Hybrid Safety

7/30/2019 Hybrid Safety

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Representative Customers


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Delphis 113 Years of Innovation

Heritage Names and Products you Know! Packard Electric Division

Delco-Remy

AC Spark Plug

Harrison Radiator

Frigidaire

Delco Radio

Inland Fisher-Guide

Saginaw Steering Gear

Fisher Body

Rochester Products

Delco-Moraine


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2008 HybridsAutomobile Drive Train Engine

Transmission Hybrid

Toyota

Prius

FWD 1.5L

4 cyl

Automatic Full

Honda

Civic

FWD 1.3L

4 cyl

Automatic

CVT

Assist

Honda

Accord

FWD 3.0 L

6 cyl

Automatic

L5

Assist

HondaInsight

FWD 1.0L3 cyl

AutomaticCVT / 5Spd M

Assist

Ford

Escape

FWD

4 WD

2.3L

4 cyl

Automatic

CVT/CVUSL

Full

Mercury

Mariner

4WD 2.3L

4 cyl

Automatic

CVT/CVUSL

Full

Mazda

Tribute

4WD 2.3L

4 cyl

Automatic

CVT/CVUSL

Full

Lexus 400 H

Toyota

Highlander

FWD

4WD

3.3L

V6

Automatic

CVT

Full

Chevrolet

Silverado

2WD

4WD

5.3L

V8

4Sp Automatic

CCCVL

Mild

GMC

Sierra

2WD

4WD

5.3L

V8

4Sp Automatic

CCCVL

Mild

Transmission Descriptions

Continuously Variable UserSelectable Lock-up (CVUSL)

Computer Controlled

Continuously Variable Lock-up

(CCCVL)

Hybrid DefinitionsAssist: The Electric Motor

Only Assists The Engine

Mild: The Electric Motor

Only Assists The Engine

Full: The Vehicle Can Use

Gas, Electric or Both ForPower


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Back to the Future

Photo of Thomas Edison with 1914 Detroit Electric Model 47

From the Smithsonian

(courtesy of the National Museum of Natural History)


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Back to the Future

1921 Owen Magnetic Model 60

Used a gasoline engine to run a generator

Which supplied electric power to motors mounted

in both rear wheels


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Development of the Hybrid

GM, Chrysler, Ford, Many of the European and Asia

n Manufactures produced all Electric Vehicles.

Best use was in small vehicles used in the city

Limited Range due to battery capacity

Recharge took several hours

Other electric vehicles that were


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42V Belt Alternator Starter System from Delphi

Delphi presented its Energen 42V Belt Alternator StarterSystem at Convergence 2002.

The system replaces a conventional vehicle's existing starterand generator with a single high-power belt-drivenmotor/generator

Providing an 8-10% fuel economy improvement in city traffic.

The system provides dual-voltage 42V/14V architecture.

In generating mode, the belt-driven electric machine, theelectronics box, which contains a power inverter and machine

controller, produces electrical power 42 volts and charges a 36-volt battery.

A DC-DC converter is used to obtain 14 volts from 42


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Engine Turnoff at Idle is Improves Vehicle Fuel Economy

A number of alternatives for implementation of the restarting functionincluding:

The existing cranking motor

12V or 36V belt-starter,

Crankshaft integrated-starter generator (ISG)More complex hybrid powertrain architectures.

The 12V belt alternator- starter (BAS) offers fast, quiet starting at a lowersystem cost. There are two challenges are

1. Need to accelerate a large engine to idle speed quickly

2. Dynamic torque control during the start for smoothness.


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42V C from Delphi

Energen 5 Designed for GM 5.3L V8


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Starter Generator

Delphi Energen 5

SG (Starter Generator)

RIC (Regulator Inverter Controller)


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Control System Layout

The engine speed has to be limited by the PCM calibration to 5000 [rpm] to prevent over

speed of the SG

The specified maximum speed allowed on the SG is 18000 [rpm].

A normal start happens when the restart of the engine after IEO (Idle Engine Off) is done

within 2 to 3 seconds.

The SG on this application is only used for warm engine restarts from an IEO event. The DCstarter is used for cold engine starts and in case of a detected fault on the RIC


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Conventional Engine

with a Belt Alternator Starter System

Hybrid uses a conventional internal combustion engine and a generator withstarter power the vehicle.

