03 - Killmann - Toyota - Hybrid Technology

Hybrid Technology –
System and vehicle design for mass production
A3PS Conference
“Alternative Propulsion Systems and Energy Carriers: Vehicle Integration and System Optimization”
Vienna, 18-19.November 2010
Gerald Killmann
Toyota Motor Europe
Copyright (C) 2010,TOYOTA MOTOR CORP.&TOYOTA MOTOR EUROPE. All Rights Reserved.
Powertrain map in future mobility
HVs & PHVs with FCHVs
internal combustion engine
Vehicle size
Route buses Heavy-duty

Passenger cars
trucks
EVs
FCHV(BUS)
Short-distance HV
commuters Delivery
trucks
Motorcycles
FCHV
EV
PHV
Small delivery vehicles

Winglet ｉ series Driving distance
Gasoline, diesel, bio-fuels, compressed
Fuel Electricity natural gas, gas to liquids, coal to liquids, etc. Hydrogen
History of Toyota & Lexus Hybrid Vehicles
’97 ’98 ’99 ’00 ’01 ’02 ’03 ’04 ’05 ’06 ’07 ’08 ’09 ’10
3rd Prius
2nd Prius
1st Prius
PHV
lim.lease
Auris
Coaster HV (series hybrid) RX400h RX450h
Estima HV Highlander Hybrid

(parallel hybrid)
Crown mild HV Camry Hybrid

Dyna
Diesel HV
GS450h
Estima Hybrid
LS600h
Crown Hybrid
Benefits of a full hybrid
Environment Fuel economy

Low emissions High fuel efficiency
(CO2, NOx, PM, HC)
Full
hybrid
Dynamic
Quietness
performance
Electric driving
Power &
acceleration
Example Prius III: Development Targets
Based on the THS architecture, which is well proven

in ~3.000.000 Toyota/Lexus hybrid vehicles sold:
1. Improvement of fuel consumption

Focus real world driving, highway cruising, winter season
2. Satisfaction of the most stringent emission regulations
3. Applicability of different vehicle models for full scale

mass production (lightweight, system output, cost)
Evolution of Hybrid System
1st system (1997) 2nd system (2003) 3rd system (2009)
Objective
First mass produced HV, Improved Performance Further improved on-road fuel
Outstanding fuel economy economy
1.5L Generator Power control 1.8L Atkinson Boost converter
(Max. 650V)
Atkinson unit Battery + Cooled EGR
engine
Overall Inverter
system Boost
Motor converter
(Max. 500V) High-rev.
Motor
Power split Chain Gear drive Reduction
Mechanical path
device drive Electrical path gear
Engine
output 43kW 57kW 73kW
Motor
output 33kW 50kW 60kW
Motor
max rev. 6,000rpm 6,400rpm 13,500rpm
Battery
(NiMH) 21kW 25kW 27kW
Vehicle
exterior
Engine Displacement
- Select 1.8L engine enlarged from current 1.5L engine
to improve fuel economy during high speed cruising
Engine operating point ( ) at 120km/h cruising (same road load)
2nd Prius (1.5L) : 2,500 rpm
3rd Prius (1.8L): 2,200 rpm
-300 rpm
2nd Prius 3rd Prius

30kW 40kW 30kW 40kW Operating line
20kW 20kW
Engine torque [Nm]
Engine torque [Nm]

10kW 10kW
Operating line
100 100
220
230 240g/kWh 240g/kWh
230
0 0
0 2000 4000 6000 0 2000 4000 6000
Engine speed [rpm] Engine speed [rpm]
Transmission and Motor
Motor speed reduction device
Compound gear
Parking gear Power split device ring gear
Planetary gear
Pinion gear
Sun gear
Motor reduction ring gear

Counter drive gear Fig．1 P410 Cross
Section
Motor speed reduction device Concept of motor downsizing

With motor speed reduction device
Compound gear Without motor speed reduction device
Parking gear Power split device ring gear (Motor Size)
Constant power line
Planetary gear Large
Pinion gear
Motor torque
Sun gear Small
Motor reduction ring gear
Counter drive gear Motor speed
Motor torque [Nm]
(motor current)
Constant power line
400Nm 2nd gen. Prius

