Ô tô hybrid hãng Toyota

What is the Hybrid Vehicle?Kind of Hybrid System – Series Hybrid System • In this system, the engine is used to supply electrical power to the motor, which then turns the wheels... What

TOYOTA Hybrid Technology

What is the Hybrid Vehicle?

THS II (TOYOTA Hybrid System)

What is the Hybrid Vehicle?

400 (ppmv)

1200 1400 1600 1800 2000

2100

What is the Hybrid Vehicle?

Why is the hybrid vehicle necessary?

Low fuel consumption and low CO2 emission

vehicle is required

Increase Automobile

market

Expanding Energy Consumption

2006 1970

What is the Hybrid Vehicle?

Why is the hybrid vehicle necessary?

– Hybrid technology is the core for eco-car development

•Low fuel consumption

•Low CO2 emission

•Low fuel consumption

•Low CO2 emission

THS II

FCHV THS

What is the Hybrid Vehicle?

Kind of Hybrid System

– Series Hybrid System

• In this system, the engine is used to supply electrical power to the motor, which then turns the wheels

What is the Hybrid Vehicle?

Kind of Hybrid System

– Parallel Hybrid System

• The wheels are driven by both the engine and the motor

What is the Hybrid Vehicle?

Kind of Hybrid System

– THS (TOYOTA Hybrid System)

• Strong points of both series/parallel systems realized

in one system

What is the Hybrid Vehicle?

THS II (TOYOTA Hybrid System)

– Concept

Higher Power Low Fuel

Consumption

What is the Hybrid Vehicle?

THS II (TOYOTA Hybrid System)

– Hybrid vehicle realizes low fuel consumption and

higher power

PRIUS (NHW20)

PRIUS (NHW11)

Corolla (1.3L) Corolla

(1.5L)

CAMRY (2.4L)

Tradeoff between performance

and fuel economy in conventional vehicle

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

THS II (TOYOTA Hybrid System)

PRIUS [NHW20]

THS II (TOYOTA Hybrid System)

Main Component Location

HV Battery

Engine Inverter

Shift Lever

Parking Switch

Shift Lever

Main Component Location

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

System Diagram

HV Battery

Brake

Actuator

Auxiliary Battery

Electric A/C Compressor

A/C Inverter

DC – DC Converter

SMR1, 2 and 3

Boost Converter

Speed Sensors

CAN

Engine ECU

Skid Control ECU

Battery ECU

DLC3

HV ECU

Click here to

see operation of shift lever

THS II (TOYOTA Hybrid System)

Outline

– Compression from conventional vehicle

Trans-mission

• A/T

• M/T Power Splitting Device

• Divide the engine, motor and generator power

• Function as CVT

Brake Hydraulic Brake ••Hydraulic BrakeRegenerative Brake Cooperative control between hydraulic and

regenerative brake Battery 12V Battery ••12V Battery201.6V Battery High-voltage supply for motor drive

THS II (TOYOTA Hybrid System)

Outline

– System operation

Start-of Normal Driving Acceleration Deceleration Stop

Electric motor only

Motor and Engine

Motor and Engine (additional power drawn from battery)

Battery charging

Engine automatically shuts off

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

Hybrid Transaxle

– Includes AC 500V motor, generator and power-dividing mechanism

– Uses a continuously variable transmission mechanism

to achieve smooth and quiet operations

Power-dividing Mechanism

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

Brake System

– ECB (Electrically Controlled Brake)

– Hydraulic brake pressure is controlled by electrical signal and cooperate regenerative brake

Skid Control ECU

Vehicle Condition

Driver’s Demand

HV ECU

Regenerative Brake Control Hydraulic Brake Control

THS II (TOYOTA Hybrid System)

Steering System

– EPS (Electric Power Steering) is used

EPS ECU EPS Motor

THS II (TOYOTA Hybrid System)

Air Conditioning System

– Compact, high-performance scroll compressor driven

by motor

Electric Inverter Compressor

THS II (TOYOTA Hybrid System)

Multi Display

– Energy Monitor

THS II (TOYOTA Hybrid System)

Multi Display

– Fuel consumption indicator

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

Service Plug

– Shut of the high-voltage circuit

Caution: Wear insulated gloves when disconnecting / connecting the Service Plug

Engine

Atkinson Cycle

– The “X” of the 1NZ-FXE indicates the use of the

Atkinson cycle, the principle applied for this vehicle’s engine

Atkinson cycle High thermal efciency

1NZ-FXE (PRIUS)