Note: All intermediate voltage cables used on the hybrid are blue for easy

identification


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Always Use the Original Vehicle Manuel

When Working on vehicles correct information is

necessary

On a GM Hybrid 12V/36V Systems You ShouldKnow Color Codes For Wiring Conduits:

Orange = 60 or More Volts

Blue = 30V to 60V

Red = Automotive Low Les than 30V


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Hybrid Configuration

Parallel Hybrid: The primary energysource can drive a generator like the

series system In addition it can also drive

the vehicle parallel to the electric motor.

The Honda Integrated Motor Assist (IMA)is an excellent example of a parallel

hybrid drive system.

Series Hybrid: The primary power sourceis the internal combustion engine which

drives a generator:

Electric power is stored in batteries usedto power an electric motor that drives the

wheels Most true Series Hybrids in use

today are medium-duty vehicles such as

transit buses


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Toyota Prius


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Prius Dash View


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Toyota Prius Hybrid Synergy Drive

Left side (black) is a 1.5 liter Internal Combustion Engine

Drives the wheels and the electric generator.

Right side (aluminum)

High voltage unit part of the Toyota Hybrid Synergy Drive


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Prius 1.5 liter, 1NZ-FXE engine


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Cylinder Head Thermos

Toyota Thermos

In Left Front Fender Ahead

of Wheel Housing

Keeps Coolant Warm toCirculate through the Head

on Cold Start

Up to Three Days Close to

200 F


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Engine Control System Sensors

VSV(for

EVAP)

Mass AirFlow Meter

Water Valve

Coolant Heat StorageTank & Water Pump

ECM

Heated Oxygen

Sensor

VSV (for CanisterClosed Valve w/

Trap Filter)

Combination

Meter VaporPressureSensor

CharcoalCanister

& VSV(for Purge FlowSwitching

Valve)

DLC3 Accelerator PedalPosition Sensor

ThrottleBody

Heated AirFuel Ratio

Sensor


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Toyota Uses a Parallel Drive SystemParallel Hybrid:

Both the battery and engine are connected to the transmission

Either the battery using the electric motor, or the engine and the

transmission, can provide propulsion power.

Also propulsion can use a combination of both


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Battery Module (98KB, MIME type)

Second generation Toyota Prius uses 28 of these modules to create a 200 volt DC battery pack

Inverter is used to "step-up" the power to 500 Volts, converting the DC battery power to theAC required for the electric motors (The module s are only 10 inches long and can be

serviced individually however labor cost will most likely force servicing as a unit)

First generation Prius utilizes conventional round NiMH batteries inside a metal battery

case to operate the 300 Volt hybrid electrical system

While the battery voltage dropped from 300 Volts, to 200 Volts in the second generation Prius,

the high-voltage inverter steps the power up to 500VA more powerful electric motor allows for approximately a 30% increase in overall power


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HVNickel-Metal Hydride Battery

Six 1.2V Nickel-Metal Hydride (Ni-MH)cells are connected in series to form one

module.

28 modules are connected in series for the

rated voltage 201.6V.


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Battery Safety Sticker

On Battery module


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Multi-Function Monitor

Energy Monitor


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High Voltage Inverter


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High Voltage Inverter

High voltage inverter unit with cover removedUsed in the NHW11 1st generation of the Prius

3 black coil like objects are capacitors


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Engine and Drive System

Motor Gen.1 Motor Gen.2

Planetary Gear SetSilent ChainTransaxle

Damper


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Honda Motor and Rotor

Use Proper tool to: Remove Rotor

Install Rotor

Very Heavy Magnetic Field

Could Injure Technician


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Toyota Planetary Gear Transmission


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Auxiliary AGM Battery


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AGM

Absorbent Glass Mat (AGM) technology is the latest innovationin maintenance-free batteries (introduced on 2001 Corvette).

The AGM battery is classified as a gas recombinant or

recombination design.

Recombination means that the hydrogen and oxygen gassesgenerated during charging are recombined to produce water.Consequently, gassing and its associated water loss are

eliminated.