(230A)
Max. motor
current -26% Max motor
by reduction gear 60kW output +20%
207Nm 3rd Prius by system voltage
(170A) 500v→650V
50kW
6400 13500
Motor revolution [rpm]
Generator length -34%
Motor length -27%
Mass reduction of electric machines 35%

Volume reduction of electric machines 40%
Transmission length -13mm (385 372mm)

Transmission weight -20% (109 88kg)
Mechanical transmission losses -20%

(bearing loss reduction, lubrication
optimisation, chain gear drive to diff.)
Power Control Unit
2nd Prius 3rd Prius
Cooling IGBT/ FWD Direct cooling structure

Insulating Solder
structure substrate Punched
Solder
plate
Heat sink
(Cooper alloy)
Grease Cold plate (Al)
Cold plate (Al)
Max.system 500V +150V 650V

voltage
Weight 21kg -45% 13.5kg
Volume 17.7L -37% 11.2L
Battery
2nd Prius 3rd Prius
Cooling system
optimisation
Comparison of battery system from vehicle frontside view

2nd Prius (white)
3rd Prius (grey)
Luggage space
415 liters +30 liters

445 liters
Battery: Energy Density
Energy density by weight (watt hours / kg)
Hydrogen Gasoline
10000 Bio-diesel
CNG
Ethanol Diesel
Liquid fuels
Gaseous fuels
Hydrogen
1000
absorbing
alloy
Batteries
Lithium-ion
Substantial R&D needed for batteries
100
Nickel metal to reach levels similar to
Lead conventional energy sources
10
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Energy density by volume (watt hours / litre)
Hybrid System Volume & Mass
Electrical System total volume reduction: 13%
Battery
Hybrid System total mass reduction : 17% Inverter
Motor
Index of electrical system total volume[%]
Transmission
Index of hybrid system total mass[%]

120 120
100 100
-13% -17%
80 80
60 60
40 40
20 20
0 0
2nd Prius 3rd Prius 2nd Prius 3rd Prius
Cost reduction for hybrid components: -40%

Fuel Economy, Emissions, Performance
- Fuel economy improvement: 7-14%
Test driving cycle 2nd Prius 3rd Prius
8.6%
U. S. Combined Mode 46 mpg 50 mpg
14.4%
NEDC Mode 104 g/km 89 g/km
7.0%
Japan 10-15 Mode 35.5 km/L 38.0 km/L
Vehicle Highway fuel consumption:

30-50mph acceleration time [sec]
3.0
Performance: 3.5
3rd
New od
120km/h const. speed: -10%
Go
+ 5% 4.0 Prius
★
4.5 2nd gen.
5.0
Prius ●
Emission level:
5.5 First - Europe: Step 5
●
6.0
14.0 12.0 10.0 8.0 6.0
- US: SULEV/ATPZEV
0-60mph - Japan: S-ULEV
acceleration time [sec]
Fuel Consumption Improvement
Hybrid transmission contributes directly and

indirectly by improving the engine operation
City Mode Highway Mode
100 Engine
Consumption [%]
improvement
Index of Fuel
Engine
operating area
Idle stop
Regeneration
50
THS :Toyota
Base THS vehicle Hybrid System
Vehicle (AT)
CO2 and NOx emissions
300
Source: VCA data 2004, 2008
Gasoline European C segment
vehicles
250
Low CO2 Emission
2004
2008
Diesel
200 2004
TtW CO2(g/km)
2008
Auris 2.2L
150 DPNR
100 2004 Prius

2009 Prius
50
0 0.05 0.10 0.15 0.20 0.25 0.30

Clean TtW NOx(g/km)
Hybrid transmission allows to use the full environmental potential of engines

Environmental performance
The Next Step: Plug-in hybrid (PHV)
Gasoline station Household electrical energy

or public charging post
Engine
Motor Battery
Fuel tank
PHV: “the best of both worlds”

Driving range and convenience
PHV in full HV mode
Holiday EV
Work
PHV in
EV mode Day trip
Shopping Gym
School
Trip Frequency
Camp Regular
Family Occasional
Visit
EV range impact on vehicle package
Prius
30 battery
25
Electricity (kWh)
Prius
battery
20
+120kg
Replacement
15
Prius
10 battery
0 20 40 60 80 100
EV range (km)
Road trial: daily trip length
Cumulative
100%
Test vehicle:
80% 80% of daily trips < 25km PHV based on

