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1、ORNL/TM-2004/247,Evaluation of 2004 Toyota Prius,Hybrid Electric Drive System,Interim Report,C.W.Ayers,J.S.Hsu,L.D.MarlinoC.W.MillerG.W.Ott,Jr.,C.B.Oland,DOCUMENT AVAILABILITY,Reports produced after January 1,1996,are generally available free via the,U.S.Department of Energy(DOE)Information Bridge.,
2、Web site http:/www.osti.gov/bridge,Reports produced before January 1,1996,may be purchased by members,of the public from the following source.,National Technical Information Service5285 Port Royal RoadSpringfield,VA 22161,Telephone 703-605-6000(1-800-553-6847)TDD 703-487-4639Fax 703-605-6900,E-mail
3、infontis.fedworld.gov,Web site http:/www.ntis.gov/support/ordernowabout.htm,Reports are available to DOE employees,DOE contractors,EnergyTechnology Data Exchange(ETDE)representatives,and International NuclearInformation System(INIS)representatives from the following source.,Office of Scientific and
4、Technical InformationP.O.Box 62,Oak Ridge,TN 37831,Telephone 865-576-8401Fax 865-576-5728,E-mail reportsadonis.osti.gov,Web site http:/www.osti.gov/contact.html,This report was prepared as an account of work sponsored by an agency of theUnited States Government.Neither the United States Government n
5、or any agencythereof,nor any of their employees,makes any warranty,express or implied,orassumes any legal liability or responsibility for the accuracy,completeness,orusefulness of any information,apparatus,product,or process disclosed,orrepresents that its use would not infringe privately owned righ
6、ts.Reference hereinto any specific commercial product,process,or service by trade name,trademark,manufacturer,or otherwise,does not necessarily constitute or imply itsendorsement,recommendation,or favoring by the United States Government orany agency thereof.The views and opinions of authors express
7、ed herein do notnecessarily state or reflect those of the United States Government or any agencythereof.,ORNL/TM-2004/247,ENGINEERING SCIENCE&TECHNOLOGY DIVISION,EVALUATION OF 2004 TOYOTA PRIUSHYBRID ELECTRIC DRIVE SYSTEM,INTERIM REPORT,C.W.Ayers,J.S.Hsu,L.D.MarlinoC.W.MillerG.W.Ott,Jr.,C.B.Oland,No
8、vember 2004,Prepared for the,U.S.Department of Energy,FreedomCar and Vehicle Technologies Program,Prepared by the,OAK RIDGE NATIONAL LABORATORY,Oak Ridge,Tennessee 37831,managed by,UT-BATTELLE,LLC,for the,U.S.DEPARTMENT OF ENERGYunder contract DE-AC05-00OR22725,iii,iv,v,vi,1,1,1,2,2,3,4,8,8,8,9,11,1
9、2,12,13,14,14,14,17,17,18,21,21,22,23,29,29,29,30,31,31,33,34,TABLE OF CONTENTS,Page,LIST OF FIGURES.LIST OF TABLES.ACRONYMS.ACKNOWLEDGEMENTS.ABSTRACT.1.INTRODUCTION.1.1 PROGRAM OVERVIEW.1.2 TESTING FACILITIES.1.3 SCOPE AND OBJECTIVE.1.4 APPROACH.2.HYBRID ELECTRIC DRIVE SYSTEM DESCRIPTION.2.1 DESIGN
10、 REQUIREMENTS.2.2 SYSTEM COMPONENTS.2.2.1 Engine.2.2.2 Power Split Device.2.2.3 Generator.2.2.4 Motor.2.2.5 Inverter.2.2.6 Battery.3.LABORATORY TESTING.3.1 ANL VEHICLE LEVEL PERFORMANCE TESTS.3.1.1 Recent Work and Tests.3.1.2 Future Test Plan.3.2 ORNL COMPONENT-LEVEL PERFORMANCE AND VALIDATION TESTS
11、.3.2.1 Locked Rotor Tests.3.2.2 Back-emf Tests.3.2.2.1 Motor Tests.3.2.2.2 Generator Tests.3.2.3 Hybrid Drive System Losses Tests.4.INVERTER AND CONVERTER EVALUATION.4.1 FUNCTIONAL AND ARCHITECTURE STUDY.4.2 CONTROL DEVELOPMENT.4.3 INVERTER MODIFICATIONS AT ANL.5.SUMMARY AND CONCLUSIONS.5.1 FINDINGS
12、 AND OBSERVATIONS.5.2 NEEDED RESEARCH AND DEVELOPMENT.REFERENCES.,ii,2.3,7,LIST OF FIGURES,Figure,Page,2.12.22.42.52.62.72.82.93.13.23.33.43.53.63.73.83.9,Component arrangement for the THS II.2004 Prius engine and hybrid drive assembly.Heat removal and lubrication scheme for the 2004 Prius hybrid el
13、ectricdrive system.Diagram of the 2004 Prius power split device.Diagram of the 2004 Prius gear train between the motor and wheels.2004 Prius gears with number of gear teeth shown.2004 Prius generator rotor.2004 Prius motor rotor and stator.2004 Prius inverter and converter unit.Instrumentation locat
14、ions for ANL testing.Sample power measurements under varying speed conditions.Sample power measurements under controlled speed conditions.Motor shaft angle versus torque(rotor locked).Locked rotor peak torque as a function of current.Motor back-emf voltage versus motor shaft speed.Generator back-emf
15、 voltage versus generator shaft speed.Hybrid electric drive system and component losses at 25C.Configuration B losses as a function of oil temperature.iii,5691011111213151617191922232528,LIST OF TABLES,Table,Page,2.13.13.23.33.43.53.63.73.83.93.103.113.123.135.15.25.3,Specification for THS II compon
16、ents.Measurement variables for ANL testing program.Motor torque versus motor shaft angle.Test conditions for back-emf voltage measurements.Back-emf voltage measurements for the 2004 Prius motor.Back-emf voltage measurements for the 2004 Prius generator.Component configurations for loss determination
17、s.Summary of hybrid drive system losses.Configuration B losses at a nominal oil temperature of 28C.Configuration B losses at a nominal oil temperature of 40C.Configuration B losses at a nominal oil temperature of 50C.Configuration B losses at a nominal oil temperature of 60C.Configuration B losses a