Overview

– Atkinson cycle

Compression Stroke < Expansion Stroke

High thermal efciency

Overview

– Specifications

Item 1NZ-FXE (’04 PRIUS) 1NZ-FE (Corolla)

No of Cylinders & Arrangement 4-Cylinder, in-line 

Valve Mechanism Chain Drive, VVT-I16-Valve DOHC, 

Bore x Stroke mm (in.) 75.0 x 84.7 (2.95 x 3.33) 

pedal position sensor

PVD coat is used to improve wear resistance

Steel material is used to improve wear resistance

-Corolla

 Prius

• Piston Ring

– Lower tension and thinner piston ring is used for friction reduction

Throttle Body (ETCS-i)

Throttle valve is controlled by the HV ECU

ETCS-i also controls the cruise control system

Radiator (for engine)

Radiator (for Inverter)

Coolant Heat Storage System

– General

• This system reduces the amount of adhesion of fuel

on the intake port wall after engine starting

Hot coolant in

the tank

Before engine start

Hot coolant to cylinder head Heated

Amount of adhesion of fuel is reduced after engine start

Coolant Heat Storage Water Pump

Water Valve

Water Pump (for Heater)

Coolant Heat Storage Tank

to / from heater core

Reverse Side

Water Pump

Water Pump

Heater Core

Cylinder Head

OF F Water

Valve

Water Pump

Water Pump

Heater Core

Cylinder Head

OF F

Hot coolant

is stored

Water Valve

Meets stop conditions

Confidential

P1115 Coolant temp sensor circuit for coolant heat storage system P1122 Water valve position sensor circuit lowP1116 Coolant temp sensor circuit stuck for coolant heat storage system P1123 Water valve position sensor circuit high

P1117 Coolant temp sensor circuit low for

coolant heat storage system P1150

Coolant Path Clog Up for Coolant Heat Storage System

P1118 Coolant temp sensor circuit high

for coolant heat storage system P1151 Coolant Heat Storage TankP1120 Water valve position sensor circuit P2601 Coolant pump control circuit range / performanceP1121 Water valve position sensor circuit stuck P2610 ECM / PCM internal engine of timer performance

Coolant Heat Storage System

– Service Point

• Coolant Replacement

 Drain engine coolant

1 Disconnect the coolant heat storage water pump connector

2 Remove the radiator cap

3 Connect a vinyl hose to drain cocks (engine, radiator, coolant

heat storage tank)

4 Loosen the drain cock plugs (engine, radiator, coolant heat

storage tank), and drain coolant

5 Drain the coolant in the radiator reservoir tank

Caution: The coolant in coolant heat storage tank is

hot even if engine and radiator are cold

Coolant Heat Storage System

– Service Point

• Coolant Replacement

 Fill engine coolant

1 Tighten the drain cock plugs and disconnect a vinyl hose (engine,

radiator, coolant heat storage tank)

2 Connect a vinyl hose to the bleeder plug of radiator and insert the

another side of hose to reservoir tank

3 Using 6 mm socket hexagon wrench, loosen the radiator bleeder plug

from service hole

4 Fill the coolant into the radiator

5 Tighten the radiator bleeder plug and install the radiator cap

6 Fill the radiator reservoir tank with coolant to the full level

7 Connect the coolant heat storage water pump connector

8 Connect the Intelligent Tester II to DLC3 and turn to IG/ON

Coolant Heat Storage System

– Service Point

• Coolant Replacement

 Fill engine coolant

9 Perform the ACTIVE TEST of water pump (coolant heat storage water

pump operates for 30 sec.)

