From: Subject: Graham's Toyota Prius Date: Mon, 13 Mar 2006 11:07:06 -0600 MIME-Version: 1.0 Content-Type: multipart/related; type="multipart/alternative"; boundary="----=_NextPart_000_0000_01C6468E.43DD6140" X-MimeOLE: Produced By Microsoft MimeOLE V6.00.2900.2670 This is a multi-part message in MIME format. ------=_NextPart_000_0000_01C6468E.43DD6140 Content-Type: multipart/alternative; boundary="----=_NextPart_001_0001_01C6468E.43DD6140" ------=_NextPart_001_0001_01C6468E.43DD6140 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Content-Location: http://www.ecrostech.com/prius/original/PriusFrames.htm Graham's Toyota Prius =0A= <body bgcolor=3D"white" text=3D"black" link=3D"blue" vlink=3D"purple" = alink=3D"red">=0A= =0A= <p>&nbsp</p>=0A= </body>=0A= ------=_NextPart_001_0001_01C6468E.43DD6140 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Content-Location: http://www.ecrostech.com/prius/original/Understanding/Contents.htm Understanding Contents

Understanding your Prius

Introduction

Powertrain=20 Components

The=20 Internal Combustion Engine

The=20 Motor / Generators

Continuously Variable Transmission

The=20 Power Split Device

What's Going On As I Drive?

Making=20 Sense of the Displays

Back to Main Contents

Glossary=20 of Terms

=A9 2001, Graham = Davies

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PowerTrain Components

The diagram below is a schematic of the Prius powertrain. =  "Schematic"=20 means that it shows the essential features, but takes liberties with = detail.=20  In particular, I have grossly simplified the way in which the = internal=20 combustion engine (ICE) drives the planet gears in the power split = device (PSD)=20 and the way that the ring gear is connected to the silent chain sprocket = and=20 motor/generator 2 (MG2).  It is, however, accurate that the shaft = from the=20 ICE (blue) passes through the shaft of MG1 and the sun gear (yellow) in = order to=20 reach the planet carrier on the other side of the PSD.

The following sections contain descriptions of the various powertrain = components.  You can read them by just scrolling down, or click on = parts of=20 the diagram to see their descriptions in any order you wish. =  There's also=20 a paragraph about what's=20 missing from the Prius that would be present in a conventional = car.

Internal Combustion = Engine

The Prius has an internal combustion engine (ICE) which is unusually = small=20 for a car of this size (1300 kg).  This is made possible by the = presence of=20 the electric motors and battery, which supplement the ICE when power = demand is=20 high.  A conventional car, with an engine sized for hard = acceleration and=20 climbing steep hills, almost always operates that engine with low = efficiency.=20  Maximum efficiency generally occurs at around half of the engine's = peak=20 power output.  A small engine can operate closer to this maximum = efficiency=20 because power demands encountered in normal driving are a larger = fraction of its=20 peak power.  The possibility of using a small engine in a hybrid = vehicle is=20 called "engine downsizing".

In addition to being downsized, the Prius engine uses many techniques = to=20 improve efficiency and broaden the range of conditions under which high=20 efficiency is achieved.  The engine uses the Atkinson cycle, rather = than=20 the usual Otto cycle, which improves efficiency particularly at lower = power by=20 reducing "pumping loss".  Limiting the maximum spin rate to 4500 = r.p.m.=20 allows lightweight parts to be used, reducing inertia and friction = losses.=20  The crankshaft is offset from the cylinder axes so that during the = combustion stroke the force from the piston is transmitted to the = crankshaft=20 through a straight rather than tilted connecting rod.  The valves = have=20 narrow stems and low force springs to reduce energy lost in operating = the=20 valves.

I have devoted an entire topic to the Prius' Internal=20 Combustion Engine.

Motor/Generators

The Prius has two electric motor/generators.  They are very = similar in=20 construction, but different in size.  Both are three-phase = synchronous AC=20 permanent magnet motors.  This sounds more complicated than it = really is.=20  The rotor (the part that spins the shaft) is a just a big, = powerful magnet=20 and has no electrical connections.  The stator (the part that stays = still=20 and is fixed to the rest of the car) contains three sets of windings. =  When=20 current is passed in one direction through one set of windings the rotor = is=20 attracted to a particular position.  By passing current = sequentially=20 through each set of windings first on one direction and then in the = other the=20 rotor can be made to move from one position to the next and therefore = rotate.=20  This is a simplistic explanation, but captures the essence of this = type of=20 motor.  If the rotor is spun by an outside force, an electric = current flows=20 in each set of windings in turn and can be used the charge the battery = or power=20 the other motor.  Thus, the same device can be a motor or a = generator=20 depending on whether current is pushed into the windings to attract the = rotor=20 magnet or drawn out and something else spins the rotor around. =  This is=20 even more simplistic, but will serve for the depth of these = explanations.

