Common faults and optimizing of Toyota Prius HEVs

EE 3203

W.N.L. Weerakkody 100573H EE 3202 Department of Electrical Engineering

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Contents
Page No 1. Abstract 2. Introduction 3. Literature Review 4. Objective 5. Work 6. Common Parts & Terminology 7. What is Synergy Drive? 8. Faults & Problems in HEVs 9. Manufacturer faults in Prius HEVs 10. Optimizing fuel 11. Acknowledgement 12. Reference 13. Appendices 3 4 6 9 10 10 12 13 14 16 18 19 20

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Abstract
Hybrid Electric Vehicles or HEVs are becoming visible to us on roads increasing the number day-byday due to its growing popularity in an exponential manner. According to sources, today, we have about 6 million hybrid electric vehicles worldwide and the truth is almost 4 million out of that 6 million has been sold during the last couple of years and by that, we can measure the trend to buy HEVs. I chose this subject Common faults and optimizing of HEVs since we see a huge trend in HEVs in Sri Lanka as well. First, I personally contacted quite a few hybrid users and asked them about the problems they faced and about the pros and cons of the HEVs they use and a selected set of observations are attached at the appendix. Then I visited Toyota Lanka and Arabian Motors Ltd where Hybrid repairing and services has been done throughout the time even when HEVs were not that famous in Sri Lanka. Most common faults that I came across were, Inverter water pump fault Horn wiring fault Front wheel bearing fault Countermeasure part fault Electric power steering (EPS) pinion shaft nut fault Power window switch fault Braking system fault HID light system fault

The problem is that almost for all these faults you have to replace the part. Then I tried to find out that how can we optimize a drive cycle of a Prius. For that one, the conclusion that I received was sooth acceleration, smooth braking and keeping the battery at a charge around 60%.

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Introduction
What is a HEV? First and foremost, HEV stands for Hybrid Electric Vehicle. As the Wikipedia claims HEV or a hybrid electric vehicle is a type of hybrid vehicle which combines a conventional internal combustion engine (ICE) propulsion system with an electric propulsion system. The popularity of these hybrid electric vehicles started to rise up exponentially in the recent past and hence many people were interested in buying HEVs. Many myths and stories related with it grew among the general public as well. It is high time to solve these mysteries because day-by-day, the gasoline oil prices are climbing sky high and we are running short of petrol as predicted by the analysis of oil repositories and it is said that the remaining oil would be enough only for 30 more years. So, to save fuel, it is better to switch into HEVs instead of conventional vehicles since it has become the most reliable technology that is adopted into vehicles up to now. There are technologies like the air car concept, fuel cell vehicles and hydrogen vehicles. But yet, the most successful solution is the hybrid electric vehicle. The presence of the electric powertrain (which will be described later in a chapter) is intended to achieve either better fuel economy than a conventional vehicle or better performance. Many types of hybrid electric vehicles are available today. We categorize them by degree to which they function as an electric vehicle and so on. Modern HEVs make use of efficiency-improving technologies such as regenerative braking, which converts the vehicle's kinetic energy into electric energy to charge the battery, rather than wasting it as heat energy as conventional brakes do which will be described in a chapter below. Some varieties of HEVs use their internal combustion engine or ICE to generate electricity by spinning an electrical generator (this combination is known as a motor-generator), to either recharge their batteries or to directly power the electric drive motors which happens differently in different kinds of hybrids like series hybrids and parallel hybrids. Many HEVs reduce idle emissions by shutting down the internal combustion engine at idle and restarting it when needed in the hybrid electric vehicles. This phenomenon is known as a start-stop system. Hybrid electric vehicles produce less emission from its ICE than a conventional gasoline car of same caliber, since an HEV's gasoline engine is usually smaller than a comparably-sized pure gasoline vehicle because it optimizes gasoline with the use of electric power as well as optimizing the fuel supplied. If not we use the energy taken from burnt fuel to directly drive the car, it can be geared to run at maximum efficiency, further improving fuel economy. As I mentioned before, here in Sri Lanka people have many myths about HEVs. One such thing is manufacturer faults. The most significant of them is that people believe that the batteries of HEVs are not good and not durable enough. But it is not true. Yes. The battery pack is somewhat highpriced, but yet it is way better in performance than a usual rechargeable battery that people know most of the times. Things like this have been addressed in this survey. People hesitate sometimes to buy a hybrid over conventional cars as they are not satisfied enough with the fuel economy of the car and some say that, the extra money that you have to pay for an Page | 4

HEV is not worth at a repair after a period of time. But, by optimizing the driving style, we can achieve higher mileage per unit fuel and that matter will also be addressed. For this project, I selected Toyota Prius specifically since it has become the number one selling Hybrid vehicle brand all over the world owning to more than half the number of vehicles sold all over the world and this will be there under literature review. There are so many myths related with HEVs. But yes, there are some very few common faults. With this, I hope to explain the real common faults about the HEVs.

