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1、Development of Integrated Motor Assist Hybrid System: Development of the Insight, a Personal Hybrid Coupe Kaoru Aoki, Shigetaka Kuroda, Shigemasa Kajiwara Hiromitsu Sato and Yoshio Yamamoto Honda R&D Co.,Ltd.Copyright 2000 Society of Automotive Engineers, Inc.Abstract ：This paper presents the techni
2、cal approach used to design and develop the powerplant for the Honda Insight, a new motor assist hybrid vehicle with an overall development objective of just half the fuel consumption of the current Civic over a wide range of driving conditions. Fuel consumption of 35km/L (Japanese 10-15 mode), and
3、3.4L/100km (98/69/EC) was realized. To achieve this, a new Integrated Motor Assist (IMA) hybrid power plant system was developed, incorporating many new technologies for packaging and integrating the motor assist system and for improving engine thermal efficiency. This was developed in combination w
4、ith a new lightweight aluminum body with low aerodynamic resistance. Environmental performance goals also included the simultaneous achievement of low emissions (half the Japanese year 2000 standards, and half the EU2000 standards), high efficiency, and recyclability. Full consideration was also giv
5、en to key consumer attributes, including crash safety performance, handling, and driving performance.Keywords：hybrid car，integration of the engine，efficient，environmental protection 1 INTRODUCTION To reduce the automobiles impact on society and the environment requires that it be increasingly cleane
6、r and more energy efficient. The issues of energy conservation, ambient air quality, and reduction in CO2 emissions are increasing raised as global environmental concerns. One solution for dealing with these issues is the hybrid automobile. Honda has developed and introduced to several major markets
7、 worldwide the Insight, a new generation of vehicle design. The Insight combines a hybrid power train with advanced body technology features to meet an overall goal of achieving the highest fuel economy practical.The hybrid power train is a motor assist parallel configuration, termed IMA for Integra
8、ted Motor Assist. This power train combines a highly efficient electric motor with a new small displacement VTEC engine, a lightweight aluminum body, and improved aerodynamics to realize 3.4L/100km (CO2:80g/km) on 98/69/EC fuel economy. Low emissions performance was also targeted with emission level
9、s achieving the EU2000. In addition to recapturing deceleration energy, the integrated motor provides high torque assist during typical urban driving accelerations. This allows a significant reduction in engine displacement and higher engine efficiency. Sustained hill climbing performance and high s
10、peed cruising capability are assured by a power-toweight ratio of approximately 56kW per metric ton. New engine technology includes the application of a new VTEC (Variable valve Timing and valve lift, Electronic Control) cylinder head design promoting high efficiency and fast catalyst activation, an
11、d a new lean NOx catalyst system which promotes lean burn combustion and a reduction in emissions. Extensive friction and weight reducing features are also applied. 2 DEVELOPMENT TARGETS AND CONCEPT Development was aimed at the achievement of extremely low fuel consumption. We set a target of twice
12、the fuel economy of the current production Civic, Hondas representative high fuel economy car at 7.0 L/100km (93/116/ EC). As a result, the Insight has the lowest fuel consumption in the world, among gasoline passenger cars.Exhaust emission performance often tends to be sacrificed for the sake of lo
13、w fuel consumption. However, we also decided to match the low emissions performance achieved by other mass production cars. Consideration was also given to recyclability (another important environmental issue), crash safety performance, and the basic car characteristics including handling and stylin
14、g.Summarizing the above, our development targets were as follows: The best fuel consumption performance in the world Ultra-low exhaust emissions Superior recyclability The worlds highest level of crash safety performance Advanced styling Practical features and responsive handling Comfortable two-sea
15、t configuration with personal utility space 3 POLICIES FOR FUEL CONSUMPTION REDUCTION In order to establish the technical approach for achieving the fuel consumption target, we conducted a detailed analysis of the energy consumption of the base car, a Civic equipped with a 1.5 liter engine. We found
16、 that it was useful to divide the targeted efficiency gains roughly into thirds, as shown in Fig. 1, in order to achieve the low fuel consumption and numerous other above-mentioned goals. These divisions are as follows. Improvement of the heat efficiency of the engine itself Recovery of braking ener
