2011 Automobile Maintenance

Advanced Course for the

Industrial Technical
Instructors
Instructor :
Lin, Jen-liano
Hybrid Electric Vehicles
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Jfy6ritf P,fectric 'Veliicfes
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draft: 2001107106
Revision: 2004107106
)lutowin Indust ria { Corp.
COPYqu(]Jff 2001
Introduction
What is a Hybrid Electric Vehicle?
Background
Introduction of Hybrid Electric
System
Advantage/Defect, Construct and
Operation
Conclusion
Re f erences
P1
1
2
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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
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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
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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.
5
6
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Fundamental Background
H EV Releases
TOYOTA _'-
THS, THS-II ",,08'(;
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
The Developing Background of
H brid Electric Vehicles
Energy Exhaustion
Reservation Issue of Petroleum
Air Pollution
Environmental Protection Regulations
Global Warming
C02 Emission
7
8
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Emissions Legislation
Now
Now
Source: Honda, 1999
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A Solid Goal of Reducing Vehicle CO
2
Emissions Volume set by Japan
~ 20
!!!.
n
g 15
lit
c:
3
"0
a: \0
o
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CD
25
."
~ 2
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o
ii: 15
c:
3
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go 10
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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
9
10
...;!LHybrid Electric Vehicle
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Countermeasure of the Vehicle Plant
TOYOTA Countermeasure to Reduce CO
2
Emissions Volume
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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
F E V ~ F H V
11
12
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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
~ 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)
13
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The Advantage/Disadvantage of a
Pure Electric Vehicle
Disadvantages:
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Short PEV endurance/ less passenger load
capacity; so with limited applications
High battery price, vehicle price higher
Charging is time-consuming and tedious
v
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
15
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
16
WHEV
The Advantage/Disadvantage of a
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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 waste-
gas 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
19
20
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 ...
-'" ,
TINO ,
,
' /
....
'"
"-
HONDA IMA
Parallel Single-Axis
INSIGHT, CIVIC
Allocation
MITSUBISHI
'
Parallel Double-Axis:
AllOCation
0
SUWADVANCE
DIHATSU EV-H
Parallel Double-Axis
MOVE
Allocation
SUBURU SHPS
Parallel Double-Axis
ELTEN CUSTOM
AllOCation
of a Hybrid
Electric Vehicle
_
._ Dynamics
Transmission
,------,
I
c-:-:-:-:-:-:-:. Electric
Transmission
Generator :':'.':':':':':':':':':

Converter
High-voltage
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
21
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Dynamics Device---THS
I Prius I
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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)
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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
25
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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
27
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
28
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Why GDI Engine has not been widely
accepted by Hybrid Electric Vehicle
1. Under same exhaustion volume, engine fuel-
saving 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.
29
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
30
-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
31
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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
33
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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
35
Electric Power-Conversion Device
Rectifier: AC to DC
Inverter:
Specific-defined Inverter: Changing DC into AC power
source and providing the motor with required power-
conversion 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 ~
Chopper: Driver for DC Servo Motor ~ ~
36
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
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Ig
I
High-
Voltage
Storage
Battery
I
nition Signal
Grounding
-
Motor
Controller

Inverter (2)

r- ----------------------------------------------,
I Motor-specific Bridge Circuit
I
I
Current
:d:


Sensor
i k'
i'\

I -X
: T . on:;
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
Ol K
on;:.

I
I
I
I
--X
I
L.....X . . I
I

. on:;

v-
I
Current
I
I Sensor
I
- - - -
: Charging-spedfic Bridge arml: I
_______________________________________________ J
37
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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
39
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
40
Planet Gear
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Dynamics Separating Mechanism
Generator Motor
Ring gear
(motor/power shaft)
Planetary gear
41
Actions of Planet Gear
Dynamics Separating Mechanism
Genenllor rpm
o
- .rpm
En!joe rpm (1IIlI1ic1e speed)
"'0 (; c) .. ,
S ... Crrler 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
-..".,
'-
- .
Sungelll carrier Ring goor
Acceleration
Genenilorrpm
-rpm
Engine rpm (1IIlI1lde $peed)
,


S ... C,nier Ring gear
Gene<ator rpm
Start up
Cruise
Molot .rpm
Engine rpm (VIlIllele speed)
42
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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"" .,..,,.. ........ "',#
43
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
44
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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
45
Computer Controlled System (4)
II Signal Output: Activator n Y ~ 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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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,

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
47
3. Detection of Battery
Voltage Sensing
Battery Abnormality Det
Leakage Detection
Voltage Abnormality De1
Storage Battery Temper
Storage Battery CUrl -
48
P?4
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Maintenance of High-Voltage Circuit
MainFrame
Supportive
I I
:: S:MR 1 Resistor
:: Storage Battery Module
Sea:::= t __

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
49
50
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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
51
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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
53
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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.
57
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).
58
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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.
59
Regenerative Brake Mode (3)
Regenerative braking
C ~ J
=/1 depression
\\
~ Regene.
ratlve
\ braking
\'- ~ ~
Bmktng \ braking
power '._. __ . "_
,
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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)
61
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
62
(.
,
---- --- ---- ~ .. - -- -._-----
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The Operation of
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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.
63
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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
65
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The Operation of Hybrid
Electric System (5)
When it decelerates and brakes
.. Charging Storage Battery
The Operat i on 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
67
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
69
The energy that runs hybrid cars
+
t
Supplying required energy
Engine
I
Engine off Engine running at
-
I
low-speed maximum efficiency
Stationary running Normal running
Source: Toyota
Battery
surplus "
Retrieving braking
energ1
Braking Stationary
70
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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
71
CO
2
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
72
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I Prius I
THS Assembly
73
THS Powertrain
74
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l t a
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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
75
Dynamics Separating Mechanism
Generator Motor
Rlng gear
(motor/power shaft)
Planetary gear
76
~ . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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<i7luto
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
77
..

Poor
78
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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

Traditional
Gasoline Engine
Vehicle

I "' 4th


Vehide
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

Fuel
Energy
-- - -- -- 50
--=-_-----100
Engine
79
80
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WHEV
(i7luto
Display Panel
81
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 CO
2
, 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 function-
specified demands, all types of models have been proposed.
82
--- -- -----
----- --- -
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Second generation Prius
Devlping Goal of THS-II
Objective:
Compatibility of Environmental
& Power Performance
83
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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"
- --- ---------
89
90
-- ------- ._-
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W
<Yluto
Drive system output improvement

.....
::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------------;-------------,
.
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

10 (seconds)
Standing start acceleratron: 0100 kmlh
Standing start and overtaking acceleration performance
92
- -
----_ .- -
----------
W

W

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
----,.,"
Sun gear C<I/Ifer Ring vo-
Engine Stop
Start & charging at stop
--
ngine rpm '.eI1ido1..-cQ

EngIno
-
Colinear graphing of gear relationships
t :-----J THSI i
I
.. __ . . :
. 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
94
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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
95
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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
98
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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)
101
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
pertormance and
/
fuel eoonomy
, " IneolMlnllonal vehldes
, - --" ,

'"""
Good acceleration -.
6
(seconds)
102
W
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Overall Energy Efficiency
Overall efficiency
!
Recent ! 88
gasoline car
.Priu!;l
(before

Prius
I
16
28
10
overall efficiency ('Yo)
(well-to-wheel)
I-_,------.----'i 2596
(after

88 32
W
Yillito
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:
103
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
104
WHEV
g{lltO
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
105
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