hybrid safety
TRANSCRIPT
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Representative Customers
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Delphis 113 Years of Innovation
Heritage Names and Products you Know! Packard Electric Division
Delco-Remy
AC Spark Plug
Harrison Radiator
Frigidaire
Delco Radio
Inland Fisher-Guide
Saginaw Steering Gear
Fisher Body
Rochester Products
Delco-Moraine
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2008 HybridsAutomobile Drive Train Engine
Transmission Hybrid
Toyota
Prius
FWD 1.5L
4 cyl
Automatic Full
Honda
Civic
FWD 1.3L
4 cyl
Automatic
CVT
Assist
Honda
Accord
FWD 3.0 L
6 cyl
Automatic
L5
Assist
HondaInsight
FWD 1.0L3 cyl
AutomaticCVT / 5Spd M
Assist
Ford
Escape
FWD
4 WD
2.3L
4 cyl
Automatic
CVT/CVUSL
Full
Mercury
Mariner
4WD 2.3L
4 cyl
Automatic
CVT/CVUSL
Full
Mazda
Tribute
4WD 2.3L
4 cyl
Automatic
CVT/CVUSL
Full
Lexus 400 H
Toyota
Highlander
FWD
4WD
3.3L
V6
Automatic
CVT
Full
Chevrolet
Silverado
2WD
4WD
5.3L
V8
4Sp Automatic
CCCVL
Mild
GMC
Sierra
2WD
4WD
5.3L
V8
4Sp Automatic
CCCVL
Mild
Transmission Descriptions
Continuously Variable UserSelectable Lock-up (CVUSL)
Computer Controlled
Continuously Variable Lock-up
(CCCVL)
Hybrid DefinitionsAssist: The Electric Motor
Only Assists The Engine
Mild: The Electric Motor
Only Assists The Engine
Full: The Vehicle Can Use
Gas, Electric or Both ForPower
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Back to the Future
Photo of Thomas Edison with 1914 Detroit Electric Model 47
From the Smithsonian
(courtesy of the National Museum of Natural History)
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Back to the Future
1921 Owen Magnetic Model 60
Used a gasoline engine to run a generator
Which supplied electric power to motors mounted
in both rear wheels
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Development of the Hybrid
GM, Chrysler, Ford, Many of the European and Asia
n Manufactures produced all Electric Vehicles.
Best use was in small vehicles used in the city
Limited Range due to battery capacity
Recharge took several hours
Other electric vehicles that were
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42V Belt Alternator Starter System from Delphi
Delphi presented its Energen 42V Belt Alternator StarterSystem at Convergence 2002.
The system replaces a conventional vehicle's existing starterand generator with a single high-power belt-drivenmotor/generator
Providing an 8-10% fuel economy improvement in city traffic.
The system provides dual-voltage 42V/14V architecture.
In generating mode, the belt-driven electric machine, theelectronics box, which contains a power inverter and machine
controller, produces electrical power 42 volts and charges a 36-volt battery.
A DC-DC converter is used to obtain 14 volts from 42
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Engine Turnoff at Idle is Improves Vehicle Fuel Economy
A number of alternatives for implementation of the restarting functionincluding:
The existing cranking motor
12V or 36V belt-starter,
Crankshaft integrated-starter generator (ISG)More complex hybrid powertrain architectures.
The 12V belt alternator- starter (BAS) offers fast, quiet starting at a lowersystem cost. There are two challenges are
1. Need to accelerate a large engine to idle speed quickly
2. Dynamic torque control during the start for smoothness.
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42V C from Delphi
Energen 5 Designed for GM 5.3L V8
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Starter Generator
Delphi Energen 5
SG (Starter Generator)
RIC (Regulator Inverter Controller)
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Control System Layout
The engine speed has to be limited by the PCM calibration to 5000 [rpm] to prevent over
speed of the SG
The specified maximum speed allowed on the SG is 18000 [rpm].
A normal start happens when the restart of the engine after IEO (Idle Engine Off) is done
within 2 to 3 seconds.
The SG on this application is only used for warm engine restarts from an IEO event. The DCstarter is used for cold engine starts and in case of a detected fault on the RIC
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Conventional Engine
with a Belt Alternator Starter System
Hybrid uses a conventional internal combustion engine and a generator withstarter power the vehicle.
