Advanced Hybrid Automotive Systems
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About this ebook
This book contains a wide array of automotive hybrid applications. Emphasis is placed on a practical approach, with the theory to back it up as well. It is, however, expected that the technician already has a basic understanding of automobiles and electronics in general. The text is also a great companion to in class training. With that in mind, learn and enjoy.
Advanced HYBRID Vehicle Systems
(vol 1), Including Toyota & Honda models
By Mandy Concepcion
Table of Contents
CHAPTER 1 (Hybrid Basics and Safety Procedures)
The Need for Hybrid Systems
Hybrid Do’s and Dont’s
Here are some definite do’s
Hybrid basics and safety procedures
Hybrid power down procedure and deactivation
High voltage measurement and equipment
Humidity and high-voltage
CHAPTER 2 (Hybrid Aerodynamics and Low Friction Tires)
Low friction components and non-belt driven coolant pump, and air conditioning compressor
The AC system
EPS system, or electric power steering
Replacement of the actual electric motor
Performing a zero rest procedure
CHAPTER 3 (Advanced Electronics for Hybrids)
The dangers of amperage and High Current Circuits
Current measurements using an electromagnetic probe (clamp on)
Voltage measurement on hybrid vehicles (advanced concepts)
Measure the high voltage circuit at the orange cables after a power down procedure
The Dropping Resistors
CHAPTER 4 (Basic Electric Motor and Power Generation)
Principle of Induction
Electric Motors and Electric Alternating Current
The DC Electric Motor
The AC Electric Motor
Important facts about electric hybrid motor generator units
Typical hybrid motor generator
Dangers of Inverter Internal Capacitors
Motor Commutation Plates
Hybrid Motor Position Sensor
Motor control techniques
Difference between a hybrid vehicle electrical motor and a regular AC motor
The TRIAC and IGBT (Isolated Gate Bipolar Transistor)
Hybrid Regenerative Breaking
CHAPTER 5 (AC and DC Power Units of Measurements)
Frequency measurements
Phase Measurement
Voltage Measurements
Using a Clamp-On AMP Probe
The 3 Phases of a HYBRID Motor (U, V, W)
The Inverter Unit on the Prius
DC Brushless Motors
CHAPTER 6 (basic battery technology)
The nickel metal hydride battery
The lithium ion battery
Toyota Prius high Voltage battery
Ultra-Capacitors
V R L A or variable regulation lead acid battery
CHAPTER 7 (The 6 Hybrid Modes of Operation)
HYBRID Computer System Control
Light Acceleration Mode
Regenerative Breaking Mode
Deceleration Mode
Normal Driving Mode
STOP Mode
M1’s Biggest Contribution to the HYBRID Unit
CHAPTER 8 (Parallel and Series Hybrid Systems)
Series hybrid system
Series, parallel, and series/parallel hybrid
Inverter Power Management
Parallel hybrid system
Parallel/Series hybrid system
Toyota motor Co. and AISIN
CHAPTER 9 (The Prius CVT or continuously variable transmission)
THS or hybrid synergy Drive
Transmission Planetary Gears
Key point to understanding the way this transmission works
HONDA CVT Transmission
Honda’s Cylinder Deactivation
Honda’s Electric Balancing
CHAPTER 10 (Toyota specific hybrid system)
Specific concepts on the Toyota hybrid
Problems with the Coolant Pump
Gas Tank Rubber Bladder
Car Off AC System
The Scanner and the HYBRID System
High Voltage Battery
MG1 and MG2 Power Output
The Toyota auxiliary 12 V battery
How to Jump Start a HYBRID
A Word About Toyota’s Keyless Entry
Dangers of Electric Mode Driving
CHAPTER 11 (Honda specific hybrid system)
The Honda hybrid system is vastly different than that of Toyota
HONDA Hybrid is a Simple Design
IMA or integrated motor assist
The Motor Generator Unit
The 12 volt St
Mandy Concepcion
Mandy Concepcion has worked in the automotive field for over 21 years. He holds a Degree in Applied Electronics Engineering as well as an ASE Master & L1 certification. For the past 16 years he has been exclusively involved in the diagnosis of all the different electronic systems found in today's vehicles. It is here where he draws extensive practical knowledge from his experience and hopes to convey it in his books. Mandy also designs and builds his own diagnostic equipment, DVD-Videos and repair software.
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Reviews for Advanced Hybrid Automotive Systems
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Book preview
Advanced Hybrid Automotive Systems - Mandy Concepcion
ADVANCED HYBRID
AUTOMOTIVE SYSTEMS
By MANDY CONCEPCION
Published by Mandy Concepcion at Smashwords
Copyright © 2006, 2011 By Mandy Concepcion.
This book is copyrighted under Federal Law to prevent the unauthorized use or copying of its contents. Under copyright law, no part of this work can be reproduced, copied or transmitted in any way or form without the written permission of its author, Mandy Concepcion.
Discover other titles by Mandy Concepcion
All charts, photos, and signal waveform captures were taken from the author’s file library. This book was written without the sponsoring of any one particular company or organization. No endorsements are made or implied. Any reference to a company or organization is made purely for sake of information.
The information, schematics diagrams, documentation, and other material in this book are provided as is
, without warranty of any kind. No warranty can be made to the testing procedures contained in this book for accuracy or completeness. In no event shall the publisher or author be liable for direct, indirect, incidental, or consequential damages in connection with, or arising out of the performance or other use of the information or materials contained in this book. The acceptance of this manual is conditional on the acceptance of this disclaimer.
The Mastertech is a registered trademark of Vetronix Corp. The DRB III & Starscan are a registered trademark of DaimlerChrysler The NGS is a registered trademark of Ford Motor Co. Any other proprietary name used in this book was done purely for explanatory purposes.
