Technology Transfer - International Environmental Technology Centre
1 TOYOTA’s Environmental Technology
Transcript of 1 TOYOTA’s Environmental Technology
1
TOYOTA’s Environmental Technology
2Vehicles that are compatible with the Environment
* High Energy Efficiency
* Low Exhaust Emissions
(Reducing CO2 Emission)
Diesel Petrol
TOYOTA D-CAT TOYOTA Hybrid System
(PM, NOx => ozone)
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TOYOTA
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Intake AirEGR Cooler
Exhaust Gas
EGR Valve
Air Fuel Ratio Sensor
Diesel Throttle
Pressure DifferenceSensor
Gas TemperatureSensor
New Common Rail System2nd Generation 180MPa
DPNR Catalytic Converter(2.0L)
Oxidation Catalytic Converter
System configuration
FuelInjector
Inter-Cooler
Air Flow Meter
VNT Turbo Charger
5DPNR catalyst cross-section
NOx Storage - Reduction Coating
Exhaust Gas Flow
Diesel Particulate FilterEnlarged View
NOx Storage -Reduction Coating
Diesel Particulate Filter
Exhaust Gas Flow
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NOx
Lean Condition Rich Condition
PM
Reduction of NOx
HCCO
H2ON2
NO+O*Pt
CO2
Filter Substrate
O* O*
CO2
Pt
PM
Filter Substrate
Storage of NOx
NOO2 NO2+O*
Filter SubstratePt
NO+O2 CO2
PtO*
PM
NO2
Filter Substrate
NOx Storage Catalyst
Continuous OxidationContinuous Oxidation
NOx Storage Catalyst
DPNR system purification mechanism
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Fuel Injector
SprayGas Flow
Additional Fuel Injector
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TOYOTA Hybrid System
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Toyota Hybrid System (THS)
TireDifferential Gear
Planetary gear
P/G
Enginedirect Torque
Engine
MotorTorque
Generator
Motor
• Vehicle is propelled by engine and/or motor• Strong hybrid with high power NiMH battery (EV driving )• Engine, motor, generator are connected by planetary gear• No clutch, no torque converter
Mechanical PathElectric Path
Battery
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Hybrid Component Location
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Gasoline EngineGasoline Engine GeneratorGenerator MotorMotor
Power split devicePower split device
THS Hardware
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Planetary carrier (engine)Planetary carrier (engine)
Ring gear Ring gear (Motor/output (Motor/output
axle)axle)
Pinion gearPinion gear
Sun gearSun gear(Generator)(Generator)
Power Split Device
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Take off from 0km/h
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Deceleration
15Vehicles that are compatible with the Environment
* High Energy Efficiency(Reducing CO2 Emission)
• Highly efficient engine
• Optimised vehicle / system efficiency
• Regenerative Braking
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Highly efficient Engine
Exhaust valve openExhaust valve open
Intake valve closeIntake valve close
Compression actualCompression actual
Mechanical CompressionMechanical CompressionPowerPower
Bore x StrokeBore x Stroke
DisplacementDisplacement
3232°°BBDCBBDC
7070~~115115°°ABDCABDC
4.84.8~~9.39.3
13.013.0
57kW/5000rpm57kW/5000rpm
φφ75 75 ×× 84.784.7
14971497
Specifications ('03 model)Specifications ('03 model)
ratioratio
Minimum SFC 225g/kWh
(3) Low friction design(3) Low friction design(2) VVT- i (2) VVT- i (1) Atkinson cycle(1) Atkinson cycle
(4) All range λ=1(4) All range λ=1
