Timothy A. Burress

Evaluation of the 2010 Toyota Prius Hybrid Synergy Drive System

Subsystems of the 2010 Toyota Prius hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies Program (VTP) not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment.

Evaluation of 2004 Toyota Prius Hybrid Electric Drive System

The 2004 Toyota Prius is a hybrid automobile equipped with a gasoline engine and a battery- and generator-powered electric motor. Both of these motive-power sources are capable of providing mechanical-drive power for the vehicle. The engine can deliver a peak-power output of 57 kilowatts (kW) at 5000 revolutions per minute (rpm) while the motor can deliver a peak-power output of 50 kW over the speed range of 1200-1540 rpm. Together, this engine-motor combination has a specified peak-power output of 82 kW at a vehicle speed of 85 kilometers per hour (km/h). In operation, the 2004 Prius exhibits superior fuel economy compared to conventionally powered automobiles. To acquire knowledge and thereby improve understanding of the propulsion technology used in the 2004 Prius, a full range of design characterization studies were conducted to evaluate the electrical and mechanical characteristics of the 2004 Prius and its hybrid electric drive system. These characterization studies included (1) a design review, (2) a packaging and fabrication assessment, (3) bench-top electrical tests, (4) back-electromotive force (emf) and locked rotor tests, (5) loss tests, (6) thermal tests at elevated temperatures, and most recently (7) full-design-range performance testing in a controlled laboratory environment. This final test effectively mapped the electrical and thermal results for motor/inverter operation over the full range of speeds and shaft loads that these assemblies are designed for in the Prius vehicle operations. This testing was undertaken by the Oak Ridge National Laboratory (ORNL) as part of the U.S. Department of Energy (DOE) - Energy Efficiency and Renewable Energy (EERE) FreedomCAR and Vehicle Technologies (FCVT) program through its vehicle systems technologies subprogram. The thermal tests at elevated temperatures were conducted late in 2004, and this report does not discuss this testing in detail. The thermal tests explored the derating of the Prius motor design if operated at temperatures as high as is normally encountered in a vehicle engine. The continuous ratings at base speed (1200 rpm) with different coolant temperatures are projected from test data at 900 rpm. A separate, comprehensive report on this thermal control study is available [1].

Evaluation of the 2007 Toyota Camry Hybrid Synergy Drive System

The U.S. Department of Energy (DOE) and American automotive manufacturers General Motors, Ford, and DaimlerChrysler began a five-year, cost-shared partnership in 1993. Currently, hybrid electric vehicle (HEV) research and development is conducted by DOE through its FreedomCAR and Vehicle Technologies (FCVT) program. The mission of the FCVT program is to develop more energy efficient and environmentally friendly highway transportation technologies. Program activities include research, development, demonstration, testing, technology validation, and technology transfer. These activities are aimed at developing technologies that can be domestically produced in a clean and cost-competitive manner. Under the FCVT program, support is provided through a three-phase approach [1] which is intended to: • Identify overall propulsion and vehicle-related needs by analyzing programmatic goals and reviewing industry’s recommendations and requirements, then develop the appropriate technical targets for systems, subsystems, and component research and development activities; • Develop and validate individual subsystems and components, including electric motors, emission control devices, battery systems, power electronics, accessories, and devices to reduce parasitic losses; and • Determine how well the components and subassemblies work together in a vehicle environment or as a complete propulsion system and whether the efficiency and performance targets at the vehicle level have been achieved. The research performed in this area will help remove technical and cost barriers to enable technology for use in such advanced vehicles as hybrid electric, plug-in hybrid electric, electric, and fuel-cell-powered vehicles.

Evaluation of the 2008 Lexus LS 600H Hybrid Synergy Drive System

Subsystems of the 2008 Lexus 600h hybrid electric vehicle (HEV) were studied and tested as part of an intensive benchmarking effort carried out to produce detailed information concerning the current state of nondomestic alternative vehicle technologies. Feedback provided by benchmarking efforts is particularly useful to partners of the Vehicle Technologies collaborative research program as it is essential in establishing reasonable yet challenging programmatic goals which facilitate development of competitive technologies. The competitive nature set forth by the Vehicle Technologies program not only promotes energy independence and economic stability, it also advocates the advancement of alternative vehicle technologies in an overall global perspective. These technologies greatly facilitate the potential to reduce dependency on depleting natural resources and mitigate harmful impacts of transportation upon the environment.