Note: All intermediate voltage cables used on the hybrid are blue for easy
identification
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Always Use the Original Vehicle Manuel
When Working on vehicles correct information is
necessary
On a GM Hybrid 12V/36V Systems You ShouldKnow Color Codes For Wiring Conduits:
Orange = 60 or More Volts
Blue = 30V to 60V
Red = Automotive Low Les than 30V
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Hybrid Configuration
Parallel Hybrid: The primary energysource can drive a generator like the
series system In addition it can also drive
the vehicle parallel to the electric motor.
The Honda Integrated Motor Assist (IMA)is an excellent example of a parallel
hybrid drive system.
Series Hybrid: The primary power sourceis the internal combustion engine which
drives a generator:
Electric power is stored in batteries usedto power an electric motor that drives the
wheels Most true Series Hybrids in use
today are medium-duty vehicles such as
transit buses
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Toyota Prius
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Prius Dash View
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Toyota Prius Hybrid Synergy Drive
Left side (black) is a 1.5 liter Internal Combustion Engine
Drives the wheels and the electric generator.
Right side (aluminum)
High voltage unit part of the Toyota Hybrid Synergy Drive
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Prius 1.5 liter, 1NZ-FXE engine
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Cylinder Head Thermos
Toyota Thermos
In Left Front Fender Ahead
of Wheel Housing
Keeps Coolant Warm toCirculate through the Head
on Cold Start
Up to Three Days Close to
200 F
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Engine Control System Sensors
VSV(for
EVAP)
Mass AirFlow Meter
Water Valve
Coolant Heat StorageTank & Water Pump
ECM
Heated Oxygen
Sensor
VSV (for CanisterClosed Valve w/
Trap Filter)
Combination
Meter VaporPressureSensor
CharcoalCanister
& VSV(for Purge FlowSwitching
Valve)
DLC3 Accelerator PedalPosition Sensor
ThrottleBody
Heated AirFuel Ratio
Sensor
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Toyota Uses a Parallel Drive SystemParallel Hybrid:
Both the battery and engine are connected to the transmission
Either the battery using the electric motor, or the engine and the
transmission, can provide propulsion power.
Also propulsion can use a combination of both
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Battery Module (98KB, MIME type)
Second generation Toyota Prius uses 28 of these modules to create a 200 volt DC battery pack
Inverter is used to "step-up" the power to 500 Volts, converting the DC battery power to theAC required for the electric motors (The module s are only 10 inches long and can be
serviced individually however labor cost will most likely force servicing as a unit)
First generation Prius utilizes conventional round NiMH batteries inside a metal battery
case to operate the 300 Volt hybrid electrical system
While the battery voltage dropped from 300 Volts, to 200 Volts in the second generation Prius,
the high-voltage inverter steps the power up to 500VA more powerful electric motor allows for approximately a 30% increase in overall power
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HVNickel-Metal Hydride Battery
Six 1.2V Nickel-Metal Hydride (Ni-MH)cells are connected in series to form one
module.
28 modules are connected in series for the
rated voltage 201.6V.
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Battery Safety Sticker
On Battery module
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Multi-Function Monitor
Energy Monitor
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High Voltage Inverter
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High Voltage Inverter
High voltage inverter unit with cover removedUsed in the NHW11 1st generation of the Prius
3 black coil like objects are capacitors
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Engine and Drive System
Motor Gen.1 Motor Gen.2
Planetary Gear SetSilent ChainTransaxle
Damper
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Honda Motor and Rotor
Use Proper tool to: Remove Rotor
Install Rotor
Very Heavy Magnetic Field
Could Injure Technician
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Toyota Planetary Gear Transmission
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Auxiliary AGM Battery
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AGM
Absorbent Glass Mat (AGM) technology is the latest innovationin maintenance-free batteries (introduced on 2001 Corvette).
The AGM battery is classified as a gas recombinant or
recombination design.
Recombination means that the hydrogen and oxygen gassesgenerated during charging are recombined to produce water.Consequently, gassing and its associated water loss are
eliminated.