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AverageAverage
AA; Optimizing Engine Operation Range; Optimizing Engine Operation Rangeby powerby power--splitsplit--device (CVT function)device (CVT function)
A
Engine OutputEngine Output
High Vehicle Efficiency => low CO2
Bra
ke T
herm
al E
ffici
ency
Bra
ke T
herm
al E
ffici
ency
BB; Improving Engine Efficiency; Improving Engine Efficiency
BAverageAverage
THS VehicleTHS Vehicle
Conventional VehicleConventional Vehicle
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FrontFrontRearRear
Hydraulic BrakeHydraulic Brake
THS ECU
Power SplitPower SplitDeviceDevice
EngineEngine
GeneratorGenerator InverterInverterBatteryBattery
BrakeBrakeMasterMasterCylinderCylinder
HydraulicHydraulicPowerPower
AdjusterAdjuster
Brake ECUBrake ECU
Regenerative BrakeRegenerative BrakeMotorMotor
Regenerative Braking System
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60
100
140
180
220
260
600 800 1000 1200 1400 1600 1800 2000 2200 2400
GasolineDiesel
’00 Prius
140g/km
’03 Prius
120g/km
Inertia Weight (kg)
CO
2Em
issi
on (g
/km
)CO2 Potential
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CO2 versus Power
0
50
100
150
200
250
300
0 20 40 60 80 100 120 140 160 180 200
Power (kW)
CO
2 Em
issi
on (g
/km
)
Gasoline
Diesel
Hybrid
'03 Prius
'00 Prius
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Inde
x of
Fue
l C
onsu
mpt
ion
[%]
Engine technologies play a key role for reduction of fuel consumption
THS (Toyota Hybrid System) BaseVehicle (AT)
50
100City ModeCity Mode
Regeneration
Engineimprovement
Idle stop
Engine operating area
Highway ModeHighway Mode
Fuel Consumption Improvement
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20
30
40
120 140 160Vehicle Speed (km/h)
Engi
ne
Effic
ienc
y (%
)
80
90
Tran
smis
sion
Effic
ienc
y (%
)
200
250
300
350
CO
2 (g
/km
)
gasoline ATdiesel ATgasoline HV
CO2 Potential in Highway cruising
Good
Good
100
• Cruising mode => reduced HV function
• Gasoline HV: equal CO2 as diesel even in highway driving.
SimulationdataVehicle spec =common
• 1L Diesel = 15% more CO2 than 1L gasoline
23Vehicles that are compatible with the Environment
* High Energy Efficiency
* Low Exhaust Emissions
•• Driving by motor (ZeroDriving by motor (Zero--emission) emission) •• Power assisted by motor at accelerationPower assisted by motor at acceleration
(all (all λλ=1)=1)•• Engine start/stop by high power MGEngine start/stop by high power MG
(PM, NOx => ozone)
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00 2020 4040 6060 8080LA4 Time [sec]LA4 Time [sec]
Vehicle SpeedVehicle Speed
Vehicle Power Vehicle Power
・ Retard Control・ λ=1 Just After Cold Start・ Retard Control・ λ=1 Just After Cold Start
Rapid CatalystWarm-up
Rapid CatalystWarm-up
Rapid Catalyst Warm upUsing Motor Drive
Vehicle is driven by motor
Motor PowerMotor Power
Engine Operation is ConstantEngine Operation is Constant
Air mass flowAir mass flow
25Effect of Rapid Catalyst Effect of Rapid Catalyst Warm up ControlWarm up Control
00
200200
400400
600600
800800
00 2020 4040 6060 8080 100100LA#4 Time [sec]LA#4 Time [sec]
Cat
alys
t Tem
pera
ture
[℃
]C
atal
yst T
empe
ratu
re [
℃]
Light-off TemperatureLight-off Temperature
SpeedSpeed
Without Power ManagementWithout Power Management
With Power ManagementWith Power Management
Rapid Warm-upRapid Warm-up
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Engine Stop Control for lowest NOxEngine Stop Control for lowest Engine Stop Control for lowest NOxNOx
