890029.PDF

U.S. Department of Energy

FreedomCAR and Vehicle Technologies, EE-2G

1000 Independence Avenue, S.W.

Washington, D.C. 20585-0121

FY 2006

Evaluation of 2004 Toyota Prius

Hybrid Electric Drive System

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

May 2005

ORNL/TM-2006/423

Engineering Science and Technology Division

Evaluation of 2004 Toyota Prius

Hybrid Electric Drive System

R. H. Staunton

C. W. Ayers

L. D. Marlino

J. N. Chiasson

University of Tennessee-Knoxville

T. A. Burress

Oak Ridge Institute for Science and Education

Publication Date: May 2006

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

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TABLE OF CONTENTS

Page

LIST OF FIGURES .............................................................................................................................. v

LIST OF TABLES ................................................................................................................................ vii

ACRONYMS AND ABBREVIATIONS ............................................................................................. viii

1. INTRODUCTION .......................................................................................................................... 1

1.1 PROGRAM OVERVIEW ......................................................................................................

1.2 TESTING FACILITIES ......................................................................................................... 2

1.3 SCOPE AND OBJECTIVE....................................................................................................

1.4 APPROACH........................................................................................................................... 3

HYBRID ELECTRIC DRIVE SYSTEM DESCRIPTION ............................................................

2.1 DESIGN REQUIREMENTS .................................................................................................

2.2 SYSTEM SUBASSEMBLIES ...............................................................................................

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 ..................................................................................................... 21

3.2.2.2 Generator tests ............................................................................................... 22

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

INVERTER, CONTROLLER, AND Z-SOURCE ACTIVITIES .................................................. 40

4.1 INVERTER ARCHITECTURE OVERVIEW....................................................................... 40

4.2 INVERTER MODIFICATIONS............................................................................................ 40

4.3 CONTROLLER DEVELOPMENT ....................................................................................... 41

4.3.1

Establishing the Need for Field Weakening ............................................................... 42

4.3.2

Controller Software..................................................................................................... 43

4.3.3

Controller Hardware ................................................................................................... 44

iii

4.4 COMPARISION OF PRIUS INVERTER AND Z-SOURCE INVERTER........................... 47

TABLE OF CONTENTS (cont’d)

Page

5. HEV SYSTEM MANUFACTURING AND PACKAGING ......................................................... 49

5.1 PMSM .................................................................................................................................... 49

5.2 INVERTER/CONVERTER ................................................................................................... 50

5.3 CONVERTER COMPONENTS ............................................................................................ 56

6. SUMMARY AND CONCLUSIONS ............................................................................................. 60

6.1 FINDINGS AND OBSERVATIONS .................................................................................... 60

6.2 NEEDED RESEARCH AND DEVELOPMENT .................................................................. 63

REFERENCES ..................................................................................................................................... 64

APPENDIX A – DRIVE-CYCLE PLOTS SHOWING CONVERTER OPERATION ....................... 65

APPENDIX B – PRIUS PERFORMANCE-MAPPING DATA ......................................................... 69

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