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Jump Start Terminal at the Auxiliary Battery

Main Junction

Block

2004 and later Prius

Jump starting a Prius is allowed if procedures

are followed

Once started the charging system will return

battery to normal state of charge

Jumper Cable Tab


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Cable Routing

Junction Box

Auxiliary Battery

HD Battery

Inverter

Motor Generator 1

Motor Generator 2

Aluminum Wiring Harness


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Battery System Layout

System Main Relay (SMR)

Battery ECU

Service Plug

Upper Case Cover

Battery Module


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Junction

Power Cable

Voltage (+)

Power Cable

Voltage (-)

+ 12V DC


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Hybrid Vehicle SafetyVehicle must be disabled

2004 & later Prius Auxiliary Battery

Toyota emblem is not chrome on the other side Turn off the hybrid system.

Vehicles with smart key, disable it and make sure

key fob is at least 15 feet away from the vehicle

Disconnect the negative (-) terminal of the 12V auxiliary battery.

20012003 Prius Auxiliary Battery


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2004 to 2008 Smart key

Toyota emblem is chrome If inside the vehicle will

start and get ready light

Outside will not start and no

ready light


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Toyota Smart Key


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Remove the Service Plug

You Must Wear insulated gloves (Be sure gloves are not damaged)

Remove Orange service plug and put it in your pocket

Do not test or make repairs for Five minutes.

2001

2003 Prius 2004 and later Prius

Orange service plug


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Toyota Prius Auxiliary Battery

Located in Trunk

12.6 V AGM

Red Cables

Should Be Disconnected to

Work ON


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Handling High Voltage Cables

High-voltage cables are orangeDo Not Touch. If you are

working near any high-voltage cables or components:

Use insulated tools

Do not leave tools or parts (bolts, nuts,

etc.) inside cabin.

Do not wear rings, watches or metal

objects

Be Cautious of High-Voltage Components


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Need to Wear High Voltage Gloves

High Voltage Class 0, rated at 1000 volts with Leather Outer Shell

Cat III Rated Fluke 1587DVOM & Insulation Tester


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High Voltage Tools


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Lexus LS600hL


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Honda Insight


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Honda Civic Hybrid


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Honda Engine


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Honda Integrated Motor Assist (IMA)


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Honda Models Use Parallel Configurations

The wheels are powered by both the internal combustionengine and an electric motor

The two Honda Integrated Motor Assist (IMA) systems utilizesmaller-than-normal gasoline engine and a thin, pancake-typeelectric motor/generator located between the engine and

transmission 1.0-liter three-cylinder in the Insight

1.3-liter four-cylinder in the Civic

When additional power is needed, when passing the integrated electricmotor/generator kicks in and supplies added power.

The motor/generator functions as a high-speed starter and for batterycharging during regenerative braking.


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Honda Configurations Not Like Ford and Toyota

Hondas hybrids cannot operate solely on battery powerIMA fits the definition of a true integrated hybrid

Designed to run super-efficiently on shared internalcombustion and electric

The less costly mild hybrids being developed by automakerstypically use an integrated starter/generator that automaticallyshuts down an engine when a vehicle stops

Then starts it up when its time to go again. Giving a slightimprovement in fuel economy of maybe 10 percent

A world apart from the 40, 50, and 60+ mpg fuel economyachieved by system like Hondas IMA.


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Honda Engine

New Honda Hybrid System uses: Intelligent engine functions to achieve an approximate 20%

increase in system output over the current system

Giving the performance of a 1.8-litre engine while improving

fuel economy Reducing the system size by 5% and attainting a greater level

of emissions control

The system offers significantly improved performance and fuel

economy over the current system.


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Honda Engine

3-stage i-VTEC uses three hydraulic passages Providing three stages of valve control depending on the

driving conditions

Achieving a combination of responsive driving conditions andfuel economy by coupling and uncoupling five rocker armassemblies

During deceleration the cylinders are idle Combustion in all four cylinders is shut off

The cylinders sealed shut

A 10% improvement in recovery of braking energy compared to thecurrent Civic

Aluminum die-cast pistons, which have less heat related expansion andless friction, ion-plated piston rings, and plateau honing of the cylinderwalls for a smoother surface.