Engi
ne S
peed
[rpm
]En
gine
Spe
ed [r
pm]
Time [sec]Time [sec]
Engine Run-on TimeEngine Run-on Time
OffOffIgnitionIgnition
Late FuelLate Fuel--cutcut
Shorten Run-on byUsing Motor PowerShorten Run-on byUsing Motor Power
OO22 SaturatedSaturated
NOxNOxHH22OOCOCO22
OO22HC,COHC,CONOxNOx
CatalystCatalyst
Modest OModest O22
HH22OOCOCO22
CatalystCatalystHC,COHC,CO
NOxNOx OO22
Schematic Modelof NOx Reduction
Schematic Modelof NOx Reduction
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NOx emission effect at Stop&Go NOx emission effect at Stop&Go NOx emission effect at Stop&Go
4040 8080Time [sec]Time [sec]
NO
xN
Ox
StopStopRunRun
1010
2020
3030A
/FA/F
EngineEngine
00
Without ControlWithout Control
NOx Reduction NOx Reduction
RunRun
(LA#4 Mode)(LA#4 Mode)
① Prevention of Lean Condition at Engine Stop① Prevention of Lean Condition at Engine Stop
② Enrichment after Restart ② Enrichment after Restart
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0
0.1
0.2
0.3
1.0 0.5 0 0.1 0.2 0.3 0.4CO(g/km) HC(g/km)
NOx(g/km)Diesel EU4regulationGasoline EU4regulation
Prius
In house data
0
0.01
0.02
0.03
PM(g
/km
) Diesel EU4 regulation
Diesel Prius
ConventionalDiesel
Emission Potential of TOYOTA’senvironmental technologies
• Prius: NOx and PM: Lowest in city and highway driving
TOYOTA D-CAT
TOYOTA D-CAT
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Prius DieselHighspeed (160km/h)
Prius Prius = DieselHighway (120~140km/h)
Prius Prius City
NOx + PM emissions
CO2
Environmental summary
Toyota DToyota D--Cat: Cat: Clean Diesel Clean Diesel
with low with low NOxNOx + PM + PM
• Prius: Most environmental friendly car
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FIA / ADAC Ecotest
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• Toyota Prius : most eco-friendly car out of 113 tested vehicles
• Toyota Avensis D-4D D-CAT best in D-segment, first diesel to reach “green” emission
FIA / ADAC Ecotest
32Vehicles that are compatible with the Environment
* High Energy Efficiency
* Low Exhaust Emissions
(Reducing CO2 Emission)
… and* attractive for the customer
Acceleration performance “TOYOTA” reliability & durability
High comfort
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9 9.5 10 11 12 1413
13.4Prius 2000Comp 9Comp 8
Comp 7Comp 6Comp 5Comp 4Comp 3
Comp 2Comp 1
10.5 11.5 12.5 13.5
Prius 20039.9
11.211.2
11.210.9
10.8
10.7
10.9
10.8
10.8
Competitive Performance0-100km/h: '03 Prius in comparison to ‘00 Prius and
Diesel market
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High power by high voltage
500V
New Prius:
Higher level
= Higher voltage
=> Lower losses
274V
Power (W) = Current (I) x Voltage (V)
Prius’2000
Hybrid Synergy Drive
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Hybrid Synergy Drive
50kW MY2003
33kW MY2000
Pow
er(k
W)
Motor power Motor torque
rpm
400N m
MY2003
350N m
MY2000Torq
ue(N
/m)
rpm
Battery
BoostConverter
Inverter
Generator
202V
202V ~
500VMotor
+ cost optimisation
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Full acceleration
0
100
200
300
400
500
600
time (sec)
Volta
ge[V
DC
]
Mot
or rp
m
Motor rpm
System voltage command
System voltage
Hybrid Synergy Drive
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NiMH Battery
Wei
ght (
kg
/ uni
t )W
eigh
t ( k
g / u
nit )
00
2020
4040
6060
8080
‘‘97 97 PriusPrius ‘‘01 01 PriusPrius New New PriusPrius
00
5050
100100
150150
Volu
me
( L /
unit
)Vo
lum
e ( L
/ un
it )
‘‘97 97 PriusPrius ‘‘01 01 PriusPrius New New PriusPrius
