hybrid technology – system and vehicle design for mass … · 2016. 2. 5. · dyna diesel hv...

Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.

Hybrid Technology –System and vehicle design for mass production

A3PS Conference “Alternative Propulsion Systems and Energy Carriers: Vehicle Integration and System Optimization”

Vienna, 18-19.November 2010

Gerald KillmannToyota Motor Europe


Powertrain map in future mobility

PHV

FCHV

FCHV(BUS)

Passenger cars Route buses

Short-distance commuters

EV

Winglet

Veh

icle

size

Delivery trucks

Heavy-duty trucks

Small delivery vehiclesｉ series

Motorcycles

FCHVs

EVs

HVs & PHVs with internal combustion engine

Driving distance

Gasoline, diesel, bio-fuels, compressednatural gas, gas to liquids, coal to liquids, etc.Electricity HydrogenFuel

HV


History of Toyota & Lexus Hybrid Vehicles’97 ’98 ’99 ’00 ’01 ’02 ’03 ’04 ’05 ’06 ’07 ’08 ’09

3rd Prius

1st Prius

2nd Prius

Camry Hybrid

GS450h

RX400h

Highlander Hybrid

Estima Hybrid

LS600h

Crown Hybrid

Crown mild HV

DynaDiesel HV

Estima HV (parallel hybrid)

Coaster HV (series hybrid) RX450h

’10

PHV lim.lease

Auris


Benefits of a full hybrid

Low emissions (CO2, NOx, PM, HC)

High fuel efficiency

Power & acceleration

Electric driving

Environment Fuel economy

Dynamic performance

Quietness

Full hybrid


Example Prius III: Development Targets

1. Improvement of fuel consumptionFocus real world driving, highway cruising, winter season

2. Satisfaction of the most stringent emission regulations

3. Applicability of different vehicle models for full scale

mass production (lightweight, system output, cost)

Based on the THS architecture, which is well proven in ~3.000.000 Toyota/Lexus hybrid vehicles sold:


1st system (1997) 3rd system (2009)2nd system (2003)

Vehicleexterior

Engineoutput

Motoroutput

Battery(NiMH)

First mass produced HV,Outstanding fuel economy

43kW

33kW

21kW

57kW

50kW

25kW

Improved Performance

73kW

60kW

27kW

Further improved on-road fuel economy

Evolution of Hybrid System

Objective

Overallsystem

Motormax rev. 6,000rpm 6,400rpm 13,500rpm

Boost converter(Max. 500V)

Reductiongear

High-rev. Motor

1.8L Atkinson + Cooled EGR

Boost converter

(Max. 650V)

Mechanical path

Electrical path

Power control unit

Inverter

Generator

Battery

Motor

Power split device

1.5L Atkinsonengine

Chain drive

Gear drive


Engine Displacement

Engine operating point ( ) at 120km/h cruising (same road load)

2nd Prius (1.5L) : 2,500 rpm

3rd Prius (1.8L): 2,200 rpm-300 rpm

- Select 1.8L engine enlarged from current 1.5L engine to improve fuel economy during high speed cruising

2nd Prius

Engine speed [rpm]

Engine torque [Nm]

10kW

20kW30kW 40kW

230 240g/kWh

0 2000 4000 60000

100Operating line

3rd Prius

Engine speed [rpm]

Engine torque [Nm]

10kW

20kW30kW 40kW

220

230240g/kWh

0 2000 4000 60000

100

Operating line


Transmission and Motor

Motor speed reduction device

Compound gear

Pinion gear

Counter drive gear

Parking gear Power split device ring gear

Motor reduction ring gear

Sun gear

Planetary gear

Fig．1 P410 Cross Section



Motor speedMotor torque

Constant power line

With motor speed reduction device

Without motor speed reduction device

(Motor Size)

Large

Small

Concept of motor downsizingMotor speed reduction device

Compound gear

Pinion gear

Counter drive gear

Parking gear Power split device ring gear

Motor reduction ring gear

Sun gear

Planetary gear



Motor revolution [rpm]

Motor torque [Nm](motor current)

400Nm(230A)

207Nm(170A)

by system voltage 500v→650V

60kW

50kW

Max. motorcurrent -26% Max motor

output +20%

Constant power line

by reduction gear

3rd Prius

2nd gen. Prius

6400 13500


Generator length -34%

Motor length -27%

Mass reduction of electric machines 35%Volume reduction of electric machines 40%

Transmission length -13mm (385 372mm)Transmission weight -20% (109 88kg)

Mechanical transmission losses -20%(bearing loss reduction, lubrication optimisation, chain gear drive to diff.)



Power Control Unit

500V 650V

Punchedplate

Cold plate (Al)

IGBT/ FWD

SolderInsulatingsubstrate

Solder

Heat sink(Cooper alloy)

Grease

Cold plate (Al)

Coolingstructure

3rd Prius2nd Prius

Direct cooling structure

Max.systemvoltage

+150V

Weight 21kg 13.5kg

Volume 17.7L 11.2L

-45%

-37%


Battery

3rd Prius2nd Prius

415 liters 445 liters

Cooling system optimisation

+30 litersLuggage space

Comparison of battery system from vehicle frontside view

2nd Prius (white)

3rd Prius (grey)


1000

10000

5000 10000

100

10

4000300020001000 6000 7000 8000 90000

Ene

rgy

dens

ity b

y w

eigh

t (w

att h

ours

/ kg

)

Energy density by volume (watt hours / litre)