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Engine, IMA and Transmission


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Honda Transmission

Steel Belt

Variable Cones


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IMA (Integrated Motor Assist)


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Motor Mode

IMA motor/generators starts the gasoline engine and brings it to 1000 RPM

As a back-up this job can be handled by the Hondas conventional 12-voltstarter when:

When the battery module state-of-charge is too low

Operating in extremely cold or hot weather

IMA system fails

Direct current from the battery module is converted to AC electric powerby the motor drive module (MDM)

This electricity is supplied to the IMA motor/generator operating in motormode for accelerating, climbing hills, and other high load conditions

For maximum acceleration, both the IMA motor/generator and gasoline engineare used

Under light acceleration, the motor/generator provides only partial assist in anamount determined by load and throttle position

Once cruising, the Honda hybrid is propelled solely by the gasoline engine


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Honda Series Hybrid:

In the series type of hybrid the engine turns a generator and the

generator can either charge the batteries or power an electric

motor that drives the transmission.

The engine never powers the vehicle directly.

Source:Toyota


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IMA (Integrated motor Assist)


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Honda Electric Motor Control

Hondas electric motor Employs coils designed with high-density windings

High-performance magnets to attain output 1.5 times that ofthe current model while maintaining the same size

The inverter used to control motor speed

Independently developed and manufactured by HondaI

Integrated with the motors ECU for more precise digitalcontrol Contributing to even greater motor efficiency and fuel economy.

Battery output has been increased by around 30% over thecurrent model More compact, custom designed battery storage box offers increased

cooling performance and vibration resistance for improved long-termreliability.


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New Honda Hybrid System Modes of Operation

Vehicle stationary

The engine is turned off and fuel consumption is zero.

Startup and accelerationThe engine operates in low-speed valve timing mode, with motor assist.

Rapid accelerationThe engine operates in high-speed valve timing mode, with motor assist.

Low-speed cruisingThe valves of all four of the engines cylinders are closed and combustion halted.The motor alone powers the vehicle.

Gentle acceleration and high-speed cruisingThe engine operating in low-speed valve timing mode powers the vehicle.

Deceleration

The valves of all four of the engines cylinders are closed and combustion halted.The motor recovers the maximum amount of energy released during decelerationand stores it in the battery.


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Specifications for the New Honda Hybrid System

Power Source:

Engine

Water-cooled in-line

Number or cylinders 4-cylinders

Displacement 1,339 Bore x stroke (mm) 73.0 x 80.0

Electric

Electric motor type:

AC synchronous drive motor (Ultra-thin DC brush- less motor)

Rated voltage (v) 158 Performance Engine Max. output 70[95]/6,000(kW[PS]/rpm)

Max. torque 123[12.5]/4,500 (Nm[kgm]/rpm)

Electric Max. output 15[20]/2,000 motor (kW[PS]/rpm) Max.torque 103[10.5]/0~1,160 (Nm[kgm]/rpm)

System Max. output 70+15[95+20] output (kW[PS]/rpm) Max.torque167[17.0] (Nm[kgm]/rpm)


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Orange Is A Safety Alert

All Orange Cables Are HighVoltage and Dangerous

Put In Service Mode and

Wait For Capacitors to drain

About 90 Seconds

Use the Proper DMM

Disconnect Auxiliary

Battery

Be Vehicles Are in NeutralBefore Pushing In Shop


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Toyota Fuse Box

UNDERHOOD

FUSE BOX


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Honda Battery


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Silverado
http://www.conceptcarz.com/vehicle/z8357/default.aspx


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Examples of Very Different Hybrids

Hybrid Features by Make/Model

Make Model Idle Stop Regenerative Braking Motor AssistEngine-Off Drive- EV

Mode

Chevrolet Silverado 1500/GMC Sierra

HybridX X

Ford Escape Hybrid X X X X

Honda Civic Hybrid X X X

Honda Insight X X X

Toyota Prius X X X X

Differentiate hybrids based on the features:Mild-Incorporate Idle Stop and Regenerative Braking

Strong-Incorporate Idle Stop, Regenerative Braking, Motor Assist, and

Engine-Off Drive-EV Mode

S i


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Saturn Vue hybrid

S V H b id E i


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Saturn Vue Hybrid Engine

S V h b id


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Saturn Vue hybrid

System Operation


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System Operation

The Saturn VUE Hybrid Used to Cover GM Vehicle Lines:

Gasoline-electric hybrid vehicle

Introduced in the summer of 2006

Uses a 36 volt electrical and a traditional 12 volt battery and sophisticated

technology to achieve its fuel savings.

