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Hệ Thống Hybrid Lexus
Hệ Thống Hybrid Lexus
Contents
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1
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Overall
Hybrid System Operation
System Diagram
Components
MG (Motor Generator)
Inverter Assembly
Cooling System
HV Battery
HV Control System
Special Notes on Service
2
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Overall -A -W
Main Components
Inverter
Assembly MG1 MG2
HV Battery
Engine
Overall -A -W
Gear Train
– 2 planetary gear units
Output
Front Sun Shaft
Gear
Damper
Long Pinion Gear Rear Sun
Sun Gear Gear
Ring Gear
Ring Gear
4
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Overall -A -W
5
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Hi
Gear
Position
Lo
MG2
6
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
+ -
Linked
At Hi gear
rpm, rpm,
Torque Torque
- At Lo gear +
Sun Gear Carrier Ring Gear Carrier Ring Front Rear
(MG1) (Engine) (Wheel) (Wheel) Gear Sun Gear Sun Gear
(Lo) (Hi) (MG2)
Power Split Planetary Gear Unit 2-stage Reduction Planetary Gear Unit
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
8
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
9
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Vehicle Start-off
Vehicle Speed
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
10
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
ON ON Brake Accelerator
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
11
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Normal Driving
Vehicle Speed
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
12
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
13
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
14
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
15
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Deceleration in D Range
Vehicle Speed
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
16
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Deceleration in S Range
Vehicle Speed
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
17
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Driving in Reverse
Vehicle Speed
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
18
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
0
B1 B2 Brake Accelerator
ON ON
Engine MG1 MG2 P
HV Battery
:Electric Path +
(Supply)
I
G M B :Electric Path
(Charge)
P R 0 0
:Mechanical
Path (Active)
:Mechanical
Path (Passive)
P: Power Split Device R: 2-stage Motor Speed Reduction Device (S) (C) (R/C) (R) (Sf) (Sr) +
G: MG1 M: MG2 B: HV Battery I: Inverter Assembly MG1 Engine Wheel Lo Hi MG2
19
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
System Diagram -A -W
20
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Components -A -W
DC/DC Converter
for EPS and Active Stabilizer
Power Cable
MG (Motor Generator) -A -W
Max. Output [kW (HP] 165 kW (221 HP) 147 kW (197 HP)
MG2 Max. Torque 300 N!m (221 ft!lbf) 275 N!m (203 ft!lbf)
Low / High Gear* 1170 (862) / 570 (420) 1072 (792) / 522 (386)
Max. System Voltage AC 650 V ¬
Water-cooled and
Cooling System Water-cooled
Oil-cooled (ATF)
*: 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.
MG1 MG2
22
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Inverter Assembly -A -W
Location
– The inverter assembly for the LHD models and RHD
models is not same (symmetric appearance).
Inverter Assembly
23
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Inverter Assembly -A -W
Inverter Assembly -A -W
System Diagram
HV ECU
Battery
Modules MG ECU
Auxiliary
Battery Hybrid Transmission
25
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Inverter Assembly
System Diagram
– Boost converter + IPM
Inverter Assembly
MG1
HV
Battery
(DC)
MG2
26
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Safety Precautions
– After removing the service plug, wait 10 minutes or
more to discharge high-voltage capacitor
– Make sure the high-voltage capacitor terminal voltage
is 0V (Tester range: 750 V or more)
High-voltage Capacitor
Discharge
0V
Elect-
ricity
Plus
Terminal
Service plug
removal 10 min.
Minus
Terminal
High-voltage Capacitor Terminal
27
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Cooling System -A -W
Cooling System
– The HV components are cooled separately from the
engine cooling system. Therefore, each cooling system
has a reservoir tank.
Inverter
Front Assembly
Reservoir
Tank Reservoir Tank
for Hybrid System
Water Pump
NOTICE:
• Use caution during the coolant replacement (Max. temp. is approx. 65 deg C
(149 deg F).
• The gasket is not reusable.
31
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
32
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
NOTE: The remaining 0.5 liters (0.53 US qts, 0.44 Imp. qts) can be refilled in
33 while bleeding air.
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
34
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
DC/DC Converter
for EPS and
Active Stabilizer
HV Battery -A -W
HV Battery Unit
– The HV battery unit mainly consists of the following
components.
DC-DC Converter
Battery Smart Unit (for Auxiliary Battery)
(Under Junction Block)
HV Battery -A -W
Battery Module
Cell
12 Cells
[Battery Modules]
37
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
Inverter Assembly
MG1
Variable- DC
voltage Inverter
System
MG2
HV Battery Unit
DC/DC Converter
DC AC 288V AC DC 12 V
Battery
Modules
¯ ¯ ¯
AMD
DC 288 V
AC AC 12V DC
Auxiliary
Battery
38
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
Junction Block
– The junction block incorporates an SMRB (positive
side), an SMRG (negative side), SMRP (negative side)
in DC/DC converter and an HV battery current sensor.
Junction Block
SMRG
SMRB
SMRP
(in DC/DC
Converter)
HV Battery -A -W
Junction Block
– Three SMRs are relays that connect and disconnect
the power source of the high-voltage circuit upon
receiving a signal from the HV ECU.