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Literature Review
In the year 1901, Ferdinand Porsche became the first person to develop the first gasoline-electric hybrid vehicle of the world, the Lohner-Porsche Mixte Hybrid. At that time, the hybrid electric vehicle did not become available. The first major issue to the market was done by Toyota as a very much upgraded version of its predecessor, the above mentioned Porche vehicle and it was the new Toyota Prius built in Japan in 1997. Soon, it another competitor came into the market produced by Honda and that was Honda Insight which started its production in 1999. But as early as that, the gasoline prices in the world was very low comparing with the extra cost that you have to pay for a hybrid electric vehicle. As far as I can remember, the diesel price in 1999, when my family bought our first van was just Rs. 13.50 and the price of petrol was just around Rs. 50.00 according to my memory.

Source: sundaytimes.lk The above diagram shows the increment in fuel prices in Sri Lanka just for 2007. Around this period of time, the fuel prices were so high and we climbing up continuously. So, due to that, hybrid electric vehicles came to the arena since it seemed that HEVs were pretty much feasible solution for end users since the oil price climbed and now, the price of a hybrid electric vehicle became reasonable for people. But the things were different in other countries of the world and they became interested in HEVs after the late 2000s and now in countries like United States of America, they have tenthousands of hybrid electric vehicles available for sale and they have become pretty much affordable as well as reliable for people. It is said that, around 6 million hybrid electric vehicles have been sold worldwide up to now. Just note that the world population is around 6 billion and there are 6 million hybrid electric vehicles in the world. The most number of HEVs have been produced by Toyota Motor Company selling around 4.5 5 million Toyota hybrid and Lexus hybrids (Lexus belongs to Toyota as well) up to now. They are distantly followed by Honda Motor Co., Ltd. by selling around 1 million hybrids up to now and Ford Motor Corporation selling around 0.2 million hybrids mostly in USA up to now. Toyota and most of the other HEV selling companies have an incredible growth in selling hybrids with Toyota selling 4 million hybrids within just below 3 years. That is 2/3 of their all-time hybrid electric vehicle sales Page | 6

Toyota Prius being the leader not only in Sri Lanka, but also in the world arena selling around 3 million units around the globe. Hybrid electric vehicles can be according to many factors. First, hybrid electric vehicles can be categorized by the degree of hybridization. Those are, Full Hybrid Mild Hybrid

Full Hybrids This type of hybrids is also called strong hybrids as well. These types can be run under 3 cases. They can run on just the engine, or it can run on just the batteries, or it might be a combination of both systems. These cars can be driven on battery power alone. A huge and high capacity battery pack is needed this operation. Examples for full hybrid systems: Toyota's Hybrid Synergy Drive which is used in Toyota Prius and Toyota Aqua Ford's hybrid system which is used in Ford Fusion Hybrid and Ford Escape Hybrid Chrysler's Two-Mode Hybrid technology

Mild Hybrids Hence the electric motor doesnt have enough power to move the vehicle on its own, Mild hybrids use the Internal Combustion Engine and the Electric Motor together. Mild hybrids have lesser fuel economy than full hybrids generally and they lack some technological aspects of full hybrid technology. Usually, they can save fuel, 15% in urban driving and 8 10% in overall cycle comparing with an ordinary vehicle of same caliber. But it is yet, way less than the saving of a full hybrid. A mild hybrid is essentially a conventional vehicle with oversize starter motor, allowing the engine to be turned off whenever the car is coasting, braking, or stopped, yet restart quickly and cleanly. The motor is often mounted between the engine and transmission, taking the place of the torque converter, and is used to supply additional propulsion energy when accelerating. Accessories can continue to run on electrical power while the gasoline engine is off, and as in other hybrid designs, the motor is used for regenerative braking to recapture energy and Regenerative breaking will be described a little later. As compared to full hybrids, mild hybrids have smaller batteries and a smaller, weaker motor/generator, which allows manufacturers to reduce cost and weight. Honda's early hybrids including the first generation Insight used this design. Starting with the 2006 Civic Hybrid, the IMA system or Integrated Motor Assist (a technology by Honda)now can propel the vehicle solely on electric power during medium speed cruising. Another example is the 2005-2007 Chevrolet Silverado Hybrid, a full-sized pickup truck. Chevrolet was able to get a 10% improvement on the Silverado's fuel efficiency by shutting down and restarting the engine on demand and using regenerative braking.