17、gy and employment of idle stop using a hybrid power plant Car body technologies including reduction of weight and reduced aerodynamic and rolling resistance. Figure 1. Target of double the fuel economy of CIVICAiming to establish a benchmark for 21st century automobile power trains, we developed thi
18、s new Integrated Motor Assist power train. This power train simultaneously achieves both extremely low fuel consumption of 3.4L/100km, and low exhaust gas emission performance, befitting a next-generation car. This paper reports on the newly developed IMA system, including the lean burn engine, elec
19、tric motor, power control unit, battery technology, and exhaust emission control technology used in the Honda Insight. 4 AIM OF THE IMA SYSTEM While developing this next-generation IMA hybrid system, we incorporated as many currently achievable technologies and techniques as possible, in order to ac
20、hieve the worlds lowest fuel consumption.The following four system development themes were established in order to meet this target.1. Recovery of deceleration energy 2. Improvement of the efficiency of the engine 3. Use of idle stop system 4. Reduction of power train size and weight 5 OVERVIEW OF T
21、HE IMA SYSTEM 5.1 SYSTEM CONFIGURATION As shown in Fig. 2, the IMA system uses the engine as the main power source and an electric motor as an auxiliary power source when accelerating. Using a motor as an auxiliary power source simplifies the overall system and makes it possible to use a compact and
22、 lightweight motor, battery, and power control unit (PCU). Figure 2. IMA SystemA permanent magnet DC brushless motor is located between the engine and the transmission. When decelerating, the rate of deceleration is calculated for each gear and the PCU controls the motor to generate electricity (rec
23、over energy), which charges a nickel-metal hydride battery. When accelerating, the amount of auxiliary power provided (hereafter called assist) is calculated from the throttle opening, engine parameters, and battery state of charge. The PCU controls the amount of current flowing from the battery to
24、the drive motor 5.2 RECOVERY OF DECELERATION ENERGY Recovering deceleration energy through regeneration makes it possible to supplement the engines output during acceleration and reduce the amount of fuel consumed. In particular, minimizing the engine displacement is an effective means of reducing f
25、riction. Engine displacement reduction also has several other benefits, such as weight reduction and increased thermal efficiency. The IMA system effectively increases the amount of regeneration during deceleration by optimizing the engine and transmission specifications. 5.3 REDUCTION OF ENGINE DIS
26、PLACEMENT Reducing engine displacement is a very important factor in improving fuel economy of a hybrid drive train. However, modern automobiles have to perform over a wide dynamic range. Reducing the displacement is equivalent to lowering the basic performance characteristics of the car. As shown i
27、n the output characteristics graph in Fig. 3, the IMA system assists the engine in the low rpm range by utilizing the hightorque performance characteristic of electric motors. The motor can increase overall toruque by over 50% in the lower rpm range used in normal driving. Output in the high rpm ran
28、ge is increased by using a Variable valve Timing and valve lift Electronic Control (VTEC) engine. Thus sufficient peak power is assured and makes it possible to use a new, small displacement 1.0 liter engine.Figure 3.Engine speed (rpm) Output performance of IMA SYSTEMAssist from the electric motor w
29、hile accelerating is a very efficient means of reducing the amount of fuel consumed. 5.4 ACHIEVING LEAN BURN ENGINE OPERATION Assist from the electric motor, based upon the throttle opening, creates quite linear torque characteristics. This, in turn, improves driveability. In addition, motor assist
30、is also provided under moderate load conditions to broaden the lean-burn operating range, bringing out the full potential of the newly developed lean burn engine. 5.5 IDLE STOP SYSTEM Stopping the engine rather than idling at stops is also an effective means for reducing fuel consumption. In order t
31、o restart the engine with the minimum amount of fuel consumption, the engine is quickly cranked to 600 rpm or more by the hightorque integrated motor before ignition occurs, as shown in Fig. 4. This makes it possible to minimize the amount of fuel consumed, in addition to the fuel saved by not runni
32、ng the engine at idle. There are many issues to be considered when performing idle stop. These include judging the drivers intent to stop, preparing for the restart, providing a smooth feeling of deceleration, and minimizing vibration of the car body when the engine stops. Figure 4.Time (sec) The number of cranking in the engine start
