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921783 | Transmission (Mechanics) | Internal Combustion Engine

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Toyota Prius manual
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  U.S. Department of Energy FreedomCAR and Vehicle Technologies, EE-2G 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121  FY 2007 EVALUATION OF 2004 TOYOTA PRIUS HYBRID ELECTRIC DRIVE SYSTEM INTERIM REPORT – REVISED  Prepared by: Oak Ridge National Laboratory Mitch Olszewski, Program Manager Submitted to: Energy Efficiency and Renewable Energy FreedomCAR and Vehicle Technologies Vehicle Systems Team Susan A. Rogers, Technology Development Manager July 2007    ORNL/TM-2004/247   ENGINEERING SCIENCE AND TECHNOLOGY DIVISION EVALUATION OF 2004 TOYOTA PRIUS HYBRID ELECTRIC DRIVE SYSTEM INTERIM REPORT – REVISED C. W. Ayers J. S. Hsu L. D. Marlino C. W. Miller G. W. Ott, Jr. C. B. Oland T. A. Burress Publication Date(s): Original Report–November 23, 2004 Revised Report–July 2007 Prepared by the OAK RIDGE NATIONAL LABORATORY Oak Ridge, Tennessee 37831 managed by UT-BATTELLE, LLC for the U.S. DEPARTMENT OF ENERGY Under contract DE-AC05-00OR22725      DOCUMENT AVAILABILITY  Reports produced after January 1, 1996, are generally available free via the U.S. Department of Energy (DOE) Information Bridge: Web site:  http://www.osti.gov/bridge Reports produced before January 1, 1996, may be purchased by members of the public from the following source: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone:  703-605-6000 (1-800-553-6847) TDD:  703-487-4639 Fax:  703-605-6900 E-mail:  info@ntis.fedworld.gov Web site:  http://www.ntis.gov/support/ordernowabout.htm Reports are available to DOE employees, DOE contractors, Energy Technology Data Exchange (ETDE) representatives, and International Nuclear Information System (INIS) representatives from the following source: Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831 Telephone:  865-576-8401 Fax:  865-576-5728 E-mail:  reports@osti.gov Web site:  http://www.osti.gov/contact.html This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.    ii TABLE OF CONTENTS Page LIST OF FIGURES.............................................................................................................................. iii LIST OF TABLES................................................................................................................................ iv ACRONYMS........................................................................................................................................ v ACKNOWLEDGEMENTS.................................................................................................................. vi REVISION INFORMATION (MAY 2007)......................................................................................... vi ABSTRACT.......................................................................................................................................... 1 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................................................................................................. 8 2.2 SYSTEM COMPONENTS.................................................................................................... 8 2.2.1 Engine......................................................................................................................... 8 2.2.2 Power Split Device..................................................................................................... 9 2.2.3 Generator.................................................................................................................... 11 2.2.4 Motor.......................................................................................................................... 12 2.2.5 Inverter........................................................................................................................ 12 2.2.6 Battery......................................................................................................................... 13 3. LABORATORY TESTING........................................................................................................... 14 3.1 ANL VEHICLE LEVEL PERFORMANCE TESTS............................................................. 14 3.1.1 Recent Work and Tests............................................................................................... 14 3.1.2 Future Test Plan.......................................................................................................... 17 3.2 ORNL COMPONENT-LEVEL PERFORMANCE AND VALIDATION TESTS............... 17 3.2.1 Locked Rotor Tests..................................................................................................... 18 3.2.2 Back-emf Tests........................................................................................................... 21 3.2.2.1 Motor tests..................................................................................................... 22 3.2.2.2 Generator tests............................................................................................... 23 3.2.3 Hybrid Drive System Losses Tests............................................................................. 24 4. INVERTER AND CONVERTER EVALUATION....................................................................... 30 4.1 FUNCTIONAL AND ARCHITECTURE STUDY............................................................... 30 4.2 CONTROL DEVELOPMENT............................................................................................... 30 4.3 INVERTER MODIFICATIONS AT ANL............................................................................ 31 5. SUMMARY AND CONCLUSIONS............................................................................................. 32 5.1 FINDINGS AND OBSERVATIONS.................................................................................... 32 5.2 NEEDED RESEARCH AND DEVELOPMENT.................................................................. 34 REFERENCES..................................................................................................................................... 35
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