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More and more hybrid vehicle products are being introduced to the mar-
ket. Among them, Toyota Prius was the pioneer and has the largest number
of units on the road. To give the reader a case study of a commer-
cially successful hybrid vehicle, the Toyota Prius technology is described
in this Appendix. This appendix will review the important technical fea-
tures of this product, including the architecture, control, and component
characteristics. The main resource for this material is autoshop101.com
(http://www.autoshop101.com/forms/Hybrid01.pdf). However, the dia-
grams have been redrawn. We gratefully acknowledge the use of material
available in autoshop101.com.
TABLE A.1
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Notes: SULEV standards are about 75% more stringent than ULEV and nearly
90% than LEV for smog forming exhaust gases.
SULEV vehicles will emit less than a single pound of HCs during 100,000 miles
of driving (about the same as spilling a half quarter of gasoline).
AT-PZEV vehicles use advanced technology capable of producing zero emis-
sion during at least part of the vehicles driving cycle.
power train and control systems. The hybrid system components include the
following:
Shift position
sensor
Inverter
Accelerator A/C Electric
position converter inverter
sensor Boost compressor
converter DCDC
ECM HV converter
Speed sensor ECV
Yew, Roll and
deceleration
Skid control
Steering angle ECU
SMR SMR SMR
Brake pedal
Auxiliary
Brake battery
MG1
ECU
MG1
Engine CAN
Planetary Mechanical power path
gear unit Battery HV
battery Hydraulic power path
ECU
Electrical signal
TABLE A.2
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Table A.3 shows the main parameters of the hybrid transaxle. Table A.4
shows the specifications of MG1 and MG2.
A.3.3 HV Battery
The HV batteries are NiMH. Six 1.2 V cells connected together in series
constitute a battery module that has a voltage of 7.2 V.
In the 20012003 Prius, 38 battery modules are divided into two holders
and connected in series and have a rated voltage of 273.6 V.
Dierential
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To wheel To wheel
Final gears
Counter
gears
Chain
Transaxle
damper
Engine
ywheel
Planetary
MG1 gear unit MG2
In the 2004 and later models, 28 battery modules are connected for a rated
voltage of 201.6 V. The cells are connected in two places to reduce the internal
resistance of the battery.
Table A.5 shows the HV battery information.
The battery ECU provides the following functions:
The SOC of the battery is controlled by the HV battery ECU. The target
SOC is 60%. When the SOC drops below the target range, the battery ECU
informs the HV ECU and then signals the engine ECM to increase its power
TABLE A.3
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Planetary gear
Number of ring gear teeth 78
Number of pinion gear teeth 23
Number of sun gear teeth 30
Differential gear ratio
Chain
Number of links 72 74
Drive sprocket 36 39
Drive sprocket 35 36
Counter gear
Drive gear 30
Driven gear 35
Final gear
Drive gear 26
Driven gear 75
Fluid capacity
Liters (US qts, lmp qts) 3.8 (4.0, 3.3) 4.6 (4.9, 4.0)
Fluid type ATF WS or equivalent ATF type T-IV or equivalent
TABLE A.4
Specification of the MG1 and MG2
MG1 Specification 2004 Model 2003 Model
Item
Type Permanent magnet motor
Function Generate engine starter
Maximum voltage (V) AC 500 AC 273.6
Cooling system Water-cooled
MG2 specification 2004 model 2003 model
Item
Type Permanent magnet motor
Function Generate engine starter
Maximum voltage(V) AC 500 AC 273.6
Maximum output kW(PS)/rpm 50 (68)/12001540 33 (45)/10405600
Maximum torque Nm (kgf.m)/rpm 400 (40.8)/01200 350 (35.7)/0400
Cooling system Water cooled
TABLE A.5
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HV Battery Information
HV Battery Pack 2004 and Later 20012003
to charge the HV battery. The normal low to high SOC deviation is 20% as
shown in Figure A.3.