Motor/generator 1 (MG1) is connected to the sun gear of the power = split=20 device.  It is the smaller of the two and is rated at a maximum = power of=20 about 18 kW.  Traditionally, its role is described as starting the = ICE and=20 controlling the ICE spin rate by generating a variable amount of = electrical=20 power.  Motor/generator 2 (MG2) is connected to the ring gear of = the power=20 split device and therefore to the reduction gears and hence the wheels.=20  Thus it is capable of directly powering the car.   It is = the=20 larger of the two and is rated at a maximum power of 33 kW.  It is=20 sometimes described as the "traction motor" and its traditional role is = to power=20 the car as a motor or recover braking energy as a generator.  Both=20 motor/generators are water-cooled.  My use of the word = "traditional" here=20 prefigures discussion elsewhere on this Web site in which I suggest that = the=20 roles of the two MGs are not so easily classified.  This can be = ignored for=20 our immediate purpose.

Inverters

Since the motor/generators operate from three-phase alternating = current and=20 the battery, like all batteries, produces direct current, some = electronics is=20 needed to convert between the two.  Each MG has an "inverter" which = performs this function.  The inverter knows the position of its = MG's rotor=20 from a sensor on the shaft and switches current through the windings as = required=20 to keep it spinning at the desired speed and with the desired torque. =  The=20 current in each winding is changed as each magnetic pole of the rotor = moves past=20 the winding and on to the next.  In addition, the inverter switches = the=20 battery voltage onto the winding and then off again very fast to vary = the=20 average size of the current and hence the torque.  Using the=20 "self-inductance" of the motor windings (an electrical property which = resists=20 current change), the inverter can actually pass a larger current through = the=20 winding than is drawn from the battery.  This only works when the = winding=20 voltage is less than the battery voltage, hence energy is conserved.=20  However, since the size of the winding current determines the = motor=20 torque, this current multiplication allows a very high torque to be = achieved=20 when the motor is turning slowly.  Up to about 7 m.p.h., MG2 is = able to=20 apply a torque of 350 newton metres to the reduction gears.  This = is what=20 makes it possible to "launch" the car at an acceptable acceleration = without the=20 use of step gears to multiply up the ICE torque.

Battery

The Prius high-voltage battery consists of 228 cells of 1.2 volts = each for a=20 total nominal voltage of 273.6 volts.  The cells are arranged in 38 = modules=20 of 6 cells each and the whole lot is assembled into a unit that is fixed = behind=20 the rear seat.  You can see where it is from the bump at the bottom = rear of=20 the trunk.  The maximum current of the battery is 80 amps discharge = and 50=20 amps charge.  This is remarkable, since each cell is similar in = size to an=20 ordinary D-cell such as you would use in a large flashlight.  In = fact, the=20 Japanese version used an earlier generation of battery cells that really = were=20 D-cells.  The rated capacity of the battery is 6.5 ampere hours, = however,=20 the car's electronics only allow 40% of this capacity to be used so as = to=20 prolong battery life.  The state of charge is allowed to vary only = between=20 40% and 80% of the rated full charge.  Multiplying up the battery = voltage=20 and current capacity, its rated energy storage capacity is 6.4 MJ = (megajoules)=20 and its usable capacity is 2.56 MJ.  This is enough energy to = accelerate=20 the car, driver and a passenger up to 65 m.p.h. (without help from the = ICE) four=20 times.  Alternatively, it is enough to raise the car through 600 = vertical=20 feet.  To produce this amount of energy, the ICE would consume = about 230=20 millilitres of gasoline (a little less than half a pint). =  (These=20 figures are provided only to give you a feel for the battery energy = storage=20 capacity.  The car should not be run without fuel and, even if it = is,=20 starting out with 80% of the rated full charge requires a long downhill = run.=20  Most of the time, you only have about 1 MJ of usable energy in the = battery.)