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Hybrid electric vehicles can be classified by the way in which power is supplied to the drivetrain of the vehicle. Parallel Hybrids Series Hybrids Power-Split Hybrids

Of these all, Toyota Prius Hybrid is special since it has the best fuel efficiency of its class and because it is the best-selling HEV in the world. Parallel Hybrids In parallel hybrids, the Internal Combustion Engine and the electric motor are both connected to the mechanical transmission and can simultaneously transmit power to drive the wheels, usually through a conventional transmission. Honda's Integrated Motor Assist (IMA) system as found in the Insight, Civic, Accord, as well as the GM Belted Alternator/Starter (BAS Hybrid) system found in the Chevrolet Malibu hybrids are examples of production parallel hybrids. Current, commercialized parallel hybrids use a single, small (<20 kW) electric motor and small battery pack as the electric motor is not designed to be the sole source of motive power from launch. Parallel hybrids are also capable of regenerative braking and the internal combustion engine can also act as a generator for supplemental recharging. Parallel hybrids are more efficient than comparable non-hybrid vehicles especially during urban stop-and-go conditions and at times during highway operation where the electric motor is permitted to contribute by the embedded computer. Series Hybrids In series hybrids, only the electric motor drives the drivetrain, and the ICE works as a generator to power the electric motor or to recharge the batteries. The battery pack can be recharged through regenerative braking or by the ICE (internal Combustion Engine). Series hybrids usually have a smaller combustion engine but a larger battery pack as compared to parallel hybrids, which makes them more expensive than parallels. This configuration makes series hybrids more efficient in city driving. Power-Split Hybrids Power-split hybrids have the benefits of a combination of series and parallel characteristics. As a result, they are more efficient overall, because series hybrids tend to be more efficient at lower speeds and parallel tend to be more efficient at high speeds; however, the cost of power-split the hybrid is higher than a pure parallel. Examples of power-split (referred to by some as "seriesparallel") hybrid powertrains include current models of Lexus and Toyota. Of all these a power-split hybrid, a full hybrid, Toyota Prius is special and lets see what are the common faults occur in these Prius Hybrid cars.

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Objective
In Sri Lanka at present, there is a huge trend in Hybrid Electric Vehicles. In order to support everybody to understand and find the common faults, drawbacks, cons and pros of HEVs, this project is done.

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Discussion
As hybrid cars become more and more popular exponentially, it is important to understand how they work. Just as the name implies, a hybrid electric vehicle is a combination or hybrid of a gas and an electric motor. The two motors work together with a number of some other factors. These added advantages the vehicles fuel efficiency and lower its emissions, and overcome the shortcomings that each type of engine has on its own. Hybrids use advanced technology to wring every mile out of each gallon of gas or watt of electric power. Hybrid vehicles have been around for a long time, many locomotives are diesel-electric hybrids and some cities have diesel-electric buses. However, it is only in recent years that gas-electric hybrid passenger vehicles have become popular. Common Parts and Terminology All gas-electric hybrids have certain parts in common. The following list describes these most common parts of them. Gas Engine This is a gas engine like most cars have except that it is smaller. Most hybrids have 3-cylinder engines that produce 65 to 80 horsepower. These engines are usually outfitted with advanced technologies that help them run more efficiently. Hybrid cars have a fuel tank like any normal vehicle. Electric Motor The electric motors are very sophisticated and expend energy to get the vehicle moving but also generate and store electricity through technologies such as regenerative braking and in idling. Generator The generator's sole job is to produce electrical power. Battery It stores the electrical energy that the vehicle produces and is needed to power the electric engine. Transmission A transmission on a hybrid vehicle does the same thing the transmission does on a normal car, it transfers power to the wheels. There are two main types of transmissions in gas-electric hybrid vehicles, parallel or series. Parallel Transmission Parallel transmission allows both the gas and electric engine to turn the transmission. Computer controls help these components work together in the most efficient way possible. The electric motor will do a lot of the work at low speeds and let the gas engine take over as speed climbs.