The vehicle is equipped with a 2.4 liter, 4-cylinder

engine and a traditional 12 volt starter motor,

which is used only for initial starts of the vehicle.

Starter Generator with three phase AC cable assembly

S t O ti


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System Operation

The PEB integrates the inverter

and DC to DC converter into one

unit

The PEB also includes the

transmission electric pump

controller as well as auxiliary

input and output drivers

The inverter portion of the power

electronics box (PEB) will control

the motoring or electrical

generating function of the SG

Other drivers include controls

which provide power to the

electric transmission oil pump

BAS H b id B tt A bl


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BAS Hybrid Battery Assembly

The BAS (Belt Alternator

System) battery assembly hasseveral components which areserviceable and can be replaced asnecessary However, the actual batteries, when

replaced need to be replaced together

Control module looks at each of themodules state of charge and condition

If one of the three modules does notmeet the set criteria with relation toeach other (exceeds 0.6 volts) this iscalled Imbalance, the batterycontrol module will not allow the

battery to function

BAS 42V Beneath the

Rear Compartment

GM H b id V hi l


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GM Hybrid Vehicles

Pi t d i D l hi' H b id I t


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Pictured is Delphi's Hybrid Inverter

Delphi research and development of hybrid powertrain

Help manufacturers like Ford fit the most efficient powertrain for their hybrids.

GM H b id V hi l


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GM Hybrid Vehicles

GM Daimler Chrysler BMW Group Global Hybrid Cooperation. The hybrid with two driving

modes optimizes power and torque for the given driving conditions

The first mode provides fuel-saving capability in low-speed and stop-and-go driving, with a

combination of full electric propulsion and engine power.

The second mode is used primarily at highway speeds to optimize fuel economy, while providing full

engine power when conditions demand it, such as trailer towing or climbing steep grades.

.

T 60 kW M t d 300 V lt B tt P k


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Two 60 kW Motors and a 300-Volt Battery Pack

Porsche Ca enne H brid S
http://www.techscoop.com.au/userimages/user1165_1156511510.JPG


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Porsche Cayenne Hybrid S

Cayenne Hybrid S


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Cayenne Hybrid S

V-8 power with four-cylinder fuelefficiency accomplished by using:

Parallel hybrid system

Audi 3.0-liter V-6

Supercharged, gasoline-direct-injectionThree-phase synchronous electric motor

Nickel-metal-hydride battery pack

Up to 385 hp and 545 lb-ft of torque

Zero to 60 mph acceleration of 6.8

seconds

Fuel economy is listed at 26 mpg on the

European driving cycle

Cayenne Hybrid S


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Cayenne Hybrid S

Using a totally new eight-speed automatic

transmission

Top vehicle speed is achieved in 6th

The two higher gears boost fuel economy by

lowering engine RPM

Eighth gear, allows the vehicle to coast without thecombustion engine at speeds up to 86 mph

Travel in all-electric mode is less than two miles

The electric motor is located between the engine and

transmissionThe acts as an alternator to capture lost energy while

the vehicle is driven


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Cayenne Hybrid S

The hybrid controller can switch between:Electric, combustion operation or any

combination of the two in 30 milliseconds

The controller accomplishes this while

monitoring 20,000 data parametersThe new design adds an electrical drive pump

to assist the conventional transmission oil pump

allowing the transmission to shifts gears

smoothly in electric mode

Cayenne Hybrid S


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Cayenne Hybrid S

The Cayenne hybrid will generate 20% less carbon

dioxide emissions than a standard engine, qualifying

it as a ULEV II

The 154-lb battery, for example, is in the spare tirewell

The hybrid Cayenne is due to roll into showrooms

by early 2010

Ford Escape Hybrid


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Ford Escape Hybrid

Safety Concerns


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Safety Concerns

Escape Hybrid or Mariner Hybrid emergency response procedures are similar to

those for a traditional gasoline powered vehicle with the exception of the highvoltage electrical system.

