Post on 27-Apr-2021
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
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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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
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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
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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:
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
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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
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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
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Transmission and Motor
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
Transmission and Motor
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
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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.)
Transmission and Motor
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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%
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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)
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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
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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%
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
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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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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”
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
CO2 reduction in well-to-wheel highest with CO2-free electric energy
Plug-in Hybrid: CO2 reduction potential
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
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
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
Towards 1 million Toyota hybrid vehicles per year
Thank you very much for your kind attention!