豐田普銳斯培訓(xùn)資料-- PRIUS THSII

1、THS II (TOYOTA Hybrid System II) nOverallnTHS II OperationnSystem DiagramnMG (Motor Generator)nInverter AssemblynHV BatterynAuxiliary BatterynTHS II Control SystemnIndicator and Warning LightnDiagnosisTHS IInOverall THS II Basic components are same as 03 PRIUS (THS)-A-K-W-QMG1EngineDifference Gear U

2、nitHV BatteryInverterMG2Planetary Gear UnitTHS IInTHS II Operation Nomographic chart Vertical lines show rpm and direction of rotation for: Sun Gear Planetary Carrier Ring Gear Spaces between vertical lines show gear ratios-A-K-W-QRotation DirectionForwardReverseTorquePlusDischargeChargeMinusChargeD

3、ischarge- MG1, MG2 Condition -THS IInTHS II Operation Engine Starting and Charging (vehicle stopped) MG1 operates as starter motor Current flowing to MG2 prevents it from turning-A-K-W-QTHS IInTHS II Operation Engine Starting and Charging (vehicle stopped) Engine turns MG1 to charge HV battery-A-K-W

4、-QTHS IInTHS II Operation Engine Starting and Charging (vehicle stopped)-A-K-W-QClick!MovieClick!MovieTHS IInTHS II Operation Vehicle Start off with engine starting Only MG2 is used when vehicle is starting off or under light load driving conditions-A-K-W-QTHS IInTHS II Operation Vehicle Start off w

5、ith engine starting MG1 operates to start the engine-A-K-W-QDrivenTHS IInTHS II Operation Vehicle Start off with engine starting-A-K-W-QClick!MovieClick!MovieTHS IInTHS II Operation During Slight Acceleration with Engine MG1 is operated by engine, and the electricity generated by MG1 is supplied to

6、MG2-A-K-W-QTHS IInTHS II Operation During Slight Acceleration with Engine-A-K-W-QClick!MovieClick!MovieTHS IInTHS II Operation During Full Throttle Acceleration Electricity to MG2 is supplied by MG1 and HV battery-A-K-W-QTHS IInTHS II Operation During Full Throttle Acceleration-A-K-W-QClick!MovieCli

7、ck!MovieTHS IInTHS II Operation During Deceleration Driving MG2 is turned by drive wheels, acting as generator to recharge HV battery-A-K-W-QTHS IInTHS II Operation During Deceleration Driving-A-K-W-QClick!MovieClick!MovieTHS IInTHS II Operation During Reverse Driving Only MG2 used for reverse drive

8、 power-A-K-W-QTHS IInTHS II Operation During Reverse Driving-A-K-W-QClick!MovieClick!MovieTHS IInSystem Diagram (Main Components)-A-K-W-QHV BatteryBrake ActuatorAuxiliary BatteryA/C CompressorA/C InverterDC DC ConverterSMR1, 2 and 3Boost ConverterMG1MG2Hybrid TransaxleInverterEngineShift Position Se

9、nsor(Shift, Select)Accelerator Pedal Position SensorEV Mode SwitchSpeed SensorsCANEngine ECU (ECM)Skid Control ECUBattery ECUHV ECUTHS IInMG (Motor Generator) MG1 and MG2 Basic construction and operation is same as 03 PRIUS-A-K-W-QMG1MG2Rated Voltage is increased(AC 273.6V AC 500V)THS IInMG (Motor G

10、enerator) MG2 Permanent magnets in the rotor arraigned in V-shape to increase motor output and torque-A-K-W-QV-shapedMagnetMG2 Rotor (04 PRIUS)MG2 Rotor (03 PRIUS)THS IInMG (Motor Generator) Specifications MG1-A-K-W-QItem04 PRIUS03 PRIUSTypeSynchronous AC MotorFunctionGenerator, Engine StarterRated

11、Voltage VAC 500AC 273.6Maximum OutputkW (PS) / rpm37.8 (51) / 950033.8 (45.9) / 8500Maximum TorqueNm (kgfm) / rpm45 (4.58) / 0 600038 (3.87) / 0 8500Amperage at maximum torqueArms7588Maximum rpm10,000 rpm9,500 rpmCooling SystemWater-cooledTHS IInMG (Motor Generator) Specifications MG2-A-K-W-QItem04