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Series Transmission In series transmission, the electric motor is the only motor that is connected to the transmission. The gas engine is connected to a generator and is used to generate electrical energy. An onboard computer determines what percentage of power comes from the battery pack and how much comes from the generator. In addition to these parts, hybrids use other tricks and technologies to improve fuel efficiency and lower emissions. Regenerative Braking Brakes remove energy from a moving car. A hybrid car captures some of this energy and stores it in the battery pack. The electric motor slows the car and by acting as a generator it charges the batteries. Regenerative braking and regenerative brakes are features that can be found in fully electric and gas-electric hybrid vehicles. Cars like the hybrid Toyota Prius, Ford Fusion Hybrid and Honda Insight, and the fully electric Tesla Roadster feature regenerative braking systems.Regenerative braking systems capitalize on the similarities in construction of electric motors and electric power generators. An electric motor's interior is made up of copper windings. It uses an electromagnetic energy field to produce torque through its main shaft when power is applied to it. A generator or dynamo is also comprised of copper windings and makes use of an electromagnetic field; applying a force to turn its rotor allows it to produce electric power. Regenerative braking is based on the principle of physics that states that energy cannot be destroyed; it can only be transformed from one form to another. Traditional Braking Systems In a traditional braking system, pressing on the brake pedal causes a pair of brake pads in each wheel to come into contact with the surface of a brake rotor. This contact produces friction, slowing down and eventually stopping the vehicle. The friction itself produces heat as an energy byproduct. Automotive engineers and designers generally perceive heat as a loss. This is the reason why, especially in high performance cars, brake cooling systems such as air dams are employed to dissipate heat from the brakes so that they can quickly regain their efficiency. Regenerative Braking Systems In a regenerative braking system, the objective is to recapture the energy byproduct that results when the brakes are applied. In electric or hybrid automobiles, the electric motor that drives the car's wheels plays a major part during braking. When the brake pedal is pressed, the regenerative braking circuit switches the motor so that it now operates in reverse to counter the direction of the wheels. This reversal actually makes it perform like a power generator or dynamo that produces electrical energy. The electricity developed is routed towards the car's storage batteries to recharge them. The efficiency of regenerative braking systems in use today has improved significantly. Some existing systems are able to capture and store as much as 70 percent of the energy that would otherwise have been lost. At higher speeds, regenerative brakes still require the assistance of traditional brake systems to be applied as a backup. This recapturing and storing of electrical energy Page | 11

may be likened to "trickle" charging of the batteries. This is because most of the time, the electric motor runs in torque producing mode to drive the vehicle. The recommended battery charging method still has to be performed to charge the batteries fully, although regenerative braking does translate to an increase in vehicle range. Idle Off A hybrid will turn the gas engine off when the car is stopped at a light or stop sign. The electric engine then powers the car as you start up again and switches to the gas engine or generator as higher speeds are reached. Advanced Materials and Design Hybrids use lightweight materials like aluminum and carbon fiber to reduce the weight of vehicle. Aerodynamic designs help cut back on drag helping to increase fuel efficiency.

All of these technologies combined help produce some very impressive gas mileage statistics. As these technologies improve we will see greater increases in fuel efficiency, and advances like plug in hybrids may eventually eliminate the need for gasoline altogether for short commutes.

How does a HEV work What is Synergy Drive? Toyota Prius has a very fuel efficient complex hybrid synergy drive system. These systems, pioneered by the Toyota Prius, use a combination of gasoline and electric engines with a continuously variable transmission to give maximum fuel economy and power delivery over a wide range of speeds and conditions. Hybrid Synergy Drive is a drive-by-wire system with no mechanical connection between the engine controls and the engine itself, and as such uses solely electrical signals to determine drive train output.

