Perkembangan Teknologi Otomotif

Pencapaian performa yang efisien & ramah lingkungan

PerkembanganTeknologi Otomotif

Kendaraanringan

1. Engine

2. Drive train

5. Safety Technology

4. Electrical

3. Chassis

6. Body

Garis Besar Perkembangan Mesin

Mekanisme Katup

SOHC (Single Over Head Camshaft)

OHV (Over Head Valve)

Teknologi Mesin

Sistem Bahan-bakar

EFI - Analog

Karburator

Sistem Pengapian

Transistorized / CDI

Konvensional (Platina)

VVT-I (Variable Valve Timing Intelligent)

DOHC (Double Over Head Camshaft)

Head Camshaft)

VVTL-I (Variable Valve Timing & Lift Intelligent

Lean Burn Engine

EFI - Microcomputer

D4 (Direct Injection Gasoline)

ESA (Electronic Spark Advance)

IIA (Integrated Ignition Assembly)

DIS (Direct Ignition System)

Sistem Pengisian

W/ IC Regulator

W/ Regulator tipeKontak Point

Teknologi Mesin

Sistem Starter

Tipe Reduksi

Konvensional

Sistem Bahan-bakarDiesel

Pompa injeksiDistributor

Pompa injeksi In Line

Alternator w/ Conductor segment

Tipe Planetari w/ Segment Conductor

Tipe Planetari

Common Rail

EFI Diesel (ECD)

Distributor

TOYOTA Hybrid Technology

BackgroundGlobal Concern on Energy Savings

Fuel price continue increaseExpanding energy consumptions

>US$ 122.17/barrel(Feb, ’12)* * ESDM

BackgroundGlobal warming caused by CO2

Global CO2 emissions from fuel combustion

CO2CO2

Drive the changing

The Changing of Market Need

CO2CO2

Drive the changing of market need

Customer basic needs on car is fun to driveand driving performance.

Focus on :Fuel efficiency, low emissions, while keep driving performance

Improving Fuel Efficiency to Reduce CO2 Emissions

TOYOTA Passion

TOYOTA Milestone

Apa itu Sistem Hybrid? Gabungan antara dua sumber tenaga

= 100HYBRID

= 100

± 50 + ± 50

100

CONVENTIONAL

Tipe Sistem Hybrid

Series Hybrid

Motor bensin memutarkan generator untuk mensuplai listrik ke motor listrik penggerak rodapenggerak roda

Contoh:

Chevrolet Volt

Paralel Hybrid

Motor bensin sebagai penggerak roda utama, motor listrik hanya membantu akselerasi.

Tipe Sistem Hybrid

Engine

Motor

Contoh:

Honda Insight, MB S400 BlueHybrid, BMW Seri 7 Hybrid

Series & Paralel Hybrid

“Power split device” secara konstan mengatur rasio tenaga motor bensin / listrik ke roda. Dapat menggerakkan kendaraan hanya dengan

Tipe Sistem Hybrid

kendaraan hanya dengan motor listrik saja.

Engine Motor

Plug-in Hybrid

Baterai dengan kapasitas lebih besar (biasanya Lithium) dapat di charge dengan listrik “rumah” untuk

Tipe Sistem Hybrid

“rumah” untuk memperbanyak penggunaan motor listrik dan mengurangi penggunaan motor bensin.

Sampai akhir 2009, Prius Plug-in akan di leasing 500 unit di Jepang, US & Eropa

Prius Low Emissions

% CO2 emission of Prius is 104 g/km ≈ 55% less than others in the same class class

% NOx emissions of Prius is 0.010 g/km and HC of Prius is 0.020 g/km ≈ less than half of others car in the same class

Prius Fuel Consumption

35.5 km/lJapan 10 – 15 ModeJapan 10 – 15 Mode

City drive : 23.2 km/l

Highway : 21.3 km/l

According to EPA test USA

Sejarah TOYOTA Hybrid

1997 20062003 20042001

Prius(NHW10) Estima PriusPrius

1999

Export to

USA(NHW10) Estima

Alphard

PriusPrius(NHW20)(NHW20)

RX400h

HighlanderCamry

1997 20062003 20042001

Crown

GS450h

USA

TOYOTA

Sejarah TOYOTA Hybrid2007 2009

LS600h PriusPrius(ZVW30)(ZVW30)

Toyota Hybrid Sales

TOYOTA Hybrid System in PRIUS Fusion between an internal combustion engine andelectric motor, achieving different function through

different power combinations to create optimum synergy and output.