12、PRIUS03 PRIUSTypeSynchronous AC MotorFunctionGenerator, Wheel DriveRated Voltage VAC 500AC 273.6Maximum OutputkW (PS) / rpm50 (68) / 1200 154033 (45) / 1040 5600Maximum TorqueNm (kgfm) / rpm400 (40.8) / 0 - 1200350 (35.7) / 0 400Amperage at maximum torqueArms230356Maximum rpm6,700 rpm6,000 rpmCoolin

13、g SystemWater-cooledTHS IInInverter Assembly General Major difference-A-K-W-QBoost converter converts the voltage DC201.6 V to DC500 VCompact IPM (Intelligent Power Module) is adoptedA/C inverter for electric A/C compressorReferencenInverter Assembly General-A-K-W-Qto MG1to MG2to HV Batteryto A/C Co

14、mpressorTHS IInInverter Assembly System Diagram-A-K-W-QHV BatteryInverter AssemblyDC - DC ConverterA/C InverterBoost ConverterIPM (IGBT)ReactorMG1MG2InverterIPM (IGBT)THS IInInverter Assembly Inverter IPM (Intelligent Power Module) converts DC AC-A-K-W-QInverter AssemblyInverterHV BatteryDCACDCBridg

15、e Circuit for MG1, 2Signal Processor / Protective Function Processor03 PRIUSUnitedBoost ConverterMG1MG2IPM (IGBT)THS IInInverter Assembly Boost Converter DC 201.6V DC 500V conversion-A-K-W-QHV BatteryDC500 VBoost ConverterIPM (IGBT)ReactorDC 500VInverter AssemblyAC500 VMG2: Discharge: ChargeMG1Inver

16、ter(IPM)ReferencenInverter Assembly Boost Converter System diagram-A-K-W-QBoost ConverterInverterIPMPower TransistorReactorIGBTIPMHV BatteryMG1MG2THS IInInverter Assembly A/C inverter DC 201.6V AC 201.6V conversion to supplies the AC voltage to electric A/C compressor-A-K-W-QA/C CompressorHV ECUHV B

17、attery A/C ECUTarget Compressor SpeedA/C InverterInverter AssemblyReferencenInverter Assembly A/C inverter System diagram-A-K-W-QHV BatteryA/C CompressorCurrent SensorA/C InverterIGBTTemp. SensorVoltage SensorPower Supply CircuitGate Drive CircuitCPUHV ECUSystem Protection Control CircuitInput / Out

18、put InterfaceTHS IInInverter Assembly Cooling Radiators (for engine and inverter) are one piece-A-K-W-QRadiator(for Engine)Radiator(for Inverter)Water PumpReceiver Tank THS IInHV Battery General Located inside trunk behind rear seat-A-K-W-QHV Battery AssemblyService PlugTHS IInHV Battery Major Diffe

19、rence-A-K-W-QThe connection portion between each cells is addedInstallation method of service plug is changedDC 201.6 VDC 273.6 V38 modules 28 modulesCAN communication for battery ECUTemp. sensor is relocatedTHS IInHV Battery Components-A-K-W-QSMR1Battery ECU Amperage SensorService Plug ConnectorSMR

20、3SMR2ResisterModulesTHS IInHV Battery Battery Module Connection is added to reduce internal resistance -A-K-W-Q03 PRIUS04 PRIUSConnectionAmperageCellTHS IInHV Battery Battery ECU ECU is changed from 16-bit CPU to 32bit CPU and uses CAN Communication-A-K-W-QService PlugTemp. Sensors (Thermistor)CANBa

21、ttery Cooling Fan RelayBattery Cooling Fan MotorHV BatteryBattery Cooling Fan ControllerBEANAmperage SensorVoltage x 14+-Battery ECU(32-bit)HV ECUA/C ECUEngine ECU (ECM)Gateway ECUTemp. x 4THS IInTHS II Control System HV Battery Control Cooling fan motor is stepless controlled-A-K-W-QCooling Fan Mot