Preface
The role of the modern automotive technician has changed drastically in the past decade. The job of today’s vehicle specialist involves a deep knowledge of a wide variety of technical disciplines. Few professions encompass such a diverse understanding of technology. The automotive technician is now expected to know about chemistry, electronics, mechanics, optics,
as well as posses a deep analytical mind. The last only comes with time and experience.
This book contains a wide array of automotive hybrid applications. Emphasis is placed on a practical approach, with the theory to back it up as well. It is, however, expected that the technician already has a basic understanding of automobiles and electronics in general. The text is also a great companion to in class training. With that in mind, learn and enjoy.
About the author:
Mandy Concepcion has worked in the automotive field for over 21 years. He holds an Associates Degree in Applied Electronics Engineering as well as an ASE L1 certification. For the past 12 years he has been exclusively involved in the diagnosis of all the different electronic systems found in today’s vehicles. It is here where he draws extensive practical knowledge from his experience and hopes to convey it in this book.
Advanced HYBRID Vehicle Systems
(vol 1), Including Toyota & Honda models
By Mandy Concepcion
Table of Contents
CHAPTER 1 (Hybrid Basics and Safety Procedures)
The Need for Hybrid Systems
Hybrid Do’s and Don'ts
Here are some definite do’s
Hybrid basics and safety procedures
Hybrid power down procedure and deactivation
High voltage measurement and equipment
Humidity and high-voltage
CHAPTER 2 (Hybrid Aerodynamics and Low Friction Tires)
Low friction components and non-belt driven coolant pump, and air conditioning compressor
The AC system
EPS system, or electric power steering
Replacement of the actual electric motor
Performing a zero rest procedure
CHAPTER 3 (Advanced Electronics for Hybrids)
The dangers of amperage and High Current Circuits
Current measurements using an electromagnetic probe (clamp on)
Voltage measurement on hybrid vehicles (advanced concepts)
Measure the high voltage circuit at the orange cables after a power down procedure
The Dropping Resistors
CHAPTER 4 (Basic Electric Motor and Power Generation)
Principle of Induction
Electric Motors and Electric Alternating Current
The DC Electric Motor
The AC Electric Motor
Important facts about electric hybrid motor generator units
Typical hybrid motor generator
Dangers of Inverter Internal Capacitors
Motor Commutation Plates
Hybrid Motor Position Sensor
Motor control techniques
Difference between a hybrid vehicle electrical motor and a regular AC motor
The TRIAC and IGBT (Isolated Gate Bipolar Transistor)
Hybrid Regenerative Breaking
CHAPTER 5 (AC and DC Power Units of Measurements)
Frequency measurements
Phase Measurement
Voltage Measurements
Using a Clamp-On AMP Probe
The 3 Phases of a HYBRID Motor (U, V, W)
The Inverter Unit on the Prius
DC Brushless Motors
CHAPTER 6 (basic battery technology)
The nickel metal hydride battery
The lithium ion battery
Toyota Prius high Voltage battery
Ultra-Capacitors
V R L A or variable regulation lead acid battery
CHAPTER 7 (The 6 Hybrid Modes of Operation)
HYBRID Computer System Control
Light Acceleration Mode
Regenerative Breaking Mode
Deceleration Mode
Normal Driving Mode
STOP Mode
M1’s Biggest Contribution to the HYBRID Unit
CHAPTER 8 (Parallel and Series Hybrid Systems)
Series hybrid system
Series, parallel, and series/parallel hybrid
Inverter Power Management
Parallel hybrid system
Parallel/Series hybrid system
Toyota motor Co. and AISIN
CHAPTER 9 (The Prius CVT or continuously variable transmission)
THS or hybrid synergy Drive
Transmission Planetary Gears
Key point to understanding the way this transmission works
HONDA CVT Transmission
Honda’s Cylinder Deactivation
Honda’s Electric Balancing
CHAPTER 10 (Toyota specific hybrid system)
Specific concepts on the Toyota hybrid
Problems with the Coolant Pump
Gas Tank Rubber Bladder
Car Off AC System
The Scanner and the HYBRID System
High Voltage Battery
MG1 and MG2 Power Output
The Toyota auxiliary 12 V battery
How to Jump Start a HYBRID
A Word About Toyota’s Keyless Entry
Dangers of Electric Mode Driving
CHAPTER 11 (Honda specific hybrid system)
The Honda hybrid system is vastly different than that of Toyota
HONDA Hybrid is a Simple Design
IMA or integrated motor assist
The Motor Generator Unit
The 12 volt Starter
Honda Electronic Balancing
The 1.3L Engine
Soft iridium spark plugs
Honda Civic Complete Cylinder Deactivation
Advanced HYBRID Automotive Systems
(vol 1), Including Toyota & Honda models
###
CHAPTER 1
(Hybrid Basics and Safety Procedures)
The Need for Hybrid Systems
The modern age has ushered new threats to the environment. Human activity and production are in constant conflict with the environment. The production all CO, NOx and Hydrocarbon or HC threatens to destroy our health in general. Industrial output and activity coupled with the increasing number of automobiles on the roads makes this threat even bigger. Automobile pollution accounts for the greatest number of carbon dioxide, NOX and hydrocarbons output into the atmosphere. Industrial activity is closely related to Sulfur and Methane pollution. Our constant dependency on oil and industrial progress for the economy also fuels another type of gas, which is CO2 or carbon dioxide. Carbon dioxide is the natural output or any combustion process. Carbon dioxide can not be eliminated since any efficiently working engine produces CO2 as its output. Industrial activity on the other hand cannot be easy to control. Since this control can affect the economy the greatest. So the easiest problem to tackle is the automobile.
* An ICE is an internal combustion engine, either gas or diesel.
* CO2 is the normal