The HV battery is air cooled. The battery ECU detects battery temperature
via three temperature sensors in the HV battery and one intake air tempera-
ture sensor. Based on their readings, the battery ECU adjusts the duty cycle
of the cooling fan to maintain the temperature of the HV battery within the
specified range.
Three SRMs are used to connect or disconnect power to the HV circuit based
on commands from the HV ECU. Two SRMs are placed on the positive side
and one is placed on the negative side, as shown in Figure A.4.
When the circuit is energized, SMR1 and SMR3 are turned on. The resistor
in line with SRM1 protects the circuit from excessive initial current (called
inrush current). Next, SRM2 is turned on and SRM1 is turned off.
When de-energized, SMR2 and SMR3 are turned off in that order and the
HV ECU verifies that the respective relays have been properly turned off.
A service plug is placed between the two battery holders. When the service
plug is removed, the HV circuit is shut off. The service plug assembly also
contains a safety interlock reed switch. Lifting the clip on the service plug
opens the reed switch, shutting off the SMR. There is also a main fuse for the
HV circuit within the service plug assembly.
Overcharge region
70%
Control
60%
region
SOC 50%
Undercharge region
SMR 2
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SMR 1 Resistor
Service
plug
SMR 3
A.3.4.2 Inverter
The inverter changes the HV DC from the HV battery into three-phase AC for
MG1 and MG2 as shown in Figure A.5. The HV ECU controls the activation
MG1
HV
battery Current sensor
IPM
converter
MG2
DCDC
inverter
A/C
Power
Inverter assembly transistor
HV ECU
A.3.4.4 AC Inverter
The inverter assembly in the 2004 and later models includes a separate inverter
for the air conditioner system that changes the HV batterys nominal voltage
of 201.6 V DC into 206.6 V AC to power the air conditioner systems electric
motor as shown in Figure A.7.
DC201.6 V
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DC/DC converter
AMD
Input lter
GND
Auxiliary
battery
IG
Converter control unit
S
A/C inverter
Current
sensor
HV
battery
Electric
compressor
Hydraulic
adjustment
area
MG2
Power splitting
device MG1 Inverter
Engine HV battery
(a) (b)
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FIGURE A.9 Braking force on the front and rear wheels: (a) without load on the rear wheels and
(b) with load in the rear wheels.
2. Brake force distribution, left and right (2004 and later models) When the
brakes are applied while the vehicle is cornering, the load applied to the
inner wheels decreases whereas the load applied to the outer wheels increases.
When the skid control ECU senses this situation (based on speed sensor out-
put), it signals the brake actuator to regulate the brake force between the left
and right wheels to prevent a skid.
pressure ECU
Brake pedal stroke
sensor signal
sensor signal
Brake
actuator
actuates the DC motor accordingly. The structure of the EPS system is shown
in Figure A.11.
The EPS ECU uses signals from the torque sensor to interpret the drivers
steering intention. It combines this information with data from other sensors
regarding the current vehicle condition to determine the amount of steering
assist that will be required. It can then control the current to the DC motor
that provides steering assist.
Gateway EUC
EPS ECU
HV ECU
DC Ready signal
motor
CAN
DLC3
When the steering wheel is turned, torque is transmitted to the pinion caus-
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ing the input shaft to rotate. The torsion bar that links the input shaft and the
pinion twists until the torque and reaction force equalize. The torque sensor
detects the twist of the torsion bar and generates an electrical signal that is
proportional to the amount of torque applied to the torsion bar. The EPS ECU
uses that signal to calculate the amount of power assist that the DC motor
should provide.
the front wheels lose traction but the rear wheels do not (front wheel
skid tendency known as understeer,
the rear wheels lose traction but the front wheels do not (rear wheel
skid tendency, or oversteer).
When the skid control ECU determines that the vehicle is in understeer or
oversteer condition, it decreases engine output and applies the brakes to the
appropriate wheels individually to control the vehicle.
When the skid control ECU senses understeer, it brakes the front and
rear inside wheel. This slows the vehicle, shifts the load to the outside
front wheel, and limits the front wheel skid.
