Tài liệu xe ô tô Lexus Hybrid - P2

1
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Contents
Click a Section Tab
2
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Overall
Hybrid System Operation
System Diagram
Components
MG (Motor Generator)
Inverter Assembly
Cooling System
HV Battery
HV Control System
Special Notes on Service
3
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Overall
Main Components
-A -W
HV Battery
Inverter
Assembly
Power Split
Planetary
Gear Unit
2-stage Motor
Speed Reduction
Device
Engine

MG1 MG2
Transfer
4
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Overall
Gear Train
–
2 planetary gear units
-A -W
Engine
Damper
MG1
2-stage Motor Speed
Reduction Device
Power Split Device
Ring Gear
Pinion Gear
Ring Gear
Sun Gear
Front Sun
Gear
Long Pinion Gear
Rear Sun
Gear
Planetary Carrier
Planetary
Carrier
Short
Pinion Gear
Output

Shaft
MG2
B1 B2
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Overall
Major Difference From GS450h
-A -W
•
Located in the HV battery unit
•
Cooling system (cabin air and cold air from rear A/C unit)
DC-DC Converter
(auxiliary battery)
•
8-step Sequential shiftmatic system is used
•
Deceleration rate control by mode select switch
HV Control
•
DC 288 V (20 module x 12 cell)
•
Cooling system (cabin air and cold air from rear A/C unit)
HV Battery Unit
•
Weight reduction (approx. 18.1 kg [40.0 lb] to approx. 20.2 kg
[44.5 lb])
Inverter
•
Specification is changedMG1, 2

ContentsItem
6
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
2-stage Motor Speed Reduction Device
–
Hi or Lo gear is selected in accordance with the vehicle
speed (MG2 speed) and accelerator pedal opening
angle, etc.
-A -W
2-stage Motor Speed
Reduction Device
Vehicle Speed (km [mph])
Lo
Hi
Gear
Position
For -A
73.0 (45.3)
42.3 (26.3)
85.2 (52.9)49.3 (30.6)
For -W
[Normal Driving Example]
MG2
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Nomographic Chart (Hybrid System Operation)
DischargeCharge-
ChargeDischarge+
Torque

-+
Rotation Direction
- MG1, MG2 Condition -
Power Split Planetary Gear Unit
2-stage Reduction Planetary Gear Unit
Sun Gear
(MG1)
Carrier
(Engine)
Ring Gear
(Wheel)
Rear
Sun Gear
(MG2)
-A -W
Ring
Gear
(Lo)
Front
Sun Gear
(Hi)
Carrier
(Wheel)
Linked
At Lo gear
-
+
rpm,
Torque
MG2

MG1
Engine
At Hi gear
+
-
rpm,
Torque
8
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Engine Starting (Vehicle Stopped)
-A -W
Engine MG1
AcceleratorBrake
R
N
DS
+
-
P
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MotorPassive Stop GeneratorActive
HV Battery
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0

MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
P
I
G M
B
R
:Electric Path
(Supply)
:Electric Path
(Charge)
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
9
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Idling (Vehicle Stopped)
-A -W
Engine MG1

R
N
DS
+
-
P
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
P
I

G M
B
R
:Electric Path
(Supply)
:Electric Path
(Charge)
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
10
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Vehicle Start-off
-A -W
Engine MG1
R
N
DS
+
-
P
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON

Vehicle Speed
0
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
I
G M
B
:Electric Path
(Supply)
:Electric Path
(Charge)
P
R
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
11
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician

Hybrid System Operation
Vehicle Start-off with Engine
-A -W
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
Engine MG1
R
N
DS
+
-
P
MotorPassive Stop GeneratorActive
MG2
Motor Generator
ON ON
HV Battery

AcceleratorBrake
I
G M
B
:Electric Path
(Supply)
:Electric Path
(Charge)
R
P
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Normal Driving
-A -W
Engine MG1
R
N
DS
+
-
P
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2

ON ON
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
I
G M
B
:Electric Path
(Supply)
:Electric Path
(Charge)
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
R

P
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
During Full Throttle Acceleration
-A -W
Engine MG1
R
N
DS
+
-
P
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+

+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
I
G M
B
R
:Electric Path
(Supply)
:Electric Path
(Charge)
P
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
During Full Throttle Acceleration
-A -W
Engine MG1
R
N
DS
+
-
P

MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
I
G M
B
R
:Electric Path
(Supply)
:Electric Path
(Charge)

P
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
High Speed Cruising
-A -W
Engine MG1
R
N
DS
+
-
P
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MG1
Engine
Wheel MG2Lo Hi
0

(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
I
G M
B
R
:Electric Path
(Supply)
:Electric Path
(Charge)
P
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Deceleration in D Range
-A -W
Engine MG1
R
N

DS
+
-
P
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
:Electric Path
(Supply)
:Electric Path
(Charge)