Source: http://www.global-greenhouse-warming.com/images/ToyotaHybrid1.jpg Page | 12

Overview of Operation In a conventional internal combustion engine, a battery is used to power accessories while the engine is turned off as well as in combination with a starter motor, which is used for starting purposes only. An alternator powers accessories and recharges the battery while the engine is in use, and the engine itself is the focus of the vehicle's motivation. In a Hybrid Synergy Drive or HSD power train, the transmission, alternator and starter motor are replaced with a pair of powerful electric motors which generate approximately 60hp, and can work either by themselves or in unison with a conventional internal combustion engine as needed. Power distribution is controlled through a combination of mechanical power splitter, and computer controlled shunts while the motors themselves are powered by a battery pack and used for start-up, low speed driving and acceleration.

Internal Combustion or Electric Power on Demand While the internal combustion engine itself may not even be active during start up, it may be used on demand for higher road speeds, increased acceleration, or to aid in increased battery charging. When the aid of the internal combustion engine is required, one of the electric motors may be used as a starter. When the aid of the gasoline engine is no longer required, the engine itself may be turned off as needed, with load shifted in full to the electric motors. This allows a hybrid engine configuration to achieve superior fuel economy without any holes of lags in power delivery.

Regenerative Braking It has been described above. Hybrid Synergy Drive equipped vehicles have managed to directly address many of the downsides found in both gasoline powered and electrically power drive trains alike, by combining their strengths into one versatile package. It is through this unique versatility in operation that hybrid technologies have become so successful compared to their fully electrically powered counterparts. Also, it's one of the main reasons why this technology may become a staple in the future of automotive technology. Now that we have knowledge in what happens in a hybrid electric vehicle, lets see the common faults in Priuses. What are the main problems in Toyota Prius? Faults and Problems in Hybrid Electric Vehicles Electric and hybrid cars have been under some hard scrutiny since their introduction to the market several years ago. Some of the claims critics have made against hybrids and electrics deal with parts and maintenance. It is true that these cars require some special care, but for the most part, naysayers have met their match with reliable vehicles that can go many years without needing any serious maintenance. Usual Maintenance

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Except for the electrical counterparts, hybrid electric vehicles have the components of a regular internal combustion engine and hence they require the same routine maintenance as any other gasoline vehicle. This includes the usual service as called by Sri Lankan people and that is changing of air filters and oil. The hybrid electric cars usually can run approximately 65,000 kilometers without changing the air filter. Theres no need of changing oil in a hybrid electric vehicle at the same intervals comparing with the gasoline engine-only cars because the electric motor or the battery of the car takes some of the load off of the engine. Therefore, the car can go between 8,000 and 16,000 kilometers between oil changes. Brake pads of a hybrid car are also need to be changed less frequently than in a conventional vehicle because of the regenerative braking properties. All other engine maintenance is much like that for any other conventional gasoline powered car. Battery Life One of the biggest attacks made on hybrids has to do with battery life. It is said that the battery life is very short, and if something were to happen to it, it is very expensive to replace. One of the keys to keeping a battery in good repair is to keep the battery charged between 40 to 60 percent. This way, the battery is never completely drained or charged, increasing its life. This can be maintained strictly through regenerative braking. Manufacturer faults of Toyota Prius HEVs There are two types of Toyota Prius HEVs in Sri Lanka which are very commonly used. Toyota Prius NHW20 (2nd Generation Prius) Toyota Prius ZVW30 (3nd Generation Prius)

Apart from these two, there are very few 1st generation vehicles as well. But since the number of vehicles is so very low, lets not discuss about those in detail. But as I was informed by the Toyota Lanka, the first battery replacement they received happened recently and it was delivered to a first generation Prius. Now, 1st generation Priuses have batteries that are old about 10-12 years and no wonder they will have to be replaced with new batteries. I have considered many cases found in the Internet and they have replaced their batteries after running about 200,000 kilometers. Here in Sri Lanka, the agents, Toyota Lanka does not import batteries for HEVs. But I was informed by them that the battery price outside is around Rs. 500,000.00 nowadays and it is a 28 cell battery. Each and every cell can be replaces in case of such replacement and one cell would cost around Rs. 30,000.00 at present. Theres another problem in Priuses and even though here in Sri Lanka we didnt have much vehicles at that time, in United States of America, it recalled Prius vehicles in 2005. That was in Highway driving, the gasoline engine shuts off. As I have described before, at speedy driving, in Toyota Synergy Drive method, gasoline engine works at high speeds. Here, sometimes it failed in 1st generation hybrids. These vehicles have been programmed to shut down either its gasoline engine or the battery power supply as needed. The program had the fault and Toyota repaired it calling the vehicles and it was not a major issue. There are some complaints from hybrid car owners concerning the engine light coming on or staying on without necessarily indicating a particular problem with the vehicle. This is issue seems to be common of most cars and newer ones in particular and could be a simple sensor glitch. But since this 1st generation scenario is out of the scope of the objectives of this project, lets look into the main manufacturer faults in common Toyota Prius HEVs in Sri Lanka.