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Jump Start Terminal at the Auxiliary Battery
Main Junction
Block
2004 and later Prius
Jump starting a Prius is allowed if procedures
are followed
Once started the charging system will return
battery to normal state of charge
Jumper Cable Tab
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Cable Routing
Junction Box
Auxiliary Battery
HD Battery
Inverter
Motor Generator 1
Motor Generator 2
Aluminum Wiring Harness
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Battery System Layout
System Main Relay (SMR)
Battery ECU
Service Plug
Upper Case Cover
Battery Module
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Junction
Power Cable
Voltage (+)
Power Cable
Voltage (-)
+ 12V DC
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Hybrid Vehicle SafetyVehicle must be disabled
2004 & later Prius Auxiliary Battery
Toyota emblem is not chrome on the other side Turn off the hybrid system.
Vehicles with smart key, disable it and make sure
key fob is at least 15 feet away from the vehicle
Disconnect the negative (-) terminal of the 12V auxiliary battery.
20012003 Prius Auxiliary Battery
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2004 to 2008 Smart key
Toyota emblem is chrome If inside the vehicle will
start and get ready light
Outside will not start and no
ready light
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Toyota Smart Key
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Remove the Service Plug
You Must Wear insulated gloves (Be sure gloves are not damaged)
Remove Orange service plug and put it in your pocket
Do not test or make repairs for Five minutes.
2001
2003 Prius 2004 and later Prius
Orange service plug
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Toyota Prius Auxiliary Battery
Located in Trunk
12.6 V AGM
Red Cables
Should Be Disconnected to
Work ON
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Handling High Voltage Cables
High-voltage cables are orangeDo Not Touch. If you are
working near any high-voltage cables or components:
Use insulated tools
Do not leave tools or parts (bolts, nuts,
etc.) inside cabin.
Do not wear rings, watches or metal
objects
Be Cautious of High-Voltage Components
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Need to Wear High Voltage Gloves
High Voltage Class 0, rated at 1000 volts with Leather Outer Shell
Cat III Rated Fluke 1587DVOM & Insulation Tester
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High Voltage Tools
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Lexus LS600hL
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Honda Insight
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Honda Civic Hybrid
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Honda Engine
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Honda Integrated Motor Assist (IMA)
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Honda Models Use Parallel Configurations
The wheels are powered by both the internal combustionengine and an electric motor
The two Honda Integrated Motor Assist (IMA) systems utilizesmaller-than-normal gasoline engine and a thin, pancake-typeelectric motor/generator located between the engine and
transmission 1.0-liter three-cylinder in the Insight
1.3-liter four-cylinder in the Civic
When additional power is needed, when passing the integrated electricmotor/generator kicks in and supplies added power.
The motor/generator functions as a high-speed starter and for batterycharging during regenerative braking.
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Honda Configurations Not Like Ford and Toyota
Hondas hybrids cannot operate solely on battery powerIMA fits the definition of a true integrated hybrid
Designed to run super-efficiently on shared internalcombustion and electric
The less costly mild hybrids being developed by automakerstypically use an integrated starter/generator that automaticallyshuts down an engine when a vehicle stops
Then starts it up when its time to go again. Giving a slightimprovement in fuel economy of maybe 10 percent
A world apart from the 40, 50, and 60+ mpg fuel economyachieved by system like Hondas IMA.
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Honda Engine
New Honda Hybrid System uses: Intelligent engine functions to achieve an approximate 20%
increase in system output over the current system
Giving the performance of a 1.8-litre engine while improving
fuel economy Reducing the system size by 5% and attainting a greater level
of emissions control
The system offers significantly improved performance and fuel
economy over the current system.
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Honda Engine
3-stage i-VTEC uses three hydraulic passages Providing three stages of valve control depending on the
driving conditions
Achieving a combination of responsive driving conditions andfuel economy by coupling and uncoupling five rocker armassemblies
During deceleration the cylinders are idle Combustion in all four cylinders is shut off
The cylinders sealed shut
A 10% improvement in recovery of braking energy compared to thecurrent Civic
Aluminum die-cast pistons, which have less heat related expansion andless friction, ion-plated piston rings, and plateau honing of the cylinderwalls for a smoother surface.
