcle speed

OiteCtdrIW from engine

Motor Traction Control

Motor traction (ol1ttol

Wheel-speed behavior at start-up on I!l snowy road

.. AcrolOi1lilor doprosslon

o 3 '" 5 6 7 8 10 lima (seconds)

99

100

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System Output Comparison Output Torque

rpm (TMCdata)

100.-----------------------------,

~ 80 120 Vehicle speed (kmfl)

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Acceleration Performance

Atteleration ;sensation SOkm

t Good

fuel economy

o Prius

0-100kmlh atceler.rtiOll

o 2 3 , 5 6 (sac;oOOs) Elapsed lime

Acceleration p"rfOrmOR(" {fMC dela,

O"'lOllkm1h Acc:.lenltIon from start

THS Prius (1.51)

Prius II

10 15 (seconds)

elerallon when overtaking

T;adeOlf belWee~ pertormance and

/

fuel eoonomy , " IneolMlnllonal vehldes

, - --" "~"'. ,

."~Ion (~.~I) '"""

Good acceleration -.

6 (seconds)

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Overall Energy Efficiency

Overall efficiency

!

Recent ! 88 gasoline car

.Priu!;l (before

impro~merrt)

Prius I

16

28

10

overall efficiency ('Yo) (well-to-wheel)

I-_,------.----'i 2596

(after ,,!~~m~~)1

88 32

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Prius-with I 37 msu

Toyol8FCHV !

50 ---

i FCHV (larget) I 70 60

Conclusion • Electric Vehicle (EV): The breakthrough of

battery technology

• FCEV: The future developing goal of a vehicle • If using hydrogen as fuel:

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• Hydrogen: One needs to solve the safety issue of storage • LH2: Issue of production cost

• If using methanol, gasoline, etc. as fuels: • One needs to reduce the fuel reset-up time • Post-processing issue of CO: Cost increases • Production of C02: Dilution Issue • Heat management issue

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References 1. Yamaoka Jouhu , "Automatic Vehicle Engineering Vol.42 No.1 0", Railway Japan, 1993 2. 1.Y amaoka Jouhu , "Automatic Vehicle Engineering Vol.44 No.12", Railway Japan, 1995 3. 1. Yamaoka Jouhu , "Automatic Vehicle Engineering Vol.46 No. 7", Railway Japan, 1997 4. 1.Yamaoka Jouhu, "Automatic Vehicle Engineering Vol.46 No.14", Railway Japan,1997 5. 1.Yamaoka Jouhu, "Automatic Vehicle Engineering Vol.47 No.1", Railway Japan, 1998 6. 1.Yamaoka Jouhu , "Automatic Vehicle Engineering Vol.48 No.9", Railway Japan, 1999 7. 1.Yamaoka Jouhu , "Automatic Vehicle Engineering Vol.48 No.11", Railway Japan, 2000 8. 1.Yamaoka Jouhu , "Automatic Vehicle Engineering Vol.49 No.12", Railway Japan, 2000 9. 1.Yamaoka Jouhu , "Automatic Vehicle Engineering Vol.49 No.1", Railway Japan, 2000

10."Toyota Prius New Model Vehicle Handout" ,Toyota Automatic Vehicle Corporation ltd., 1997

11 ... www.toyota.co.jp .. 12 ... www.honda.co.jp .. 13."Electric and Hybrid Vehicles PT-21", SAE, 1981 14.Bradford Bates, "Electric Vehicles PT -40" , SAE, 1992 15. Che, hsien hsiung, "Practice of Electrically-driven Devices" ,Chi-Shue Publsher, 1978

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