▲▲25% 25%
▲▲15% 15%
Power density trend of battery(W/Kg)
1999 1995 2000 2005 2010
Other HV'S Battery
1997 Prius
2000 Prius
New Prius
- Air-cooled (3 sensors)- integrated Battery-CU- 28modules x 7.2V
=> 201.6V
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SOCSOC
TimeTimeUndercharging areaUndercharging area
Upper limitUpper limit
Lower limitLower limit
Target SOCTarget SOC
Actual Actual SOCSOC
Overcharging areaOvercharging area
State of Charge Control
• Key for highest durability
Inte
rnal
Res
ista
nce
[mΩ
/mod
ule]
Distance Driven [km]
0
2
4
6
8
10
12
14
16
0 50 100 150 200 250 300 350
‘00 Prius ‘03 Prius
[ @40℃ ]
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Engine start/stop by generator
Time [sec]Time [sec]
AA
A'A'
BB
B'B'Intake closeIntake close
120 120 oo ABDCABDC
Intake closeIntake close90 90 ooABDCABDC
--1010
00
1010
--0.20.2 00 0.20.2 0.40.4 0.60.6 0.80.8 1100
10001000
--1010
00
1010
Engi
ne s
peed
Engi
ne s
peed
Acc
eler
atio
nA
ccel
erat
ion
Acc
eler
atio
nA
ccel
erat
ion
(m / sec(m / sec 22))
(rpm)(rpm)
(m / sec(m / sec 22))
Low noiseLow noiseby engineby enginestopstop
Low Low vibrationsvibrationsby low by low comprcompr..ratio atratio atengineenginestartstart
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Toyota Dyna Hybrid (2003) Hino Ranger Hybrid (4’2004)Hino Dutro Hybrid (2003)
Diesel Hybrid
41Vehicles that are compatible with the Environment
* High Energy Efficiency
* Low Exhaust Emissions
… and* attractive for the customer
What’s the benchmark for the future ?
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Toyota Data: Japanese 10-15 mode*1 Natural gas to hydrogen
Total Efficiency(%)0 10 20 30 40
Tank toWheel
(%)
Well toTank (%)
CurrentGasoline AT
'97THS
'00THS'03THS'02FCHVFCHV(Target)
3788 32%
1688
2888
3288
5058*1
6070
14%
25%
28%
29%
42%
(Ref. THS with conventional engine) 22%
Comparison with Fuel Cell in Well to Wheel Efficiency
'03 THS exceed ‘02FCHV efficiency in well to wheel
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Low Temperature Startability
The generated water freezes
Low temperature starting is a major issue
e-e-HydrogenHydrogen
AirAir((OO22))
H2H2 O2O2
H2OH2O
e-e- ElectricityElectricity
H+H+
H+H+
WaterWaterWaterWater
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Hydrogen Storage Technology
WeightIssue: Volume Boil-off gas
High pressure hydrogen tank
Liquid hydrogen tankHydrogen-absorbing alloy tank
and: Hydrogen Infrastructure ?
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TOYOTA FINE-S
Fuel-Cell Research
• Exciting prototype cars for an exciting technology
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ICE Hybrid Vehicle Fuel Cell Vehicle
Engine Fuel Cell
>Battery
>Motor >Regenerative braking
>Vehicle power management
>Inverter
Common Tech.
Evolution of Hybrid Technology
• HV and FC are based on common technologies• Easy to transfer the technologies
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Conclusion
The Ultimate ECO-CarThe Ultimate ECO-Car
Electricity
FCHV
EV
Electricity
FCHV
EV
HSD
Gasoline
THS
D4
Lean-burn
VVT-i
HSD
Gasoline
THS
D4
Lean-burn
VVT-i
Diesel
HV
Toyota D-CAT
Common-rail
Diesel
HV
Toyota D-CAT
Common-rail
Alternative fuel
CNG
Alternative fuel
CNG
Hybrid TechnologyHybrid TechnologyHybrid TechnologyHybrid TechnologyHybrid TechnologyHybrid Technology
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Thank you Thank you
for your attentionfor your attention