Batteries

Hydrogen

CNG

Hydrogen absorbing alloy

Gaseous fuels

Ethanol

GasolineBio-diesel

DieselLiquid fuels

Lithium-ionNickel metal

Lead

Substantial R&D needed for batteries to reach levels similar to

conventional energy sources

Battery: Energy Density


Hybrid System Volume & Mass

-13%

2nd Prius 3rd PriusIndex of electrical system total volume[%

]

120

100

80

60

40

20

02nd Prius 3rd Prius

-17%

Index of hybrid system total mass[%

]

120

100

80

60

40

20

0

Battery

InverterMotorTransmission

Electrical System total volume reduction: 13%Hybrid System total mass reduction : 17%

Cost reduction for hybrid components: -40%


Fuel Economy, Emissions, Performance- Fuel economy improvement: 7-14%

Test driving cycle 3rd Prius

U. S. Combined Mode 46 mpg

NEDC Mode

Japan 10-15 Mode

2nd Prius

104 g/km

35.5 km/L

50 mpg

38.0 km/L

8.6%

14.4%

7.0%

Highway fuel consumption: 120km/h const. speed: -10%

Emission level: - Europe: Step 5- US: SULEV/ATPZEV- Japan: S-ULEV

3.0

3.5

4.0

4.5

5.0

5.5

6.014.0 12.0 10.0 8.0 6.0

0-60mph

acceleration time [sec]30-50mph acceleration time [sec]

●

●

★

New

Prius

2nd gen. Prius

First

Good

3.0

3.5

4.0

4.5

5.0

5.5

6.014.0 12.0 10.0 8.0 6.0

0-60mph

acceleration time [sec]30-50mph acceleration time [sec]

●

●

★

New

Prius

2nd gen. Prius

First

Good

Good

VehiclePerformance:+ 5%

89 g/km

3333rdrdrdrd


Inde

x of

Fue

l C

onsu

mpt

ion

[%]

Hybrid transmission contributes directly and indirectly by improving the engine operation

THS :Toyota

Hybrid SystemTHS vehicleBaseVehicle (AT)

50

100City ModeCity Mode

Regeneration

Engineimprovement

Idle stop

Engine operating area

Highway ModeHighway Mode

Fuel Consumption Improvement


2004 Prius

50

100

150

200

250

300

0 0.05 0.10 0.15 0.20 0.25 0.30

Gasoline

Diesel

Low

CO

2 E

mis

sion

TtW

CO

2(g/

km)

Clean TtW NOx(g/km)

Environmental performance

Source: VCA data 2004, 2008European C segment vehicles

2008

2004

2004

2009 Prius

2008

2008

Auris 2.2LDPNR

CO2 and NOx emissions

Hybrid transmission allows to use the full environmental potential of engines


Household electrical energyor public charging post

Gasoline station

Motor BatteryEngine

Fuel tank

The Next Step: Plug-in hybrid (PHV)

PHV: “the best of both worlds”


School

Work

Shopping Gym

Driving range and convenience

Camp

Day trip

Holiday

FamilyVisit

PHV in full HV mode

EV

PHV inEV mode

Trip Frequency

Regular

Occasional


0

5

10

15

20

25

30

20 40 60 80 100EV range (km)

Ele

ctric

ity (

kWh)

Priusbattery

+120kg

Priusbattery

Priusbattery

Rep

lace

men

t

EV range impact on vehicle package


0%

20%

40%

60%

80%

100%

20

Trip range (km)

Tri

ps (

%)

Cumulative

0 10 30 40 50 60 80 10070 90

PHV tests with EDFNov 07-June 08

55% of daily trips < 10km

80% of daily trips < 25km

Road trial: daily trip length

Test vehicle:

PHV based on Prius 2, 10km EV range


Driving distance of 1 trip (km)

PHV tests with EDFNov 07-June 080 10 20 30 40 50 60

20

40

60

80

100

Fue

l effi

cien

cy (

km/L

)

Road trial: fuel efficiency

Improvement: 60% fuel efficiency 37.5% fuel consumptionfor trips < 25km

Test vehicle:

PHV based on Prius 2, 10km EV range

Fue

l Con

sum

ptio

n (L

/100

km)

5

2.5

1.33

1.25

1.0

1010km

/L

L/10

0km


CO2 reduction in well-to-wheel highest with CO2-free electric energy

Plug-in Hybrid: CO2 reduction potential


First PHV application

Limited lease, globally 600 (Europe ~200)

Cooperation with electricity providers (e.g. EDF France: Strassburg)

Development targets:

• EV range: ~20 km (Li-ion battery)

• CO2 figures: <60 g/km

• EV max speed: ~100 km/h

• Charging time: less than 2 hours (220V, 16A)

• Normal vehicle useability (5 persons + trunk)

Next: PHV mass production start 2012


Toyota Hybrid System applications

Engine

Fuel tank

Motor

Battery

Engine

H2

tank

Motor

Battery

FC stack

HV

Engine

Fuel tank

Motor

Battery

EV

Engine

Fuel tank

Motor

Battery

PHV FCHV

Using hybrid technology for PHV, EV and FCHV


Gasoline,diesel

Gaseousfuels Biofuels Synthetic

fuels Electricity Hydrogen

CO2 reduction Air qualityEnergy diversity

Hybrid technology

Ultimate Eco-Car

The right car, the right place, the right time

Conclusion

Plug-in Hybrid technology

Hybrid is a key technology for all type of powertrains


Towards 1 million Toyota hybrid vehicles per year

Thank you very much for your kind attention!

hybrid technology – system and vehicle design for mass … · 2016. 2. 5. · dyna diesel hv...

Documents