10 Loosen the radiator bleeder plug and fill the coolant into the radiator

11 Tighten the radiator bleeder plug

12 Repeat the steps 9 to 11 until coolant cannot be added

13 Disconnect the vinyl hose

14 Warm-up engine until the thermostat is opened (inspection mode)

15 Stop the engine, and wait until the coolant gets cold

16 Fill the coolant into the radiator

17 Repeat the step 14 to 16 until coolant level stops going down

18 Check DTC and clear the DTC which relates to the water pump

Fuel System

(Vapor reducing fuel tank)

Reduce the amount of

when vehicle is

parked

Fuel System

(Vapor reducing fuel tank)

It is composed of two parts:

a metal outer tank,

Fuel System

(Vapor reducing fuel tank)

Fuel Sender Gauge

Sub-tank is installed

inside the fuel tank,

inside which a fuel

pump and sender

gauge are attached

Sub-tank

Fuel Sender Gauge

Fuel System

(Vapor reducing fuel tank)Fuel Sender Gauge

The fuel pump and

sender gauge can not

be removed from the

Drive Belt System

– A/C compressor pulley is not existing

– Simply belt layout

A/C compressor pulley

is not existing

Water Pump Pulley

Crank Pulley

Idler Pulley Adjust Bolt

Hybrid Transaxle

– Capacity: 3.8 liters

driven Gear

Counter-Final Ring Gear

Chain-driven Sprocket

Reduction Mechanism

Diferential Mechanism

Hybrid Transaxle

MG2

– When driving  Main power to engine power (Starting

of) or provides supplementary – When braking  Converts kinetic energy to

electrical energy

MG2

Hybrid Transaxle

Speed Sensor (Resolver)

– Detects position, speed and direction of MG1 / MG2 rotors

Speed Sensor

(for MG1)

Speed Sensor (for MG2)

Hybrid Transaxle

Transaxle Damper

– Installed at location of conventional clutch

Reduces shock which occurs when kinetic energy is transmitted

Hybrid Transaxle

Cooling System

– Cooling circuit is used for both MG1 / MG2

– Separate cooling system from engine

Hybrid Transaxle

Mayor Diferent with Prius Generation III

Inverter Assembly

A/C Inverter

voltage System

voltage System

Variable-MG1

MG2

Inverter

DC - DC Converter

DC - DC Converter

(IPM)

Inverter Assembly

Inverter Operation

– Motor control

Motor Torque is controlled

by the current value

Motor Speed is controlled by

the frequency

Low Torque

High Torque

Low Speed High Speed

DC 12V

DC

 AC

Variable-Inverter Assembly

A/C inverter

– DC201.6V  AC201.6V conversion

Electric Inverter Compressor

HV ECU

HV Battery

A/C ECU

Target Compressor Speed

Inverter Assembly

Cooling System

– Cooling circuit is used for inverter assembly

– Separate cooling system from engine

HV Battery Assembly

HV Battery Assembly

Power Supply

– The HV battery supplies power to MG1 / MG2

– The auxiliary battery supplies power to HV ECU and Engine ECU (all ECU)

– When both are functioning properly, the vehicle will start

HV Battery (DC 201.6V)

Auxiliary Battery

(DC 12V)

HV Battery Assembly

Battery Module

– Nickel metal hydride (Ni-MH) battery

(1.2V x 6 cells) x 28 modules = 168 cells = DC 201.6 V

28 Module

Module (1.2V x 6 cells)

Temp Sensors (Thermistor) Battery

SOC Control Cooling Fan Control

Cooling Fan Control

Electrical Leakage Detection for High-voltage System

Electrical Leakage Detection for High-voltage System Diagnosis Function for HV Battery

Diagnosis Function for HV Battery

HV Battery Condition Detection

HV Battery Condition Detection

Relay

Battery Cooling Fan

Controller

HV Battery Assembly

Battery ECU

– Controls SOC to match THS characteristics

– The SOC is maintained at approx, 60% A margin is given for further recharging via regenerative braking– Sends requests to HV ECU to obtain desired SOC

HV Battery Assembly

SOC Control

– When the SOC is dropped, battery ECU sends the

“Charge Request” signal to HV ECU

Battery ECU

Drive Charge

Voltage (SOC)

SOC

Charge Request

Power Request

Charging

Control

HV ECU Engine ECU

MG1

HV Battery Assembly

SMR (System Main Relay)

– Turns ON / OFF the high-voltage circuit

SMR1

SMR2 SMR3

HV Battery Assembly

Service Plug

– Shut of the high voltage circuit manually

Service Plug

HV Battery Assembly

Auxiliary Battery

– Jump Start Terminal

• ”+” terminal of auxiliary battery for jump start is used

Jump Start Terminal

Auxiliary Battery

– Jump Start Procedure Auxiliary Battery

Special Notes on Service

Positive Terminal Negative Terminal

Click Movie

THS II Operation

Device Diferential Mechanism

THS II Operation

Power-dividing Mechanism (Planetary Gears)

– Sun gear: MG1

– Planetary Carrier: Engine

– Ring Gear: MG2 (Front Wheel)

Engine

Chain Power-dividing

Mechanism

Unit Planetary gear

Unit Planetary gear Ring Gear Planetary Carrier

Sun Gear

Perangkat Pembagi Power

Bagan Nomographic

Arah Rotasi

-Kondisi MG1, MG2

Bagan Nomographic

Prinsip Kerja-1

Sun gear: fixed (tertahan)

Ring gear: berputar (input)

Planetary carrier: ?