Torque(N·m)

Motor

Engine

Speed (rpm)

2000 4000 6000

100

200

300

400

Auxiliary Battery(Sealed Type)

2ZR-FXE Engine

Cooler

HV Battery Unit• Battery Module

(DC 201.6 V)• Junction Block• Battery Smart Unit

THS Main Components

Power Cable

Inverter with Converter Assembly• Boost Converter • Inverter• MG ECU• DC/DC Converter

for Auxiliary Battery

ECM

Power Management Control ECU (HV CPU)

Cooler Compressor with Motor Assembly

P410 Hybrid Transaxle• MG1 • MG2

THS Main Components

Inverter/ConverterEngine

High Voltage Cables: Orange Color

THS Main Components• Power-dividing Mechanism (Planetary Gears)

§ MG1 – Sun Gear

§ MG2 – Ring Gear Wheels

§ Engine – PlanetaryCarrierCarrier

THS Main ComponentsHybrid Transaxle

THS Main Components

Blue: EngineBlue: Engine

Click, movie

Yellow: MG1

Orange: MG2

Yellow: MG1

Orange: MG2

THS Main Components

• Power-dividing Mechanism (Planetary Gears)

Planetary Carrier: fixedRing Gear: rotates (input)

Ring Gear: fixed

Planetary Carrier: rotates (input)

THS Main Components

• Power-dividing Mechanism (Planetary Gears)

Planetary Carrier: fixedRing Gear: rotates (input) cnt : mundur mesin diam

THS Main Components

Planetary GearsChain-drive Sprocket

Hybrid Transaxle

MG2 MG1

THS Main ComponentsHybrid Transaxle

Counter Drive GearGear

Final Drive Pinion Gear

Counter-driven Gear

Final Ring Gear

Chain-driven Sprocket

Reduction Mechanism

Differential Mechanism

THS Main ComponentsHybrid Transaxle• MG1 / MG2

– Compact and lightweight, highly efficient AC 650 V motor generator

MG2MG1

THS Main ComponentsHybrid Transaxle• MG1

– Main operations ® Generator

– When engine starting ® Starter

MG1Stator Coil

Rotor

Speed Sensor

THS Main Components• MG2

– When driving ® Main power to engine power (Starting off) or provides supplementary

– When braking ® Converts kinetic energy to electrical energy

MG2Stator Coil Rotor

Speed Sensor

THS Main Components

1NZ-FXE Engine with Atkinson Cycle(Same engine basis with Yaris & Vios)

THS Main ComponentsAtkinson Cycle:Compression < Expansion

Compression Expansion

Depending on driving condition, cylinder volume is varied by VVT-i operation

THS Main ComponentsEngine• Atkinson Cycle

– Depending on the driving condition, the cylinder volume is varied by VVT-i

Valve Timing (Intake Valve) Cylinder Volume

TDC

105°

72°

VVT-i Operation

BDC

THS Main ComponentsEngine• Atkinson Cycle

– Intake valve close timing is late

Valve Timing (Intake Valve) Cylinder Volume

TDC

105°

Co

mp

ress

ion

S

tro

ke

Exp

ansi

on

Str

oke

BDC

THS Main ComponentsEngine• Atkinson Cycle

– Intake valve close timing is early

Valve Timing (Intake Valve) Cylinder Volume

TDC

72° Exp

ansi

on

Str

oke

Co

mp

ress

ion

S

tro

ke

BDC

THS Main ComponentsInverter Assembly• Components

– Inverter

• DC « AC high voltage

– Variable-voltage System• DC201.6V stepped up to max. DC500V

– DC-DC Converter• DC201.6V stepped down to DC 12V

– A/C Inverter

• DC ® AC to drives the A/C compressor

THS Main ComponentsInverter Assembly

HV Battery

Inverter AssemblyInverter Assembly

Variable-voltage System

MG1

MG2

Inverter

HV Battery

A/C Inverter

MG2

DC - DC Converter

THS Main ComponentsInverter Assembly

Variable-voltage

Max. DC 650V­­ ¯̄DC 201.6V

Inverter AssemblyInverter Assembly

MG1

HV Battery

DC 201.6V DC500VVariable-voltage System

•IPM (IGBT)•Reactor

AC500V

MG2

: Discharge : Charge

MG1

Inverter(IPM)