Prius 2,
10km EV range
Trips (%)
60%
55% of daily trips < 10km
40%
20%
PHV tests with EDF

0% Nov 07-June 08
0 10 20 30 40 50 60 70 80 90 100
Trip range (km)
Road trial: fuel efficiency
L/100km
km/L
Test vehicle:
10 10 PHV based on
5 20 Prius 2,
10km EV range
Improvement:
2.5 40 60% fuel efficiency
37.5% fuel consumption
1.33 60 for trips < 25km
1.25 80
1.0 100 PHV tests with EDF

0 10 20 30 40 50 60
Fuel efficiency (km/L)
Nov 07-June 08
Fuel Consumption
Driving distance of 1 trip (km)

(L/100km)
Plug-in Hybrid: CO2 reduction potential
CO2 reduction in well-to-wheel highest with CO2-free electric energy
First PHV application
Limited lease, globally 600 (Europe ~200)
Cooperation with electricity providers

(e.g. EDF France: Strassburg)
Development targets:
• EV range: ~20 km (Li-ion battery)
• CO2 figures: <60 g/km
• EV max speed: ~100 km/h
• Charging time: less than 2 hours (220V, 16A)
• Normal vehicle useability (5 persons + trunk)
Next: PHV mass production start 2012
Toyota Hybrid System applications
Using hybrid technology for PHV, EV and FCHV
HV
Engine
Motor
Fuel
tank
Battery PHV EV FCHV
Engine Engine Engine

Motor Motor FC stack Motor
Fuel Fuel H2
tank tank tank
Battery Battery Battery
Conclusion
Hybrid is a key technology for all type of powertrains
Ultimate Eco-Car
Energy diversity CO2 reduction Air quality
Plug-in Hybrid technology
Hybrid technology
Gasoline, Gaseous Biofuels Synthetic Electricity Hydrogen

diesel fuels fuels
The right car, the right place, the right time
Towards 1 million Toyota hybrid vehicles per year
Thank you very much

for your kind attention!

03 - Killmann - Toyota - Hybrid Technology

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03 - Killmann - Toyota - Hybrid Technology

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Hybrid Technology –

System and vehicle design for mass production

Route buses Heavy-duty

Small delivery vehicles

Coaster HV (series hybrid) RX400h RX450h

Estima HV Highlander Hybrid

Crown mild HV Camry Hybrid

Environment Fuel economy

Based on the THS architecture, which is well proven

1. Improvement of fuel consumption

2. Satisfaction of the most stringent emission regulations

3. Applicability of different vehicle models for full scale

2nd Prius 3rd Prius

Engine torque [Nm]

Motor speed reduction device

Motor reduction ring gear

Motor speed reduction device Concept of motor downsizing

400Nm 2nd gen. Prius

Generator length -34%

Motor length -27%

Mass reduction of electric machines 35%

Transmission length -13mm (385 372mm)

Mechanical transmission losses -20%

Cooling IGBT/ FWD Direct cooling structure

Max.system 500V +150V 650V

Volume 17.7L -37% 11.2L

2nd Prius 3rd Prius

Comparison of battery system from vehicle frontside view

3rd Prius (grey)

415 liters +30 liters

Index of hybrid system total mass[%]

Cost reduction for hybrid components: -40%

Vehicle Highway fuel consumption:

Hybrid transmission contributes directly and

100 2004 Prius

0 0.05 0.10 0.15 0.20 0.25 0.30

Hybrid transmission allows to use the full environmental potential of engines

Gasoline station Household electrical energy

PHV: “the best of both worlds”

80% 80% of daily trips < 25km PHV based on

PHV tests with EDF

1.0 100 PHV tests with EDF

Driving distance of 1 trip (km)

CO2 reduction in well-to-wheel highest with CO2-free electric energy

Cooperation with electricity providers

Next: PHV mass production start 2012

Using hybrid technology for PHV, EV and FCHV

Battery PHV EV FCHV

Engine Engine Engine

Battery Battery Battery

Gasoline, Gaseous Biofuels Synthetic Electricity Hydrogen

The right car, the right place, the right time

Thank you very much

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