Toyota Prius hybrid drive system is a peak in the industry, has always been our benchmark. In 2017, Prius introduced the new gearbox P610, which is called Prius2017 (also known as Prius IV) and represents Toyota's latest understanding of HEV drives.
The fourth-generation hybrid transmission P610 is arranged parallel to the top and bottom of the double motor. Instead of the original planetary gear reduction mechanism, use parallel axis gears. However, the power split is still accomplished by a single row of planetary gears.
YOUTUB has a video detailing the dismantling of this gearbox. We extracted key processes. When the gear box is disassembled, it can be seen that the motor and the generator are arranged in parallel in the box, and the assembly space is particularly compact.
The generator is 23kw, the motor is flat and the motor end is plastic, which can provide higher insulation, and can improve the heat dissipation at the end of the winding.
The motor is an 8-pole, 48-slot classical matching scheme. It uses hairpin windings and the motor is flat, with a maximum torque of 163 NM and a maximum speed of 17,000 rpm.
From the close-up drawing, we can see that the hairpin winding structure is particularly compact and beautiful. 8-slot per slot, the end size is particularly small.
Innovating the larger rotor, the rotor adopts a high-speed enhanced V-structure. In one slot, the magnet is divided into two sections. In order to suppress torque ripple and cogging torque, an auxiliary slot is formed on the rotor surface.
Prius 2017 from the data
The following is a comparison of the technical changes in the Prius2017 (four generations) relative to previous generations.
1High speed is the development trend
The most obvious feature is that the rotational speed from three generations to four generations has increased from 13500rpm to 17000rpm, and the torque has dropped from 207Nm to 163Nm.
2 increase in power density
The obvious benefit of high speed is that the power density can be increased. In addition, the volumetric power density of the fourth generation of other technologies is increased by 36% to reach 5.7kw/L, and the weight power density is increased from 1.6 to 1.7kw/kg. Technical requirements of DOE2020.
3 smaller size
Compared to previous generations of data, the fourth generation of motors achieved the first reduction of the stator diameter, from 269mm to 215mm. At least two pedestal numbers crossed in the middle.
4 further increase efficiency
At the same time as the power density is increased, the efficiency of the motor is not reduced, the loss is reduced by 20%, and the maximum efficiency is 97%, which indicates that there is a big breakthrough in the design level of the fourth-generation motor.
5 increase cooling power
From the disclosed data, we found that the maximum allowable current density of the fourth-generation Prius (P610) is 58% higher than that of the third-generation Prius (P410), which is a great improvement, indicating that the cooling efficiency of the motor has achieved a breakthrough.
The four-generation prius motor uses the same coaxial cooling oil pump as the three generations. The cooling oil pump is installed in the bracket at the end of the motor shaft. It can be seen that this is a simple gear displacement pump.
The oil pump rotor and the motor rotor are installed coaxially. Since the number of rotor teeth is smaller than that of the stator teeth, this type of pump rotor rotates once, and it will form a volume space with alternating cycles. When the space becomes larger, the oil is sucked in, the space becomes smaller, and the oil is reduced. Press out.
Through comparison, it was found that the outer diameter of the fourth generation Prius oil pump was the same as that of the second generation and the third generation, and the height was increased. This meant that the flow of the oil pump was increased and the cooling capacity was improved.
The prius motor's oil circuit design is more sophisticated, in particular, is the design of the rotor oil circuit, ingeniously unique: the oil pump presses the oil into the hollow shaft of the rotor, in the middle of the core, set a section containing from the shaft to the inner hole The oil circuit is then provided with an oil path from the inner hole to the middle hole in the iron core of the outer end section, and finally the oil path is guided to the outer hole closest to the magnetic steel. The closer the cooling oil path is to the heat of the magnet steel, the easier it is to carry away, which greatly improves the cooling effect of the rotor.
Similarly, it can be inferred that the rotor cooling oil circuit of the motor can be seen from the end plate of the rotor. Both the magnetic steel and the magnetic steel on both sides of the V-type magnetic pole are designed with cooling channels, and the cooling effect on the rotor is considerable.
Core Technology breakthrough
From the above data, we can discover the advancement of Toyota Motor Engineer's design technology. From the published literature, we can see breakthroughs in the following core technologies:
1 magnetic pole structure breakthrough
The fourth-generation prius uses a new V-structure design, which is a high-speed modified magnetic pole structure. In order to adapt to the high-speed operation of 17000 rpm, two bypass magnetic bridges have been added. In addition, in order to reduce the eddy current loss of the magnetic steel at high speed, the magnetic steel is divided into two sections in the axial section.
Not only that, in order to reduce the stator iron consumption and torque ripple, Prius adopted a sinusoidal magnetic pole design means, through a reasonable combination of V and a magnetic steel size and grade, can form a more sinusoidal air gap magnetic density. Compared with the third generation and fourth generation, the third harmonic of the permanent magnet air gap flux density is greatly reduced (significantly reduced iron loss), and the fifth harmonic is suppressed (improved torque ripple).
2 The maturity of hairpin winding technology
After years of development, Prius's flat wire winding technology has been further improved. Compared to the third generation, the slot fill rate increased by 15%. And achieved breakthroughs in the following two areas:
Flat wire insulation materials are optimized, thinner, withstand voltage levels are higher, and new insulation materials have better welding characteristics;
High speed flat wire winding molding technology (designed to reduce high frequency skin effect);
3 light rare earth rare earth technology
Toyota's development of new Dy-free rare-earth permanent magnet technology, significantly reducing the amount of rare earth, compared to the third generation of magnetic steel consumption decreased by 15%, while reducing the use of rare earths by 85%, thereby increasing the cost of competitive advantage.
Sensor structure:
A lens collects light of a particular color, and a color filter filters light of other colors, projecting one color onto the area
Connection mode of Sensor and substrate:
COB: Module takes the sensor die and connects the sensor to the substrate through the gold wire.
CSP/TSF: Sensor is connected to the substrate and packaged when shipped.
IR Cut and Blue Galss:
The function of IR Cut is to filter out the light frequency invisible to human eyes (reflected back). What human eyes can see is 400~700nm.
Blue Glass absorbs infrared rays, which are not easy to be reflected internally
The Image circle of the Lens needs to cover the sensor's sensitive area
Lens shading:
A condition in which light is unevenly distributed, such as when the center is lit and the outside is dimmed. This is mainly because most of the light is concentrated in the middle, and because different wavelengths of light are imprinted in different places
FOV:
The lens Angle of the module must be the same as that of the lens; otherwise, when the lens Angle is too large, dark Angle may appear.
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