THS Main ComponentsInverter Assembly

Inverter Assembly

– Cooling circuit is used for inverter assembly

– Separate cooling system from engine

Reservoir TankReservoir

Pump

RadiatorElectric Water Pump

MG1 / 2

Radiator

Inverter

THS Main ComponentsBatteray

HV Battery 12V Battery

THS Main ComponentsHV Batteray

The Battery has been made from Nickel-Metal Hydride (201.6V)’04 PRIUS: 168 cell ((1.2V x 6 cells) x 28 modules) = DC 201.6 V

THS Main ComponentsHV Batteray

Current Sensor

Module

SMR3

SMR2

Resister

Battery ECU

SMR1

Service Plug Connector

THS Main Components• Battery ECU

– Maintains control of HV battery SOC (State of charge)

– Ensures battery capability

Battery ECU

SOC Control

Cooling Fan Control

Electrical Leakage Detection for High-voltage System

Diagnosis Function for HV Battery

HV Battery Condition Detection

•HV ECU

CAN

Battery Cooling Fan Relay

Service Plug

Temp. Sensors (Thermistor)

Battery Cooling Fan Motor

HV BatteryCurrentSensor

+

-

High-voltage System for HV Battery•HV ECU•Engine ECU•A/C ECU

Battery Cooling Fan Controller

THS Main Components• Battery ECU

– Controls SOC to match THS characteristics

– The SOC is maintained at approx, 60%. A margin is given for further recharging via regenerative braking

– Sends requests to HV ECU to obtain desired SOC

THS Main Components• SOC Control

– When the SOC is dropped, battery ECU sends the “Charge Request” signal to HV ECU

Battery ECU

SOC

Charge Request

Power Request

HV ECUEngine ECU

HV Battery Engine

DriveCharge

Voltage (SOC)

Charging

Control

MG1

Information Display (New/3rd Gen Prius)

THS Main Components

THS Main Components

Information Display (2nd Gen Prius)

THS Main Components

Item Prius Corolla Altis

Engine Type 2ZR-FXE 1.8L 16V DOHC VVT-I

1ZZ-FE 1.8L 16V DOHC VVT-I

Compression ratio 13.0 : 1 10 : 1

Max Output PS/rpm 99/5,200 143/6,000

Maximum Torque kgm/rpm 14.2/4,000 19.1/4,200

THS Main Components

Motor Type Synchronous AC motor (650 V)

Maximum output in PS 81.6

Maximum torque Nm 207 (546 setelah di reduksi)

Total System Maximum output in PS 136

Battery Type Nickel-metal hydride

THS : How it Works

Gasoline Engine

Motor/Generator Battery

Engine

Motor/GeneratorPower-split Device

PCU/Inverter

THS : How it Works1. Start and low to mid-range speeds

The engine stops when in an inefficient range,such as at start-up such as at start-up and in low to mid-rangespeeds. The vehicle runs on the motor alone.

Click, movie

THS : How it Works

Engine power is divided by the power split device.Some of the power turns the generator, which in turn

2. Driving under normal conditions

turndrives the motor. The rest of the power drives the wheels directly. Power allocation is controlled to maximize efficiency.Click, movie

THS : How it Works

Extra power is supplied from thebattery, while the engine and

3. Sudden acceleration

engine andhigh-output motor provide smoothresponse for improvedacceleration characteristics.

Click, movie

THS : How it Works

The high-output motor acts as a high-output generator,driven by the vehicle’s wheels. This regenerative braking

4. Deceleration, braking

brakingsystem recovers kinetic energy as electrical energy,which is stored in the high-performance battery.

Click, movie

THS : How it Works

Battery level is managed to maintain sufficient reserves. The engine

5. Battery recharging

The enginedrives the generator to recharge the battery when necessary.

Click, movie

THS System Operation

Start-offNormal Driving Acceleration Deceleration Stop

Electric motor only

Motor and Engine

Motor and Engine (additional power

drawn from battery)

Battery charging

Engine automatically

shuts off

THS : Others System• Brake System

– ECB (Electrically Controlled Brake)

– Hydraulic brake pressure is controlled by electrical signal and cooperate regenerative brake

Hydraulic Brake

Skid Control ECU

Vehicle Condition

Driver’s Demand

HV ECU

Regenerative Brake Control

Hydraulic Brake Control

THS : Others SystemBrake System

– The total brake force provided by both hydraulic and regenerative brakes matches the braking power required

62

Regenerative Brake Hydraulic Brake

THANK YOU