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Engine, IMA and Transmission
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Honda Transmission
Steel Belt
Variable Cones
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IMA (Integrated Motor Assist)
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Motor Mode
IMA motor/generators starts the gasoline engine and brings it to 1000 RPM
As a back-up this job can be handled by the Hondas conventional 12-voltstarter when:
When the battery module state-of-charge is too low
Operating in extremely cold or hot weather
IMA system fails
Direct current from the battery module is converted to AC electric powerby the motor drive module (MDM)
This electricity is supplied to the IMA motor/generator operating in motormode for accelerating, climbing hills, and other high load conditions
For maximum acceleration, both the IMA motor/generator and gasoline engineare used
Under light acceleration, the motor/generator provides only partial assist in anamount determined by load and throttle position
Once cruising, the Honda hybrid is propelled solely by the gasoline engine
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IMA (Integrated Motor Assist)
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IMA (Integrated Motor Assist)
Honda Series Hybrid:
In the series type of hybrid the engine turns a generator and the
generator can either charge the batteries or power an electric
motor that drives the transmission.
The engine never powers the vehicle directly.
Source:Toyota
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IMA (Integrated motor Assist)
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Honda Electric Motor Control
Hondas electric motor Employs coils designed with high-density windings
High-performance magnets to attain output 1.5 times that ofthe current model while maintaining the same size
The inverter used to control motor speed
Independently developed and manufactured by HondaI
Integrated with the motors ECU for more precise digitalcontrol Contributing to even greater motor efficiency and fuel economy.
Battery output has been increased by around 30% over thecurrent model More compact, custom designed battery storage box offers increased
cooling performance and vibration resistance for improved long-termreliability.
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New Honda Hybrid System Modes of Operation
Vehicle stationary
The engine is turned off and fuel consumption is zero.
Startup and accelerationThe engine operates in low-speed valve timing mode, with motor assist.
Rapid accelerationThe engine operates in high-speed valve timing mode, with motor assist.
Low-speed cruisingThe valves of all four of the engines cylinders are closed and combustion halted.The motor alone powers the vehicle.
Gentle acceleration and high-speed cruisingThe engine operating in low-speed valve timing mode powers the vehicle.
Deceleration
The valves of all four of the engines cylinders are closed and combustion halted.The motor recovers the maximum amount of energy released during decelerationand stores it in the battery.
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Specifications for the New Honda Hybrid System
Power Source:
Engine
Water-cooled in-line
Number or cylinders 4-cylinders
Displacement 1,339 Bore x stroke (mm) 73.0 x 80.0
Electric
Electric motor type:
AC synchronous drive motor (Ultra-thin DC brush- less motor)
Rated voltage (v) 158 Performance Engine Max. output 70[95]/6,000(kW[PS]/rpm)
Max. torque 123[12.5]/4,500 (Nm[kgm]/rpm)
Electric Max. output 15[20]/2,000 motor (kW[PS]/rpm) Max.torque 103[10.5]/0~1,160 (Nm[kgm]/rpm)
System Max. output 70+15[95+20] output (kW[PS]/rpm) Max.torque167[17.0] (Nm[kgm]/rpm)
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Orange Is A Safety Alert
All Orange Cables Are HighVoltage and Dangerous
Put In Service Mode and
Wait For Capacitors to drain
About 90 Seconds
Use the Proper DMM
Disconnect Auxiliary
Battery
Be Vehicles Are in NeutralBefore Pushing In Shop
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Toyota Fuse Box
UNDERHOOD
FUSE BOX
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Honda Battery
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Silverado
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Examples of Very Different Hybrids
Hybrid Features by Make/Model
Make Model Idle Stop Regenerative Braking Motor AssistEngine-Off Drive- EV
Mode
Chevrolet Silverado 1500/GMC Sierra
HybridX X
Ford Escape Hybrid X X X X
Honda Civic Hybrid X X X
Honda Insight X X X
Toyota Prius X X X X
Differentiate hybrids based on the features:Mild-Incorporate Idle Stop and Regenerative Braking
Strong-Incorporate Idle Stop, Regenerative Braking, Motor Assist, and
Engine-Off Drive-EV Mode
S i
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Saturn Vue hybrid
S V H b id E i
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Saturn Vue Hybrid Engine
S V h b id
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Saturn Vue hybrid
System Operation
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System Operation
The Saturn VUE Hybrid Used to Cover GM Vehicle Lines:
Gasoline-electric hybrid vehicle
Introduced in the summer of 2006
Uses a 36 volt electrical and a traditional 12 volt battery and sophisticated
technology to achieve its fuel savings.