The Escape Hybrid or Mariner Hybrid vehicle uses a conventional gasoline

engine in addition to an electric motor to power the vehicle. The energy used to

power the vehicle comes from gasoline (used by the internal combustion engine)

and electricity (used by the electric motor). The energy used to power the vehicleis stored:

Gasoline is stored in a traditional fuel tank

Electricity is stored in the high voltage batteryPACK

Safety Concerns


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Safety Concerns

The combination of a gasoline engine and electric motor

provides for improved performance (V6 performance with a 4

cylinder engine and electric motor), reduced emissions and

most importantlyimproved fuel economy. The system is

self contained (a generator recharges the battery duringbraking and cruising) so you never have to plug a hybrid in to

recharge the batteries.

Safety Concerns


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Safety Concerns

The information will allow you to respond to Escape Hybrid or Mariner

Hybrid vehicles as safely as you do with conventional vehicles.

The Escape Hybrid or Mariner Hybrid has been designed with many

features for your protection. These features should help provide you with

safe access to the vehicle under various conditions. However whenever

you approach a high voltage vehicle in a Fire, Rescue or Recovery

situation, you must always follow one cardinal rule.

ALWAYS ASSUME THE VEHICLE IS POWERED UP

HYBRID VEHICLE IDENTIFICATION


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ESCAPE HYBRID OR MARINER HYBRID VEHICLE

IDENTIFICATIONA unique Hybrid label is located on the lift gate, the front

driver's door, and the front passenger's door. This can be

used to identify an Escape Hybrid or Mariner Hybrid

vehicle.



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Ford Escape Hybrid


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Ford Escape Hybrid

Ford Escape Hybrid


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Ford Escape Hybrid

Ford Escape Hybrid Component Location


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Ford Escape Hybrid Component Location

NOTE: All High Voltage wires and harnesses are wrapped in orange-colored insulation.

Warning Decal


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Warning Decal

Battery and Inertia Switch Location


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Battery and Inertia Switch Location

Escapes Battery


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Escapes Battery

Batteries consist of 250 individual cells (similar in shape to a size D flashlightbattery). Each individual battery cell is contained in a stainless steel case.

Each individual cell is 1.3 volts. The cells are welded and wrapped together in

groups of 5 to form a module. There are 50 modules in the battery pack. The total

voltage of the battery pack is 300 volts DC

The batteries are Ni-MH (Nickel-Metal Hydride). The battery pack contains sealedbatteries similar to the batteries used in radio control toys, laptop computers and cell

phones.

The battery case is designed to be water resistant. The battery cells contain a base

electrolyte (consisting of potassium hydroxide as the dominant active ingredient) that

is absorbed in a special paper. The electrolyte will not leak from the battery undermost conditions; however if the battery is crushed, it is possible for a small amount

(drops) of electrolyte to leak.

Two cautions should be observed when working with a damaged battery


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Two cautions should be observed when working with a damaged battery

1. Exposure to electrolyte could cause skin/eye irritation and or burns. Ifexposed, rinse with large amounts of wateruntil the soapy feel is gone.

Safety items such as face mask, insulated rubber gloves and boots, and a

protective raincoat or apron are required when handling a damaged battery

2. If the battery is exposed to intense heat, it is possible that hydrogen could

be released from the battery. Appropriate cautions should be taken to makesure the area is properly ventilatedsuch as opening/removing the lift gate

or rear glass.

Note: The High Voltage Service Disconnect Switchshould be moved to the service/shipping position if

possible

APPROACHING A DAMAGED HIGH VOLTAGE VEHICLE


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1. FOLLOW EXISTING TRAINING AND INCIDENT COMMANDER

DIRECTION

This information as it pertains to the Escape Hybrid or Mariner Hybrid. The

same rules apply when approaching any potential high voltage situation.

Always follow your high voltage safety training. Some pre-cautions to be taken

in any high voltage situation include:

Remove all jewelry, watches, necklaces, earrings, etc. Metal objects are conductors

of electricity.

Wear the necessary protective clothing (high voltage rubber gloves, face shield,

insulated boots, protective raincoat or apron)

Bring the following equipment:o Class ABC powder type fire extinguisher

o A non-conductive objectabout 5 feet long (1.5 meters)used to safely push

someone away from the vehicle if they accidentally come in contact with high

voltage.