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First, the production of the second generation Prius Hybrid or the Toyota Prius NHW20 was started in 2004 by Toyota and was produced till 2009. Approximately 670,000 Prius vehicles are being recalled in the United States to inspect and in some cases replace the steering intermediate extension shaft recently in November 2012 on vehicles between 2004 and 2009. But yet according to Toyota Lanka, no complaints from Sri Lanka have been received. There is a very common manufacturer fault in these vehicles and that is the only major issue with Toyota Prius. The NHW20 has a huge problem with its Inverter Motor Pump. On 2004 through certain 2007 model year Prius vehicles, there is a possibility that air may remain at the bearing of the Hybrid Electric Water Pump (HV Water Pump), causing pump actuation to be slow. In this condition, the temperature of the coolant could rise and become high, which will result in illumination of the Malfunction Indicator Light (check engine light "ON") for diagnostic code P0A93 with information code 346 (Inverter cooling system malfunction). Says Toyota website. This condition is caused by air being introduced into the hybrid cooling system. When air is introduced into the hybrid cooling system, it may become trapped, causing the pump actuation to be slow. In this condition, the temperature of the coolant could rise and become high, which will result in illumination of the Malfunction Indicator Light. Many people come to Toyota Lanka because they see this indicator. If the amount of coolant for the inverter is insufficient or the air bleeding is inadequate during replacement of the coolant, air can be introduced into the system. The Hybrid Electric Water Pump (HV Water Pump) is an electrically driven coolant pump that circulates coolant through the hybrid components to provide cooling. The HV Water Pump serves a different purpose than the engine water pump. This situation can be seen in Sri Lanka. But in USA and Japan, there was a major recall of Toyota Priuses to solve this issue. Then another small issue is there commonly in the Prius NHW20. That is with its horn wiring. It is again a common manufacturing fault. Since it is a complex electrical system in these cars, what they do at Toyota Lanka is that they replace these units. Then the other very common type used in Sri Lanka is the generation 3 Prius or Toyota Prius ZVW30. According to Toyota Lanka, Japanese vehicles do not have any fault in this type. But in UK models of Prius, There is a problem with the front wheel bearing. There has been a number of complains about that and what they do is replacing the front wheel bearing. Then again theres an issue with this ZVW30 model as I was told by Toyota and sometimes with NHW20 as well according to the reviews of the Prius users. That is called Countermeasure part problem. The countermeasure part should be replaced to solve that. That can be diagnosed when a sudden AC cutoff occurs in a Prius or by checking coolant tube, which can be diagnosed. In Sri Lanka, the most common problems are those ones. But apart from that there are some common, but not as common as above faults available in Prius. One such is Electric power steering (EPS) pinion shaft nut fault. It is said that this fault is there in earlier hybrids between 2001 and 2003. The Electric Power Steering (EPS) system provides power assistance to reduce steering effort. It generates torque using a power steering motor and a reduction mechanism which are assembled in the steering gear box assembly. If the steering wheel is repeatedly and strongly turned to the fulllock position, there is a possibility the nuts securing the pinion shaft in the steering gear box assembly may become loose. If the vehicle is continuously operated in this condition, over time, the customer will gradually notice significant increased steering effort when making a left turn. Page | 15

