400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2006-01-1341 Construction of Hybrid Vehicle Motor Generator ECU Naoki Maeda Electronics Engineering Div. 2, TOYOTA MOTOR CORPORATION Reprinted From: Advanced H ybrid Vehicle Powertrains 2006 (SP-2008) 2006 SAE World Congress Detroit, Michigan April 3-6, 2006 The Engineering Meetings Board has approved this paper for publication. It has successfully completed SAE's peer review process under th e supervision of the session organi zer. This process requires a minimum of three (3) reviews by industry experts. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licensing requests contact:SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: [email protected]: 724-772-4028 Fax: 724-776-3036 For multiple print copies contact: SAE Customer Service Tel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-0790Email: [email protected] ISSN 0148-7191 Copyright © 2006 SAE International Positions and opinions advanced in this paper are those of the author(s ) and not necessarily those of SAE. The author is solely responsible for the content of th e paper. A process is available by which discussions will be printed with the pap er if it is publishe d in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publicat ion by SAE should send the manuscript or a 300 word abstract to Se cretary, Engineering Meetings Board, SAE. Printed in USA 2006-01-1341 Construction of Hybrid Vehicle Motor Generator ECU Naoki Maeda Electronics Engineering Div. 2, TOYOTA MOTOR CORPORATION Copyright © 2006 SAE International ABSTRACT Fig. 1 Hybrid system diagram Boost ConverterMG1Power Control Unit Current SensorIPM Motor Generator ECUHVBatteryThis paper introduces a motor generator ECU used in the latest model of the hybrid system that Toyota Motor Corporation has developed. This new system is far more sophisticated than that of the current model (2005 MY Lexus RX400h). The motor generator ECU is a major component of the hybrid vehicle and is built into the power control unit. It controls the boost converter (which boosts the HV battery output voltage), a first motor-generator (MG1 in Fig. 1, which generates high voltage in order to operate MG2 and charge the HV battery) and a second motor-generator (MG2 in Fig. 1, which generates motive force for the wheels by electrical power). This ECU is scheduled to be released on the market in 2006. The hardware configuration of the motor generator ECU is the main theme of this paper. INTRODUCTION The expectation for hybrid vehicles have risen more and more because they offer a solution for issues involving the environment such as CO2 reduction. Until now, only a few specific hybrid vehicles have been launched on the market. However, the production number is still small. To increase use of hybrid vehicle, it is necessary to not only reduce their cost but also to miniaturize hybrid components. Especially, the miniaturization of the Power Control Unit (PCU) is important for mass production. As one way to achieve this, we have developed a next generation motor generator ECU (MG ECU) built into the Power Control Unit. The content of the development is described in the next section. HYBRID SYSTEM & MOTOR GENERATOR ECU 1. SYSTEM-OUTLINE Fig. 1 shows the outline of the newly developed hybrid system. The Power Control Unit is the main component of the hybrid system. It is composed of a Boost Converter, an Intelligent Power Module (IPM), a current sensor , an MG ECU, etc. In general terms, the Power Control Unit might be called an Inverter Assembly becaus