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2011 Automobile Maintenance Advanced Course for the
Industrial Technical Instructors
Instructor : Lin, Jen-liano
~ Hybrid Electric Vehicles <7{uto
Jfy6ritf P,fectric 'Veliicfes
W
W Hybrid Electric Vehicle <7{uto
<!lluto
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
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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.
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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
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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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W WilltO
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
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."
~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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W Hybrid Electric Vehicles g[llto
W lIEf
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:
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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 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
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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 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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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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W HEV -YJ[lltO
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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
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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"" .,..,,.. ........ "',#
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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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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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- ~--------------------------------------~
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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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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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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
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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.
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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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~-----------------------
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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
W HEV -Gt'{llto
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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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W YlilltO
W HEV Ylillto
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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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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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
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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)
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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:
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
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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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