The vehicle is equipped with a 2.4 liter, 4-cylinder
engine and a traditional 12 volt starter motor,
which is used only for initial starts of the vehicle.
Starter Generator with three phase AC cable assembly
S t O ti
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System Operation
The PEB integrates the inverter
and DC to DC converter into one
unit
The PEB also includes the
transmission electric pump
controller as well as auxiliary
input and output drivers
The inverter portion of the power
electronics box (PEB) will control
the motoring or electrical
generating function of the SG
Other drivers include controls
which provide power to the
electric transmission oil pump
BAS H b id B tt A bl
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BAS Hybrid Battery Assembly
The BAS (Belt Alternator
System) battery assembly hasseveral components which areserviceable and can be replaced asnecessary However, the actual batteries, when
replaced need to be replaced together
Control module looks at each of themodules state of charge and condition
If one of the three modules does notmeet the set criteria with relation toeach other (exceeds 0.6 volts) this iscalled Imbalance, the batterycontrol module will not allow the
battery to function
BAS 42V Beneath the
Rear Compartment
GM H b id V hi l
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GM Hybrid Vehicles
Pi t d i D l hi' H b id I t
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Pictured is Delphi's Hybrid Inverter
Delphi research and development of hybrid powertrain
Help manufacturers like Ford fit the most efficient powertrain for their hybrids.
GM H b id V hi l
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GM Hybrid Vehicles
GM Daimler Chrysler BMW Group Global Hybrid Cooperation. The hybrid with two driving
modes optimizes power and torque for the given driving conditions
The first mode provides fuel-saving capability in low-speed and stop-and-go driving, with a
combination of full electric propulsion and engine power.
The second mode is used primarily at highway speeds to optimize fuel economy, while providing full
engine power when conditions demand it, such as trailer towing or climbing steep grades.
.
T 60 kW M t d 300 V lt B tt P k
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Two 60 kW Motors and a 300-Volt Battery Pack
Porsche Ca enne H brid S
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Porsche Cayenne Hybrid S
Cayenne Hybrid S
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Cayenne Hybrid S
V-8 power with four-cylinder fuelefficiency accomplished by using:
Parallel hybrid system
Audi 3.0-liter V-6
Supercharged, gasoline-direct-injectionThree-phase synchronous electric motor
Nickel-metal-hydride battery pack
Up to 385 hp and 545 lb-ft of torque
Zero to 60 mph acceleration of 6.8
seconds
Fuel economy is listed at 26 mpg on the
European driving cycle
Cayenne Hybrid S
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Cayenne Hybrid S
Using a totally new eight-speed automatic
transmission
Top vehicle speed is achieved in 6th
The two higher gears boost fuel economy by
lowering engine RPM
Eighth gear, allows the vehicle to coast without thecombustion engine at speeds up to 86 mph
Travel in all-electric mode is less than two miles
The electric motor is located between the engine and
transmissionThe acts as an alternator to capture lost energy while
the vehicle is driven
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Cayenne Hybrid S
The hybrid controller can switch between:Electric, combustion operation or any
combination of the two in 30 milliseconds
The controller accomplishes this while
monitoring 20,000 data parametersThe new design adds an electrical drive pump
to assist the conventional transmission oil pump
allowing the transmission to shifts gears
smoothly in electric mode
Cayenne Hybrid S
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Cayenne Hybrid S
The Cayenne hybrid will generate 20% less carbon
dioxide emissions than a standard engine, qualifying
it as a ULEV II
The 154-lb battery, for example, is in the spare tirewell
The hybrid Cayenne is due to roll into showrooms
by early 2010
Ford Escape Hybrid
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Ford Escape Hybrid
Safety Concerns
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Safety Concerns
Escape Hybrid or Mariner Hybrid emergency response procedures are similar to
those for a traditional gasoline powered vehicle with the exception of the highvoltage electrical system.