In the Internet another issue that I found was a small problem with power window switch. The company says the switch may have a notchy or sticky feel. If owners try to use a commercial lubricant to eliminate the condition, it could cause the assembly to melt, smoke or in the worst case, catch on fire. Model years 2007 to 2009 are affected but Toyota says is has received no injury claims due to the problem. Problem can be found in Camry hybrid as well. There is another problem in Prius which is related with the braking system. Technical experts explain the problem as a "disconnect" in the vehicle's complex anti-lock brake system (ABS) that causes less than a one-second lag. With the delay, a vehicle going 72 kmph will have traveled nearly another 90 feet before the brakes begin to take hold. Brakes in hybrids such as the Prius operate differently from brakes in most cars. In addition to standard brakes, which use friction from pads pressed against drums or rotors, the electric motors in hybrids help slow them. The process also generates electricity, which is regenerative braking that I had described above, to recharge the batteries. Regenerative breaking and usual hydraulic braking with anti-locking braking system seems not to work properly in some cars. It is said to happen due to a software fault in the embedded computer system of Prius. There is a rare problem with HID headlamps of Prius as well. There we need to replace the bulbs. Those are the common faults in Toyota Prius. Now, lets briefly see what we can do to eliminate them. As I was informed, for those main three problems that Prius has in Sri Lanka, we have to replace the equipment. For the Inverter water pump problem, a new inverter water pump which came after 2009 should be replaced. For horn wiring and front wheel bearing issues also can be corrected by replacing the respective units. Countermeasure part can also be replaced if there is a fault. All these 3 can be done at Toyota Lanka and at other places where are the repairs of HEVs are undertaken. They said that there are no sufficient experts in Sri Lanka to repair these equipment rather than replacing. For Electric power steering (EPS) pinion shaft nut fault, the part has to be changed as well. That sticky power window button fault is not something that usually we worry in Sri Lanka. So, no repair has been asked to do on that as I was informed. The braking system failure is somewhat a common problem found in Sri Lanka as well. To avoid that, the software related to that should be upgraded. These HEVs have very sophisticated embedded computers. So updating the software is a key to keep the car in good shape. For the HID lamp fault which is rare here, we should replace the lamp. Now, lets see what we can do to optimize fuel efficiency. Optimizing Fuel Efficiency If mentioned in brief, fuel efficiency depends vastly on driving style of the driver.

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First, to use the vehicle fuel efficiently, we should avoid quick acceleration. As I mentioned earlier, Prius usually uses the electric system at lower speeds and if we accelerate quickly, the car needs more power and to give that the internal combustion engine kicks in. Hence the fuel efficiency goes down. We should accelerate smoothly to optimize fuel. Smooth braking is also a method to optimize fuel. Prius uses a regenerative breaking system as I described before. There is s hydraulic breaking system as well. At hard breaking, i.e. when you want to stop the vehicle quickly, without regenerative breaking, hydraulic braking comes out. The switching between slow and smooth regenerative braking and hydraulic braking is done by the processor inside. Below, I have added a graph to describe how it switches. So regenerative braking works only when we brake slowly and smoothly. By that way, we can optimize fuel.

Apart from that, to optimize the vehicle, it is recommended by Toyota Lanka to use Octane 95 petrol for Toyota Prius ZVW30. Regular engine tuneups would make the car efficient as well. We can perform an EGR cleaning (Exhaust gas recirculation) to optimize hybrids as well.

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Acknowledgement
My sincere gratitude should go towards Dr. Udayanga Hemapala, Senior Lecturer in the Department of Electrical Engineering, University of Moratuwa for guiding me to study about this very interesting and inspiring topic. My special thank goes to Dr. Asanka Rodrigo, Senior Lecturer, Department of Electrical Engineering, University of Moratuwa for issuing me relevant letters so that I could go and meet the relevant companies to get necessary details. As a special person, I would like to thank Mr. Mahesh Abeysinghe, Technical Engineer, a graduate of University of Moratuwa and now working at Toyota Lanka (Private) Limited as the Technical Engineer handling all the hybrid electric vehicles for giving me fullest support by providing necessary information. Again, my special thanks goes to Mr. Ranjith Salpitikorala, a vehicle importer for helping me to contact with the people repairing hybrid electric vehicles (Arabian Motors, an engineer and Toyota Lanka). I would like to thank everybody who gave me information about their hybrid electric vehicles and I would like to convey my heartiest gratitude to all the other people who were always supportive.

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Reference
Sunday Times http://en.wikipedia.org http://www.howstuffworks.com/hybrid-car.htm http://www.fueleconomy.gov/feg/hybridtech.shtml http://www.mtu.edu/hybrid/ http://www.hybridcars.com/first-gen-hybrid-batteries/