HV Battery Unit
SMRB
Voltage
Inverter
Battery Modules
Assembly
Service Plug
SMRP
0 Time
Resister ON
(+)SMRB OFF
SMRG
SMRP ON
HV ECU (-) OFF
SMRG ON
OFF
40
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
41
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
Serial Communication
Blower Motor Mode Control
Battery Smart Unit
Controller Damper
HV Battery Voltage Leak Detection Circuit
Detection Circuit Detection for HV Battery
Sub Blower Blower Fan
Fan Motor Motor
Voltage HV Battery Sub Blower Fan Rear A/C Unit
42
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Intake Air
Temperature Sensor
43
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
44
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery -A -W
Suction Inlets
45
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
46
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
IGCT
Relay
HV Battery
Unit
IGCT
DC/DC
AMD
HV
Battery DC/DC Converter
Auxiliary
SMRP Battery
SMRP
VLO
NODD
IDH+DT GN
AMD Terminal
47
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
2
3
Service Hole Cover
48
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Battery
[Interlock Button]
Lock Release
Rear LH Bracket
50
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Rear LH Side
Front RH Side
Rear LH Bracket
NOTE:
Place a piece of cardboard or other similar object to protect the HV
51 battery and vehicle body from damage.
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Control System -A -W
EV Drive Mode
– In the EV drive mode, the vehicle runs like an electric
vehicle which is driven with only the electric motor.
– When the EV drive mode switch is pushed on in the
READY ON state, the EV drive mode will be turned on
and the EV drive mode indicator light will be
illuminated
EV Drive Mode
Indicator Light
52
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Control System -A -W
EV Drive Mode
– In the following conditions, the EV drive mode may not
be turned on and the message appears in the multi-
information display with beep sound.
53
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
EV Drive Mode
– The engine is always started when power switch ON
(READY ON state) under normal conditions. However,
the hybrid system can be turned on the EV Drive Mode
by performing the following procedure.
1. Turn the power switch ON without depressing the
brake pedal and then confirm conditions of defroster
(OFF) and hybrid battery (Charging level is 4 or
more).
2. Push and hold the EV drive mode switch and then
push the power switch while depressing the brake
pedal (The engine may start depending on the
system conditions*).
*: Engine coolant temp. is less then 0 deg C (32 deg F), etc.
54
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Control System -A -W
EV Drive Mode
– The EV drive mode may be automatically cancelled in
the following conditions. In this case, a beep sounds
and the EV drive mode indicator light flashes and then
goes out.
• The HV battery charging level is 2 or lower.
• The vehicle speed exceeds the following speed:
" About 40 km/h (25 mph) at engine coolant temp.
is approx. 40 deg C (104 deg F) or more
" About 30 km/h (19 mph) at engine coolant temp.
less than 40 deg C (104 deg F)
• The accelerator pedal is depressed strongly.
Reference
• Available driving range differs depending on factors such as the HV battery charging level
or air conditioning condition, the driving range is from about several hundred meters to 1
km (about 0.6 miles).
• Hybrid vehicle is designed to have the best fuel economy during normal driving (driving
using a combination of gasoline engine and electric motor power). Frequent use of the EV
drive mode may worsen fuel economy.
55
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Control System -A -W
56
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
HV Control System -A -W
Cutoff interlocked SMRs are turned OFF when the driver turns the
with the power mode power mode OFF.
The HV ECU receives a signal of the occurrence of
Cutoff in the event of
a collision via the airbag sensor assembly, and
a collision
Automatic Cutoff turns OFF the SMRs.
[System Main The interlock device detects whether the service
Relays] (SMRs) plug is installed. If the technician forgets to
Cutoff when the
remove the service plug, and they perform a
interlock device is
high-voltage operation, removing the inverter
activated
with converter assembly cover will turn OFF the
SMRs due to the interlock circuit.
• The service plug located in the middle of the HV
battery makes it possible to cut off all high-
voltage circuits.
Manual Cutoff with Service Plug • Remove the service plug when inspecting or
maintaining high-voltage circuits.
(Wait for 10 min. after removing the
service plug )
57
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
If a Battery is Discharged
– When the battery is discharged, the following
conditions occur:
• Auxiliary battery
" No combination meter display even with the
power mode ON.
" Unable to enter the READY-ON state.
" Headlights are dim and the horn sound is weak.
• HV battery
" The hybrid system detects abnormality and
displays a warning message on the multi-
information display.
" Unable to enter the READY-ON state.
" DTC P3000-388,389 (HV battery malfunction) is
stored in the HV ECU.
58
Model Outline for Technician Hybrid System Engine Chassis Body Electrical
Auxiliary Battery
– Sealed type battery is used. Therefore, do NOT
perform a quick charge.
• Charging
" Charge at 5.0 A or less within 12 hours
• Replacement
" Replace dedicated battery for LS600hL / LS600h
Temp. Sensor
With brake
depression
Accelerator
OFF Pedal IG-ON
¯ ¯
IG-ON READY
Inspection Mode
– Set to the Inspection Mode before performing the
following operation.
Inspection Mode Function
Necessity for Inspection Mode Continuous Motor TRC
engine running prohibited
When the vehicle is stopped, the engine must be kept
running for the purpose of checking the following;
• Ignition timing test
• Exhaust gas test (Idling), etc.
O O
When the operation of VSC and TRC must be prohibited
for the purpose of checking the following;
• Speedometer test
• A 4-wheel dynamometer test
Inspection Mode
– Vehicle Condition during Inspection Mode
• Engine (“P” Range)
Accelerator Pedal Opening Engine Speed (rpm)
Accelerator pedal is not depressed. Approximately 1,000 rpm.
Accelerator pedal is depressed less than 60 %. Approximately 1,500 rpm.
Accelerator pedal is depressed more than 60 %. Approximately 2,500 rpm.
• Hybrid Transmission
" 2-stage motor speed reduction device is fixed to
Hi gear.
NOTE: Basic operation during inspection mode is the same as the GS450h.
62