The Escape Hybrid or Mariner Hybrid vehicle uses a conventional gasoline
engine in addition to an electric motor to power the vehicle. The energy used to
power the vehicle comes from gasoline (used by the internal combustion engine)
and electricity (used by the electric motor). The energy used to power the vehicleis stored:
Gasoline is stored in a traditional fuel tank
Electricity is stored in the high voltage batteryPACK
Safety Concerns
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Safety Concerns
The combination of a gasoline engine and electric motor
provides for improved performance (V6 performance with a 4
cylinder engine and electric motor), reduced emissions and
most importantlyimproved fuel economy. The system is
self contained (a generator recharges the battery duringbraking and cruising) so you never have to plug a hybrid in to
recharge the batteries.
Safety Concerns
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Safety Concerns
The information will allow you to respond to Escape Hybrid or Mariner
Hybrid vehicles as safely as you do with conventional vehicles.
The Escape Hybrid or Mariner Hybrid has been designed with many
features for your protection. These features should help provide you with
safe access to the vehicle under various conditions. However whenever
you approach a high voltage vehicle in a Fire, Rescue or Recovery
situation, you must always follow one cardinal rule.
ALWAYS ASSUME THE VEHICLE IS POWERED UP
HYBRID VEHICLE IDENTIFICATION
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ESCAPE HYBRID OR MARINER HYBRID VEHICLE
IDENTIFICATIONA unique Hybrid label is located on the lift gate, the front
driver's door, and the front passenger's door. This can be
used to identify an Escape Hybrid or Mariner Hybrid
vehicle.
HYBRID VEHICLE IDENTIFICATION
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HYBRID VEHICLE IDENTIFICATION
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Ford Escape Hybrid
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Ford Escape Hybrid
Ford Escape Hybrid
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Ford Escape Hybrid
Ford Escape Hybrid Component Location
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Ford Escape Hybrid Component Location
NOTE: All High Voltage wires and harnesses are wrapped in orange-colored insulation.
Warning Decal
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Warning Decal
Battery and Inertia Switch Location
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Battery and Inertia Switch Location
Escapes Battery
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Escapes Battery
Batteries consist of 250 individual cells (similar in shape to a size D flashlightbattery). Each individual battery cell is contained in a stainless steel case.
Each individual cell is 1.3 volts. The cells are welded and wrapped together in
groups of 5 to form a module. There are 50 modules in the battery pack. The total
voltage of the battery pack is 300 volts DC
The batteries are Ni-MH (Nickel-Metal Hydride). The battery pack contains sealedbatteries similar to the batteries used in radio control toys, laptop computers and cell
phones.
The battery case is designed to be water resistant. The battery cells contain a base
electrolyte (consisting of potassium hydroxide as the dominant active ingredient) that
is absorbed in a special paper. The electrolyte will not leak from the battery undermost conditions; however if the battery is crushed, it is possible for a small amount
(drops) of electrolyte to leak.
Two cautions should be observed when working with a damaged battery
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Two cautions should be observed when working with a damaged battery
1. Exposure to electrolyte could cause skin/eye irritation and or burns. Ifexposed, rinse with large amounts of wateruntil the soapy feel is gone.
Safety items such as face mask, insulated rubber gloves and boots, and a
protective raincoat or apron are required when handling a damaged battery
2. If the battery is exposed to intense heat, it is possible that hydrogen could
be released from the battery. Appropriate cautions should be taken to makesure the area is properly ventilatedsuch as opening/removing the lift gate
or rear glass.
Note: The High Voltage Service Disconnect Switchshould be moved to the service/shipping position if
possible
APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE
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APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE
1. FOLLOW EXISTING TRAINING AND INCIDENT COMMANDER
DIRECTION
This information as it pertains to the Escape Hybrid or Mariner Hybrid. The
same rules apply when approaching any potential high voltage situation.
Always follow your high voltage safety training. Some pre-cautions to be taken
in any high voltage situation include:
Remove all jewelry, watches, necklaces, earrings, etc. Metal objects are conductors
of electricity.
Wear the necessary protective clothing (high voltage rubber gloves, face shield,
insulated boots, protective raincoat or apron)
Bring the following equipment:o Class ABC powder type fire extinguisher
o A non-conductive objectabout 5 feet long (1.5 meters)used to safely push
someone away from the vehicle if they accidentally come in contact with high
voltage.
APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE
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O C NG G G VO G V C
2. APPROACHING A DAMAGED VEHICLE
Disable the high voltage electrical system using as many of the following steps
possible:
Secure the vehicle - Put the shift lever into Park. Remove the ignition key.
Block the wheels if necessary. Removing the ignition key or turning it to theoff position will disconnect the high voltage system.
Disconnect the negative cable from the 12-volt batterythis will also
disconnect the high voltage.
If possible, place the High Voltage Service Disconnect Switch (see section on
Hybrid components for location) into the service position. To place it in theservice position, turn counter clockwise and then lift out. Reinsert the
Disconnect Switch with the arrow aligned to the service or shipping position.
High Voltage Service Disconnect Switch
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High Voltage Service Disconnect Switch
Place in-service orshipping position
WARNINGRemoving the High Voltage Service Disconnect Switch
disconnects high voltage from the vehicle. The individual cells inside the
battery pack will still be charged. Do not cut into the high voltage battery case
or penetrate the batteries in any way.
APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE
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SPECIAL NOTES
If the vehicle is on fire, use Class ABC powder type extinguisher to contain and smother the
flames. Or, if water is used, large amounts are required (e.g., from a fire hydrant).
If the vehicle has any exposed cables, make sure you are wearing insulated gloves and other
protective clothing. Do not touch any broken or damaged orange cables. Treat severed lines
as if they contain high voltage.
If the vehicle is submerged in water, do not touch any high voltage components or cables
while extricating the occupant. Do not remove the vehicle until you are sure the high voltage
battery is completely discharged. A submerged high voltage battery may produce a fizzing or
bubbling reaction. The high voltage battery will be discharged when the fizzing or bubbling
has completely stopped
3. IF THE HIGH VOLTAGE BATTERY CASE HAS BEEN RUPTURED
Just like any other battery: hose the area down with large amounts of water.
Moving the Vehicle
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Moving the Vehicle
4. MOVING DAMAGED VEHICLESWRECKER DRIVERS
Turn the vehicle ignition key to the accessory position to release the locking
steering wheel.
If possible, remove the High Voltage Service Disconnect Switch by turning it
counter-clockwise and lifting out. Reinstall in the service/shipping position.
Follow guidelines in the Wrecker Tow Manual.
Front Tow: Wheel Lift with Dolly for 4WD and no Dolly for FWD
Rear Tow: Wheel lift with Dolly for all (FWD or 4WD)
Flat bed: Front and Rear
5. SPECIAL NOTE TO SALVAGE YARDS
If a vehicle with a high voltage battery is to be scrapped, the high voltage battery
must be disposed of properly.
Cooling System in
H b id El i V hi l
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Hybrid Electric Vehicles
Fuel economy and environmentally friendly vehicles have
expedited HEV development in recent years.
HEVs are the helping meet these needs
In addition to the IC (Internal Combustion) engine in aconventional vehicle, an HEV has several electrical
subsystems, such as: Electric motor
Electric motor inverter
Voltage converter
Traction battery
All needing thermal management.
Streamlining Under Hood Air
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Streamlining Under Hood Air
HEV Cooling System Needs An AdditionalCooling System
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Coo g Syste
There are different coolant temperature and fluid flowrates.
The engine cooling system is already slammed into anarrow space under the hood now we must add:
Heat exchanger Electric pump and plumbing
Due to a large electrical capacity
Mechanical pump's used in the conventional cooling
are replaced with electrical components responding tovehicle cooling demands.
Next Generation Radiator
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Next Generation Radiator
Delphi is working on the next generation of radiators,which will be ultra compact.
The designs will further reduce weight and materials
used while enhancing performance.
Hybrid Cooling System
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Hybrid Cooling System
Delphi is leveraging its system knowledge
to address the specific needs for hybridengines:
Including increased cooling requirements forthe new electrical loop
Additional heat exchangers in the existingsystem space while also providing additionalcooling power
Delphi's air-to-oil cooler technology willhelp achieve lower transmission oil
temperature requirements.
DELPHI Cooling Module