 Referensi ke bagan

Klik di atas untuk melihat film (movie)

THS II Operation

Engine Starting and Idling

Click! Movie

Vehicle

Speed

Click!

animasi

Menghidupkan Mesin

Menghidupkan Mesin

MG1 bekerja sebagai motor starter

 Referensi ke bagan

Menghidupkan Mesin

Starting Mesin dan Idling

Mesin menggerakkan MG1 untuk mengisi baterai HV

 Referensi ke bagan

animasi

Kendaraan Mulai Berjalan

 Referensi ke bagan

Starting Off-2

MG1 bekerja untuk menghidupkan mesin saat

dibutuhkan tambahan power

Vehicle

Speed

THS II Operation

Accelerating Under Low Load (Light Throttle)

– Request more power, MG1 starts engine

Click! Movie Click!

animasi

Selama Merayap (Cruising):

Selama Merayap (Cruising):

MG2 membangkitkan listrik untuk MG1

Unit planetary gear bertindak sebagai CVT

 Referensi ke bagan

Selama Merayap (Cruising):

Akselerasi Ringan

MG1 membangkitkan listrik untuk MG2

MG2 menyediakan power penggerak tambahan

 Referensi ke bagan

animasi

Akselerasi Full Throttle

 Referensi ke bagan

Akselerasi Full Throttle

animasi

animasi

Motor Traction Control

Mengontrol MG2 dan rem hidrolik

MG2

Traction Control

Gaya

Sensor Kecepatan

Kecepatan Tinggi

ECU Skid Control ECU

HV

Sensor Kecepatan

Setiap Roda

Slipping

Kontrol

Kontrol Bantuan Menanjak

Mengontrol rem hidrolik belakang

ECU HV

Traction Control

Gaya Pengereman

ECU Skid Control

Sinyal Sensor Kecepatan MG2 dll.

Mencegah kendaraan dari terguling ke belakang

THS II Operation

THS-II Control

– Motor Drive Mode Control (except U.S.A model)

• In this mode, the vehicle is driven by only MG2 by operating the EV Mode Switch

Drive

Accelerator Pedal Position Sensor

Battery ECU

•SOC Condition

•Battery Temp.

EV Mode Switch

Skid Control ECU

Speed Sensors

Combination

Meter

Gateway ECU

Engine ECU

THS II Operation

THS-II Control

– Motor Drive Mode Control (except U.S.A model)

• EV Mode Switch is momentary type

LHD Model

EV Mode Switch

EV mode canceling conditions

•EV mode switch is pushed

•HV battery SOC drops

•HV battery temp is low or high

EV mode canceling conditions

•EV mode switch is pushed

•HV battery SOC drops

•HV battery temp is low or high

ECB (Electronically Controlled Brake)

ECB (Electronically Controlled Brake)

Brake Force Generation

Indicator and Warning

Indicator and Warning

Multi Display

– Energy monitor shows the energy flow

Oil Pressure Warning

High Engine Coolant Temperature Warning

Hybrid System Abnormal

HV Battery Warning

Discharge Warning

EPS Warning

Indicator and Warning

Multi Display

– Warning message

Other Systems

Other Systems

EPS (Electric Power Steering)

– Column assist type EPS is used

Column Assist Type EPS

Reduction Mechanism

EPS ECU

DC Motor (12V)

Torque Sensor

IL 1 1

ND-OIL 8

Service Point

Service Point

Inspection Mode

– In the inspection mode, engine is continuously

operated (P range) and motor TRC is turned of

Note: Other hybrid vehicle has several types of inspection mode

Mode Vehicle Condition Purpose Transferring Procedure

Inspection

Mode-2WD Inspection

(Inspection Mod1)

• Keeps engine running (P range)

• Intelligent tester (Active Test)