Evaluation of 2004 Toyota Prius Hybrid Electric Drive System

… of 2004 Toyota Prius. Hybrid Electric Drive System. Prepared … and the ECU (many more lines exist than are shown in the simplified schematic). Extracting and …

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Evaluation of 2004 Toyota Prius Hybrid Electric Drive System
1. INTRODUCTION… 1
1.1 PROGRAM OVERVIEW… 1
1.2 TESTING FACILITIES… 2
1.3 SCOPE AND OBJECTIVE… 2
1.4 APPROACH… 3

2. HYBRID ELECTRIC DRIVE SYSTEM DESCRIPTION… 4
2.1 DESIGN REQUIREMENTS … 7
2.2 SYSTEM SUBASSEMBLIES… 7
2.2.1 Engine … 8
2.2.2 Power-Split Device …
2.2.3 Generator … 10
2.2.4 Motor … 10
2.2.5 Inverter… 10
2.2.6 Battery… 11

3. LABORATORY TESTING … 12
3.1 ANL VEHICLE -EVEL PERFORMANCE TESTS… 12
3.1.1 Initial Performance Testing at ANL… 12
3.1.2 Vehicle Data Characterizing Boost-Converter Operation… 14
3.2 ORNL SUBSYSTEM-LEVEL PERFORMANCE AND VALIDATION TESTS … 18
3.2.1 Locked Rotor Tests… 19
3.2.2 Back-emf Tests … 21
3.2.2.1 Motor tests …
3.2.2.2 Generator tests …
3.2.3 Hybrid Drive System Loss Tests … 23
3.3 HEV SYSTEM TESTING OVER THE FULL DESIGN RANGE … 28
3.3.1 Test Configuration … 29
3.3.2 General Test Plan and Data Verification … 30
3.3.3 Motor/Inverter Test Data and Efficiency Maps … 33
3.3.4 Buck/Boost-Converter Test Data and Efficiency Maps… 36

4. INVERTER, CONTROLLER, AND Z-SOURCE ACTIVITIES … 40
4.1 INVERTER ARCHITECTURE OVERVIEW… 40
4.2 INVERTER MODIFICATIONS…
4.3 CONTROLLER DEVELOPMENT …
4.3.1 Establishing the Need for Field Weakening … 42
4.3.2 Controller Software… 43
4.3.3 Controller Hardware …44

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