18、t a nominal oil temperature of 70C.Configuration B losses at a nominal oil temperature of 80C.Summary of gear train losses at 25C.Summary of back-emf test results.Summary of motor current and torque test results.iv,814202121222324252626272728323233,emf,ACRONYMS,acANLAPRFdcDOEEEREFCVTGMRHEVkm/hkWNTRC
19、NmORNLPEEMRCPMrmsrpmTHS IIW,alternating currentArgonne National LaboratoryAdvanced Powertrain Research Facilitydirect currentU.S.Department of EnergyEnergy Efficiency and Renewable Energyelectromotive force(measured in volts)FreedomCar and Vehicle TechnologiesGiant Magneto Resistivehybrid electric v
20、ehiclekilometers per hourkilowattNational Transportation Research Centernewton meterOak Ridge National LaboratoryPower Electronics and Electric Machinery Research Centerpermanent magnetroot mean squarerevolutions per minuteToyota Hybrid System(new generation)wattsv,ACKNOWLEDGMENTS,Preparation of thi
21、s report was sponsored by the U.S.Department of Energy,Office of Energy Efficiencyand Renewable Energy through its FreedomCar and Vehicle Technologies Program.Special thanks aregiven to Susan Rogers of the Vehicle Systems Technologies subprogram for authorizing this work andoverseeing its developmen
22、t.Don Adams of the Oak Ridge National Laboratory is also acknowledged forhis overall contribution and guidance for the project.,vi,ABSTRACT,Laboratory tests were conducted to evaluate the electrical and mechanical performance of the 2004Toyota Prius and its hybrid electric drive system.As a hybrid v
23、ehicle,the 2004 Prius uses both agasoline-powered internal combustion engine and a battery-powered electric motor as motive powersources.Innovative algorithms for combining these two power sources results in improved fuelefficiency and reduced emissions compared to traditional automobiles.,Initial o
24、bjectives of the laboratory tests were to measure motor and generator back-electromotive force(emf)voltages and determine gearbox-related power losses over a specified range of shaft speeds andlubricating oil temperatures.Follow-on work will involve additional performance testing of the motor,genera
25、tor,and inverter.Information contained in this interim report summarizes the test results obtainedto date,describes preliminary conclusions and findings,and identifies additional areas for further study.,1.INTRODUCTION,The 2004 Toyota Prius is a hybrid automobile equipped with a gasoline engine and
26、a battery-poweredelectric motor.Both of these motive power sources are capable of providing mechanical drive power forthe vehicle.The engine can deliver a peak power output of 57 kilowatts(kW)at 5000 revolutions perminute(rpm)while the motor can deliver a peak power output of 50 kW at 1300 rpm.Toget
27、her,thisengine-motor combination has a specified peak power output of 82 kW at a vehicle speed of85 kilometers per hour(km/h).In operation,the 2004 Prius exhibits superior fuel economy compared toconventionally powered automobiles.,To acquire knowledge and thereby improve understanding of the propul
28、sion technology used in the 2004Prius,laboratory tests were conducted to evaluate the electrical and mechanical characteristics of the 2004Prius and its hybrid electric drive system.This testing was undertaken by the Oak Ridge NationalLaboratory(ORNL)as part of the U.S.Department of Energy(DOE)Energ
29、y Efficiency and RenewableEnergy(EERE)FreedomCar and Vehicle Technologies(FCVT)Program through its vehicle systemstechnologies subprogram.,1.1 PROGRAM OVERVIEW,The Hybrid Electric Vehicle(HEV)program officially began in 1993 as a five-year cost-sharedpartnership between DOE and American auto manufac
30、turers:General Motors,Ford,and,DaimlerChrysler.They committed to produce production-feasible HEV propulsion systems by 1998,first-generation prototypes by 2000,and market-ready HEVs by 2003.,Currently,HEV research and development is conducted by DOE through its FCVT Program.Themission of the FCVT pr
31、ogram is to develop more energy efficient and environmentally friendly highwaytransportation technologies.Program activities include research,development,demonstration,testing,technology validation,and technology transfer.These activities are aimed at developing technologies thatcan be domestically
32、produced in a clean and cost-competitive manner.,The vehicle systems technologies subprogram,which is one of four subprograms under the FCVTprogram,supports the efforts of the FreedomCAR through a three-phase approach intended to:,1,Identify overall propulsion and vehicle-related needs by analyzing
33、programmatic goals andreviewing industrys recommendations and requirements,then develop the appropriate technicaltargets for systems,subsystems,and component research and development activities;,Develop and validate individual subsystems and components,including electric motors,emissioncontrol devic