The Prius also has an auxiliary battery, which is not shown. =  This is a=20 12 volt, 28 ampere hour lead-acid battery that lives on the left side of = the car=20 in the trunk.  Its purpose is to supply power to the electronics = and=20 accessories when the hybrid system is turned off and the high-voltage = battery=20 main relay is off.  When the hybrid system is running, the 12 volt = supply=20 is from a DC-to-DC converter running from the high-voltage system. =  This=20 will also recharge the auxiliary battery if necessary.

Power Split Device

The torque and power of the ICE and both motor/generators is combined = and=20 distributed by a planetary gear set called by Toyota the "power split = device"=20 (PSD).  Although not terribly complicated in construction, this = device is=20 tricky to understand and even trickier to see in the full context of the = powertrain operation.  Therefore, I devote several other topics to=20 discussion of the Power=20 Split Device.  In brief, it allows the Prius to operate in both = series-=20 and parallel-hybrid modes of operation at the same time and gain some of = the=20 advantages of each mode.  The ICE can drive the wheels directly=20 (mechanically) through the PSD.  At the same time, a variable = amount of=20 power can be drawn off from the ICE and turned into electricity. =  This can=20 charge the battery or be passed to one of the motor/generators to help = drive the=20 wheels.  The flexibility of this mechanical/electrical power split = allows=20 the Prius to improve fuel economy and control emissions in a way that = would not=20 be possible with a hard mechanical linkage between ICE and wheels, as in = a=20 parallel-hybrid, but without the electrical energy loss of a = series-hybrid.

The Prius is often said to have a CVT or Continuously Variable = Transmission=20 and it is the PSD that is responsible for this.  However, a = conventional=20 CVT is just like a normal gearbox except that the gear ratio can be = varied=20 continuously rather than in a small number of steps (first gear, second = gear,=20 etc.).  I explain in another topic why the Prius PSD is most unlike = a=20 conventional CVT.

Silent Chain and Reduction = Gears

The use of a chain drive is rather unusual, but all conventional cars = have=20 reduction gears between the engine and the axles.  Their purpose is = to=20 allow the engine to spin faster than the wheels and also to multiply up = the=20 torque produced by the engine to a larger torque at the wheels. =  The ratios=20 by which spin rate is reduced and torque is increased are necessarily = the same=20 (neglecting friction) due to the law of conservation of energy. =  The ratio=20 is called the "final drive ratio".  The final drive ratio of the = 2001 model=20 year US Prius is 3.905.  This is achieved in the following way:=20

If we perform the simple arithmetic 36/39 * 44/30 * 75/26, we get (to = four=20 significant digits) 3.905.

My guess as to why a chain drive is used is that it avoids the axial = thrust=20 (force along the shaft) which would be produced by the usual helical-cut = gears=20 used in automotive transmissions.  This could also be avoided by = using spur=20 (straight-cut) gears, but these are noisy.  Axial thrust is not a = problem=20 on the intermediate shafts and can be accommodated by conical roller = bearings.=20  However, it might not be so easy to deal with on the output shaft = of the=20 PSD.  Remember, this is just my guess and may be completely = wrong.

Differential, Axles and = Wheels

There is nothing very unusual about the differential, axles and = wheels of the=20 Prius.  As in a conventional car, the differential allows the = inside and=20 outside wheels to turn at slightly different rates when the car is going = round a=20 corner.  The axles pass the torque from the differential to the = wheel hubs=20 and include a joint to allow the wheels to move up and down with the = suspension.=20  The wheels are a light-weight aluminum alloy and are fitted with = low=20 rolling resistance high-pressure tires.  The tires have a rolling = radius of=20 about 11.1 inches, which means that for each revolution of the wheel, = the car=20 travels 69 =BE inches.

What's Missing

The Prius powertrain may look complicated, but we must take into = account=20 several things that a conventional car needs that the Prius design has = dispensed=20 with.  These are:=20

So, the complexity of the Prius is not actually much greater than a=20 conventional car.  In addition, new and unfamiliar parts such as = the=20 motor/generators and the PSD are actually likely to have higher = reliability and=20 longer service life than some of the parts that have been = eliminated.

Last edited June 26, 2002.  All material Copyright =A9 2001, 2002 Graham Davies. =  No liability accepted.

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