When the skid control ECU senses oversteer condition, it brakes the
front and rear outside wheel. This restrains the skid and moves the
vehicle back toward its intended path.
Enhanced VSC also provides the appropriate amount of steering assist based
on driving conditions by coordinating EPC and VSC control as shown in
Figure A.12.
1. When starting off and traveling at low speed, MG2 provides the pri-
mary motive force. The engine may start immediately if the HV battery
2010 by Taylor and Francis Group, LLC
CAN
The operation modes of the engine, MG1, and MG2 are depicted in response
to different driving conditions as follows.
Stopped: If HV battery is fully charged and the vehicle is not mov-
ing, the engine may stop. The engine will start up automatically if the
HV battery needs charging. Also, if MAX AC is selected in the 2001
2003 models, the engine will run continuously due to the engine-driven
compressor. The 2004 and later models use an electrically driven compres-
sor. Figure A.13 shows the depicted operation modes of the engine, MG1,
and MG2.
Starting out: When starting out under light load and light throttle, only
MG2 turns to provide power. The engine does not run and the vehicle runs
on electric power only. MG1 rotates backwards and just idles. It does not
generate electricity, as illustrated in Figure A.14.
Engine starting: As the speed increases above 24 km/h to 32 km/h (15
20 mph), the engine starts. The engine is started by MG1. The operations
of the engine, MG1, and MG2 are shown in Figure A.15.
2010 by Taylor and Francis Group, LLC
Ready on
Vehicle is stopped
Vehicle
speed Planetary gear
MG2 & nal drive MG1 Engine
0 Time
HV
Inverter
ECU
Drive
Driven
HV battery
Light acceleration with engine: In this mode, the engine delivers its power to
the driven wheels and MG1, which is generating. MG2 may assist the engine
for propulsion if required, depending on the engine power and the requested
driving power. In this mode, the energy generated by MG1 may be equal to the
energy delivered to MG2. The drive train operates as an EVT. The operations
of the engine, MG1, and MG2 are shown in Figure A.16.
Starting out
Vechicle is driving by MG2
Vehicle
speed Planetary gear
MG2 & nal drive MG1 Engine
0 Time
HV
Inverter
ECU
Drive
Driven
HV battery
Engine starting
MG1 turns the engine
Vehicle
Planetary gear
speed MG2 & nal drive MG1 Engine
0 Time
HV
Inverter
ECU
Drive
Driven
HV battery
0 Time
HV
Inverter
ECU
Drive
Driven
HV battery
0 Time
HV
Inverter
ECU
Drive
Driven
HV battery
generated by MG1. Thus, the HV battery pack contributes energy to the drive
train and its SOC drops.
High-speed cruising: In this mode, the shaft of MG1 is fixed to the vehicle
stationary frame and the drive train is operated in pure torque-coupling mode.
Both the engine and MG2 propel the vehicle as shown in Figure A.19.
Driving with maximum speed: In this mode, both MG1 and MG2 receive
power from the HV battery pack and deliver their mechanical power to the
Planetary gear
MG2 & nal drive MG1 Engine
0 Time
HV
Inverter
Drive ECU
Driven
HV battery
0 Time
HV
Inverter
ECU
Drive
Driven
HV battery
drive train. In this case, MG1 turns in the opposite direction as shown in
Figure A.20.
Deceleration or braking: When the vehicle is decelerating or braking, the
engine is shut down. MG2 becomes a generator and is turned by the
drive wheels and generates electricity to recharge the HV battery pack. The
operation is shown in Figure A.21.
0 Time
HV
Inverter
ECU
+ Drive
Driven
HV battery
MG1 Engine MG2
0 Time
HV
Inverter
ECU
Drive
Driven by wheels
HV battery
Reverse: When the vehicle moves in reverse direction, MG2 turns in the
reverse direction as an electric motor. The engine is shut down. MG1 turns in
the forward direction and just idles as shown in Figure A.22.
0 Time
HV
Inverter
ECU
Drive
HV battery