P
I
G M
B
R
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Deceleration in S Range
-A -W
Engine MG1
R
N
DS
+
-
P
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly

MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
:Electric Path
(Supply)
:Electric Path
(Charge)
P
I
G M
B
R
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Driving in Reverse

-A -W
Engine MG1
R
N
DS
+
-
P
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MotorPassive Stop GeneratorActive
MG2
Motor Generator
B1 B2
ON ON
Vehicle Speed
0
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake

:Mechanical
Path (Active)
:Mechanical
Path (Passive)
:Electric Path
(Supply)
:Electric Path
(Charge)
P
I
G M
B
R
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Hybrid System Operation
Driving with EV Drive Mode
-A -W
Engine MG1
R
N
DS
+
-
P
P: Power Split Device R: 2-stage Motor Speed Reduction Device
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly
MotorPassive Stop GeneratorActive
MG2
Motor Generator

B1 B2
ON ON
Vehicle Speed
0
MG1
Engine
Wheel MG2Lo Hi
0
(C)
(S)
(R/C)
+
+
(Sr)(R) (Sf)
0
HV Battery
AcceleratorBrake
I
G M
B
:Electric Path
(Supply)
:Electric Path
(Charge)
P
R
:Mechanical
Path (Active)
:Mechanical
Path (Passive)

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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
-A -W
System Diagram
System Diagram (Overall)
21
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
-A -W
Components
Layout of Main Components
HV Battery Unit
• Battery Module (DC 288 V)
• DC/DC Converter
for Auxiliary Battery
•
Junction Block
•
Battery Smart Unit
Power Cable
Inverter Assembly
• Boost Converter
• Inverter
• MG ECU
NOTE: This is LHD model illustration
Auxiliary
Battery
Engine ECU (ECM)
HV ECU
DC/DC Converter
for EPS and Active Stabilizer

L110F Hybrid Transmission
• MG1 & MG2
• Electric Oil Pump
2UR-FSE
Engine
Electric A/C
Compressor with Inverter
Oil Pump
Controller
Water Pump
for HV System
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
MG (Motor Generator)
MG1 and MG2 Specifications
-A -W
Low / High Gear* 1072 (792) / 522 (386)1170 (862) / 570 (420)
Max. System Voltage
Max. Torque
Max. Output [kW (HP]
Type
Max. System Voltage
Type
MG2
MG1
Water-cooled
Water-cooled and
Oil-cooled (ATF)
Cooling System
←AC 650 V

275 Nm (203 ftlbf)300 Nm (221 ftlbf)
147 kW (197 HP)165 kW (221 HP)
←Permanent Magnet Motor
←AC 650 V
←Permanent Magnet Motor
GS450hLS600hL / LS600h
MG
(Motor Generator)
MG1
MG2
*: Torque is boosted 3.90 times by the Lo gear, and 1.90 times by the Hi gear of the
2-stage motor speed reduction device.
23
Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Inverter Assembly
Location
–
The inverter assembly for the LHD models and RHD
models is not same (symmetric appearance).
-A -W
LHD Models
RHD Models
Inverter Assembly
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Inverter Assembly
Main Components and Functions of Inverter Assembly
-A -W
Converts the high-voltage direct current from the boost converter into three-
phase alternating current for driving the MG1 and MG2.

Inverter
OutlineItem
Controls the inverter and boost converter in order to drive the MG1 or MG2, or
causes them to generate electricity in accordance with the signals received
from the HV ECU.
Boosts the nominal voltage of DC 288 V that is output by the HV battery to
the maximum voltage of DC 650 V. The boost converter consists of the boost
IPM (Integrated Power Module) with a built-in IGBT (Insulated Gate Bipolar
Transistor) which performs the switching control, and the reactor which stores
energy. By using these components, the boost converter boosts the voltage.
MG ECU
Boost
Converter
High-voltage Cable
Terminal for MG1
Inverter with Converter
Connector (low-voltage)
MG ECU
Portion
Coolant Opening
(from Radiator)
High-voltage Cable
Terminal for A/C Compressor
High-voltage
Cable Terminal
for HV Battery
NOTE: These are LHD model illustrations
High-voltage Cable
Terminal for MG2
Inverter

and Boost
Converter
Portion
High-voltage
Capacitor
Portion
Coolant Opening
(to Hybrid Transmission)
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Body ElectricalModel Outline Hybrid System Engine Chassisfor Technician
Inverter Assembly
System Diagram
-A -W
Hybrid Transmission
MG ECU
Auxiliary
Battery
Boost Converter
(DC 288 V ⇔ DC 650 V [max.])
Inverter (DC ⇔ AC)
Electric A/C
Compressor
with Inverter
HV Battery Unit
for MG1 for MG2
MG1
MG2
Battery
Modules
Inverter Assembly

DC/DC Converter
[Auxiliary Battery]
(DC288vV ⇒ DC 12 V)
SMR
HV ECU