34、es,battery systems,power electronics,accessories,and devices to reduce parasiticlosses;and,Determine how well the components and subsystems work together in a vehicle environment or as acomplete propulsion system and whether the efficiency and performance targets at the vehicle levelhave been achiev
35、ed.,Source:http:/www.eere.energy.gov/vehiclesandfuels/technologies/systems/index.shtml,The research performed under the Vehicle Systems subprogram will help remove technical and costbarriers to enable technology for use in such advanced vehicles as hybrid and fuel-cell-powered vehicles.,1.2 TESTING
36、FACILITIES,Evaluation of the 2004 Prius and its hybrid electric drive system involved both vehicle-level andcomponent-level performance testing.Vehicle-level testing is being conducted at the AdvancedPowertrain Research Facility(APRF)located at the Argonne National Laboratory(ANL),9700 S.CassAvenue,
37、Argonne,Illinois.The APRF is a multi-dynamometer vehicle test facility capable of testingconventional and hybrid vehicle propulsion systems and vehicles.Component-level testing is beingconducted by ORNL at its Power Electronics and Electric Machinery Research Center(PEEMRC).ThePEEMRC is a broad-base
38、d research center for power electronic inverters and electric machinery(motor)development.Located in the recently constructed National User Facility known as the NationalTransportation Research Center(NTRC),the PEEMRC has more than 9000 square feet of space fordeveloping and building the next genera
39、tion prototypes of inverters,rectifiers,and electric machinetechnology.,1.3 SCOPE AND OBJECTIVE,This interim report summarizes vehicle-level and component-level test results obtained to date for the2004 Prius and various electrical and mechanical components of its hybrid electric drive system.Thepri
40、mary objective of these tests was to characterize the electrical and mechanical performance of the 2004Prius.,Information about the 2004 Prius and its technical design features are presented in Chapter 2 to serve as afoundation for subsequent discussions about the various components of the hybrid el
41、ectric drive systemthat were tested.Laboratory test results are summarized in Chapter 3.They include electrical andmechanical data that have been acquired to date at ANL and ORNL.The objectives of these tests were tocharacterize the functional performance of the hybrid electric drive system and to u
42、nderstand the designmethodology used in the construction of the various system components specifically the generator,traction motor,and inverter.Information about the inverter and converter is presented in Chapter 4.Thisinformation includes discussions about the functional characteristics and contro
43、l development for theinverter and converter and a description of inverter modifications that will provide a way to measurecurrent and voltage values at specific locations.Preliminary conclusions and findings based on theacquired test data along with areas of needed research and development are prese
44、nted in Chapter 5.,2,1.4 APPROACH,Complementary electrical and mechanical data from vehicle-level and component-level tests wereacquired to gain a full understanding of the 2004 Prius performance.These data were then used todetermine back-emf voltage and energy loss values over the specified operati
45、ng range of the vehicle.,Vehicle-level tests are being performed at the APRF with the electrical and mechanical systems installedin the original factory configuration.The inverter,motor,generator,axles,and related components areinstrumented to acquire power flow data needed to characterize vehicle p
46、erformance.,Component-level tests are being performed at the NTRC by removing the hybrid electric drive systemand inverter from the vehicle and mechanically connecting the shaft to a dynamometer.This arrangementalso requires a reconfiguration of the inverter so that it will operate outside the vehic
47、le.Using thisapproach makes it possible to separately evaluate the performance of each power-related component ofthe hybrid electric drive system.Component-level test results provide data needed to characterize theoverall performance of the 2004 Prius.,3,2.HYBRID ELECTRIC DRIVE SYSTEM DESCRIPTION,Th
48、e 2004 Prius is a new-generation hybrid automobile that was introduced into the market inSeptember 2003 by the Toyota Motor Corporation.As a hybrid vehicle,the 2004 Prius uses both agasoline-powered internal combustion engine capable of delivering a peak power output of 57 kW and abattery-powered el
49、ectric motor capable of delivering a peak power output of 50 kW as motive powersources.Combining these two-motive power sources results in improved fuel efficiency and reducedemissions compared to traditional automobiles and provides the 2004 Prius with the following energy-saving characteristics.,E
50、nergy-loss reduction is achieved by automatically stopping the engine when idling.Energy is recovered and reused by capturing kinetic energy that is normally wasted as heat,during deceleration and braking.The starter and electric motor then convert this energy toelectricity for use.,Engine is able t