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Appendix
Name: Mr. Muthubanda Ekanayake Occupation: Retired Police Officer Vehicle: Honda Insight Hybrid Manufacture Year: 2010 Mileage after buying the vehicle: 7000 km Average fuel consumption: 22 kilometers per liter Pros: Heating of the engine is very low. No need to worry about overheating. Engine switches off at idling. So when the car is stopped at traffic, it wont consume much energy as usual cars do. The display that has been provided indicates the available mileage that can be run without refilling gasoline. It is an added advantage over many common cars of its type. (Sedan) He says that earlier it did cost a lot to replace a battery. Around Rs. 450,000.00. Now as the hybrid electric vehicles have become more common in Sri Lanka, the price of the battery unit has also reduced and according to him the value now is around Rs. 125,000.00 and one cell is around Rs. 13,000.00. He says that it is usually should be serviced around 14,000 km run and he says that it is an added advantage. Cons: He claims that since these cars are little rare to find than conventional corolla and so on, the parts are a bit expensive. He says that the cost for a service is around Rs. 14,000.00 Rs. 15,000.00 and that is a small disadvantage over usual vehicles.

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Name: Mr. Gunasekara Occupation: Customs Officer Vehicle: Toyota Prius Hybrid Manufacture Year: 2009 Mileage after buying the vehicle: 40,000 km Average fuel consumption: 20 kilometers per liter Pros: He has 3 vehicles for his family and he says that the vehicle is pretty much stable. Handling is good. No problem with sounds coming out of the vehicle. Cons: Acceleration is somewhat lesser than his other vehicles. But works well in power mode. i.e. acceleration is not satisfactory in economy mode, but satisfactory enough on power mode. Ground clearance is very low and it is not enough for Sri Lankan roads. In the 1800cc model, interior space is very good and in 1500cc model, it is a negative point. He owns a 1800cc model, so it can be considered as a pro for his vehicle. When you park that vehicle in day time, since it has a huge portion of its surface covered with glass parts, the interior gets heated up lot more than a usual vehicle does.

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Name: Dr. Rathnayake Occupation: Specialist Doctor Vehicle: Honda Insight Hybrid Manufacture Year: 2010 Mileage after buying the vehicle: 5000 km Average fuel consumption: 21 kilometers per liter Pros: Heating of the engine is very low. At idling, electric motor works on its own so that the internal combustion engine switches off and hence saves a lot of fuel. Cons: When you are at a small slope uphill, acceleration is not enough comparing with other cars. He owns 4 vehicles and from his experience, he claims that and he says that there are no considerable negative points of a hybrid electric vehicle.

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Name: Mr. Nimal Senadheera Occupation: Factory Manager, Coool beverages Vehicle: Toyota Prius Hybrid Manufacture Year: 2008 Mileage after buying the vehicle: 30,000 km Average fuel consumption: 20 - 25 kilometers per liter Pros: Fuel efficiency is the best comparing with the vehicles he has used before, none of them are hybrid electric vehicles though. Has a good air conditioning system with it. Comfortable driving experience. Least sound comes out of the car. Very less smoke emission. Maintenance is easy since no need to worry about usual checking with water/coolent levels and so on. It indicates almost everything you need to know at the display panel. Emits very low level of heat from the engine. Cons: Not steady enough comparing with the Toyota Corolla Axio that he drives. But says that his first choice among the two cars is Prius since he travels about 3000 3500 kms in a month and it saves a lot for his pocket comparing with the Axio.

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Name: Dr. Saman Occupation: Lecturer, Faculty of Livestock, Fisheries & Nutrition, Wayamba University of Sri Lanka. Vehicle: Toyota Prius Hybrid Manufacture Year: 2008 Mileage after buying the vehicle: 25,000 km Average fuel consumption: When he bought the car, it was 28 - 30 kilometers per liter and now, the figure is around 20 kilometers per liter according to him. Pros: High fuel efficiency makes the life easier for him since he travels daily from his home to the University. No need to do the green test. Green test is the smoke emission level test that is now a law that is a must-to-get for any vehicle to run on the road for a particular period of time. But hybrid electric vehicles need not to go for that test and that is an added advantage, even though not technically. Cons: He claims that the price of a battery is so high that many people wont be able to afford it when it comes to a replacing of battery. There is an environmental concern attached with the batteries as well according to him. In Sri Lanka, we do not have a method to recycle these batteries. But in developed countries, they have. Here, we have to dispose the used battery and by that we might dump heavy metals like lead or arsenic to environment and it can harm and unbalance environment a lot. Ground clearance is not enough mainly because of the angle that it has been built in order to optimize fuel by its shape. The lower part of the car comes at a small angle and hence, the ground clearance is not equal everywhere.

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