Evaluation of 2005 Honda Accord Hybrid Electric Drive System

The Hybrid Electric Vehicle (HEV) program officially began in 1993 as a five-year, cost-shared partnership between the U.S. Department of Energy (DOE) and American auto manufacturers: General Motors, Ford, and Daimler Chrysler. Currently, HEV research and development is conducted by DOE through its FreedomCAR and Vehicle Technologies (FCVT) program. The mission of the FCVT program is to develop more energy efficient and environmentally friendly highway transportation technologies. Program activities include research, development, demonstration, testing, technology validation, and technology transfer. These activities are aimed at developing technologies that can be domestically produced in a clean and cost-competitive manner. The vehicle systems technologies subprogram, which is one of four subprograms under the FCVT program, supports the efforts of the FreedomCAR through a three-phase approach [1] intended to: (1) Identify overall propulsion and vehicle-related needs by analyzing programmatic goals and reviewing industrys recommendations and requirements, then develop the appropriate technical targets for systems, subsystems, and component research and development activities; (2) Develop and validate individual subsystems and components, including electric motors, emission control devices, battery systems, power electronics, accessories, and devices to reduce parasitic losses; and (3) Determine how well the components and subassemblies work together in a vehicle environment or as a complete propulsion system and whether the efficiency and performance targets at the vehicle level have been achieved. The research performed under the vehicle systems subprogram will help remove technical and cost barriers to enable technology for use in such advanced vehicles as hybrid electric, plug-in electric, and fuel-cell-powered vehicles.

Benchmarking EV and HEV power electronics and electric machines

This paper presents information from an ongoing benchmarking project being conducted at Oak Ridge National Laboratory (ORNL) and funded by the Department of Energy (DOE). Beginning with the 2004 Toyota Prius, ORNL has benchmarked components from many on-the-road EVs, HEVs, and PHEVs. Detailed design, packaging, and operational assessments are presented on power electronic converters (such as inverters, buck converters, and bi-directional boost converters), electric motors (such as the primary drive motor and generator), and other associated components. Packaging assessments reveal mass, volume, and material compositions, and empirical evaluations provide efficiency, performance, and operational data throughout the entire operation range of each component.

Power-factor and torque calculation with consideration of cross saturation of the interior permanent magnet synchronous motor with brushless field excitation

This paper introduces a new method for calculating the power factor and output torque by considering the cross saturation between direct-axis (d-axis) and quadrature-axis (q-axis) of an interior permanent magnet synchronous motor (IPMSM). The conventional two-axis IPMSM model is modified to include the cross saturation effect by adding the cross-coupled inductance terms. This paper also contains the new method of calculating the cross-coupled inductance values as well as self-inductance values in d- and q-axes. The analyzed motor is a high-speed brushless field excitation machine that offers high torque per ampere per core length at low speed and weakened flux at high speed, which was developed for the traction motor of a hybrid electric vehicle.

Effect of Side Permanent Magnets for Reluctance Interior Permanent Magnet Machines

A traditional electric machine uses two dimensional magnetic flux paths in its rotor. This paper presents the development work on the utilization of the third dimension of a rotor. As an example, the air gap flux of a radial gap interior permanent magnet motor can be significantly enhanced by additional permanent magnets (PM) mounted at the sides of the rotor. A prototype motor built with this concept provided higher efficiency and required a shorter stator core length for the same power output as the Toyota/Prius traction drive motor.

Report on Toyota/Prius Motor Torque Capability, Torque Property, No-Load Back EMF, and Mechanical Losses, Revised May 2007

In todays hybrid vehicle market, the Toyota/Prius drive system is currently considered the leader in electrical, mechanical, and manufacturing innovations. It is significant that in todays marketplace, Toyota is able to manufacture and sell the vehicle for a profit. This projects objective is to test the torque capability of the 2004 Prius motor and to analyze the torque properties relating to the rotor structure. The tested values of no-load back electromotive force (emf) and mechanical losses are also presented.

Stator tooth and rotor pole shaping for low pole flux switching permanent magnet machines to reduce even order harmonics in flux linkage

High-speed machines require structurally robust rotor to withstand high centrifugal forces. Flux switching permanent magnet (FSPM) machines are ideal for high speeds since they have a simple and robust rotor structure. They also utilize permanent magnet (PM) in the stator enabling them to achieve high power density. It is desirable to keep the operating frequency minimized to reduce core losses and cost of power electronics. A 6-stator slot, 4-rotor pole (6/4) FSPM machine has the lowest operating frequency for a three phase FSPM configuration but suffers from heavy harmonic distortion in flux linkage. This paper aims to identify structural modifications that can minimize the dominant 2nd order harmonic component to make the 6/4 configuration amiable for high-speed applications. The analysis and methods proposed in this paper will be useful in tackling harmonic content of FSPM machines in general.