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O C NG G G VO G V C

2. APPROACHING A DAMAGED VEHICLE

Disable the high voltage electrical system using as many of the following steps

possible:

Secure the vehicle - Put the shift lever into Park. Remove the ignition key.

Block the wheels if necessary. Removing the ignition key or turning it to theoff position will disconnect the high voltage system.

Disconnect the negative cable from the 12-volt batterythis will also

disconnect the high voltage.

If possible, place the High Voltage Service Disconnect Switch (see section on

Hybrid components for location) into the service position. To place it in theservice position, turn counter clockwise and then lift out. Reinsert the

Disconnect Switch with the arrow aligned to the service or shipping position.

High Voltage Service Disconnect Switch


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High Voltage Service Disconnect Switch

Place in-service orshipping position

WARNINGRemoving the High Voltage Service Disconnect Switch

disconnects high voltage from the vehicle. The individual cells inside the

battery pack will still be charged. Do not cut into the high voltage battery case

or penetrate the batteries in any way.



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SPECIAL NOTES

If the vehicle is on fire, use Class ABC powder type extinguisher to contain and smother the

flames. Or, if water is used, large amounts are required (e.g., from a fire hydrant).

If the vehicle has any exposed cables, make sure you are wearing insulated gloves and other

protective clothing. Do not touch any broken or damaged orange cables. Treat severed lines

as if they contain high voltage.

If the vehicle is submerged in water, do not touch any high voltage components or cables

while extricating the occupant. Do not remove the vehicle until you are sure the high voltage

battery is completely discharged. A submerged high voltage battery may produce a fizzing or

bubbling reaction. The high voltage battery will be discharged when the fizzing or bubbling

has completely stopped

3. IF THE HIGH VOLTAGE BATTERY CASE HAS BEEN RUPTURED

Just like any other battery: hose the area down with large amounts of water.

Moving the Vehicle


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Moving the Vehicle

4. MOVING DAMAGED VEHICLESWRECKER DRIVERS

Turn the vehicle ignition key to the accessory position to release the locking

steering wheel.

If possible, remove the High Voltage Service Disconnect Switch by turning it

counter-clockwise and lifting out. Reinstall in the service/shipping position.

Follow guidelines in the Wrecker Tow Manual.

Front Tow: Wheel Lift with Dolly for 4WD and no Dolly for FWD

Rear Tow: Wheel lift with Dolly for all (FWD or 4WD)

Flat bed: Front and Rear

5. SPECIAL NOTE TO SALVAGE YARDS

If a vehicle with a high voltage battery is to be scrapped, the high voltage battery

must be disposed of properly.

Cooling System in

H b id El i V hi l


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Hybrid Electric Vehicles

Fuel economy and environmentally friendly vehicles have

expedited HEV development in recent years.

HEVs are the helping meet these needs

In addition to the IC (Internal Combustion) engine in aconventional vehicle, an HEV has several electrical

subsystems, such as: Electric motor

Electric motor inverter

Voltage converter

Traction battery

All needing thermal management.

Streamlining Under Hood Air


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Streamlining Under Hood Air

HEV Cooling System Needs An AdditionalCooling System


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Coo g Syste

There are different coolant temperature and fluid flowrates.

The engine cooling system is already slammed into anarrow space under the hood now we must add:

Heat exchanger Electric pump and plumbing

Due to a large electrical capacity

Mechanical pump's used in the conventional cooling

are replaced with electrical components responding tovehicle cooling demands.

Next Generation Radiator


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Next Generation Radiator

Delphi is working on the next generation of radiators,which will be ultra compact.

The designs will further reduce weight and materials

used while enhancing performance.

Hybrid Cooling System


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Hybrid Cooling System

Delphi is leveraging its system knowledge

to address the specific needs for hybridengines:

Including increased cooling requirements forthe new electrical loop

Additional heat exchangers in the existingsystem space while also providing additionalcooling power

Delphi's air-to-oil cooler technology willhelp achieve lower transmission oil

temperature requirements.

DELPHI Cooling Module

Hybrid Safety

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Transcript of Hybrid Safety