22、orDuty SignalCooling Fan ControllerMInput Duty Ratio(from Battery ECU)Output Voltage 3095413(%)(V)Cooling Fan ControllerBattery ECUTemp. Sensors (HV Battery)A/C ECUTHS IInHV Battery Cooling System Battery ECU executes a command to switch cooling fan ON when battery temp. rises-A-K-W-QBattery ModuleC

23、ooling FanAir Inlet: Temp. SensorCooling FanControllerReferencenHV Battery Cooling System Temp. sensors-A-K-W-QReverse SideBattery Temp. SensorsIntake Air Temp. SensorTHS IInHV Battery Service Plug Cut the high voltage circuit-A-K-W-QService PlugService PointnHV Battery Service Plug Installation-A-K

24、-W-QConnect the service plugTurn the leverPush the lever downward until the click is heard THS IInAuxiliary Battery General Auxiliary battery is relocated-A-K-W-QAuxiliary Battery (Sealed-type)HV BatteryTHS IInAuxiliary BatterynJump Start Terminaln+ terminal of auxiliary battery for jump start is ad

25、opted at engine room R/BJump Start Terminal-A-K-W-QTHS IInTHS II Control System Motive Force Suppression Control When wheel is slipping, HV ECU control the MG2 motive force and apply the hydraulic brake force-A-K-W-QMG2Traction Control Brake ForceInverterSpeed SensorHigh SpeedSkid Control ECUHV ECUE

26、ach wheel Speed SensorsSlipping THS IInTHS II Control System Motive Force Suppression Control When front wheels are slipped and vehicle rolls back on a steep slope, rear brakes are applied -A-K-W-QHV ECUTraction ControlBrake ForceSkid Control ECUMG2 Speed Sensor Signal etc.Prevents the vehicle from

27、sliding backwardsTHS IInTHS II Control System Uphill Assist Control When starting off on a steep slope, MG2 motive force is increased-A-K-W-QHV ECUIncrease MG2 motive forceMG2 Speed Sensor Signal etc.SlowlyWhen accelerator pedal OFFTHS IInTHS II Control System Motor Drive Mode Control In this mode,

28、the vehicle is driven with only MG2 by manually pushing on the EV mode switch -W-QDriveAccelerator Pedal Position SensorBattery ECUSOC ConditionBattery Temp.EV Mode SwitchSkid Control ECUSpeed SensorsCombination MeterGateway ECUEV Mode Indicator LightHV ECUInverterHV BatteryEngine ECUTHS IInTHS II C

29、ontrol System Motor Drive Mode Control EV mode switch is momentary type-W-QEV mode switch LHD ModelTHS IInTHS II Control System Motor Drive Mode Control Operation conditions-W-QEV ModeNormalPushEV mode canceling conditionsEV mode switch is pushedHV battery SOC dropsHV battery temp. is low or highEng

30、ine is warming upVehicle speed exceeds the specified speedThe accelerator pedal position angle exceeds the specified valueorTHS IInTHS II Control System Motor Drive Mode Control EV mode indicator light and buzzer -W-QEV Mode Indicator LightModeEV Mode IndicatorBuzzerNormal ModeOFFOFFNormal Mode EV M

31、odeONOFFProhibit “Normal Mode EV Mode”O(jiān)FFSounds 3 timesEV Mode Normal Mode (EV mode is canceled during EV mode)Blinks 3 times OFFSounds 3 timesTHS IInIndicator and Warning Light Combination Meter-A-K-W-QREADY LightMaster Warning LightMalfunction Indicator LightEV Mode Indicator Light (-W, -Q)THS IIn

32、Indicator and Warning Light Multi Display Warning marks-A-K-W-QAutomatic Headlight Leveling System WarningOil Pressure WarningHigh Engine Coolant Temperature WarningHybrid System AbnormalHV Battery WarningDischarge WarningEPS WarningTHS IInDiagnosis Inspection Mode Perform the following steps in order within 60 secondsChange the power mode to OFF inspection mode canceledOFF IG-ONDepress twiceDepress twiceDepress