Evaluation of 2004 Toyota Prius Hybrid Electric Drive System
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Engineering Science and Technology Division
- Univ. of Tennessee, Knoxville, TN (United States)
- Oak Ridge Inst. for Science and Education (ORISE), Oak Ridge, TN (United States)
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. This report summarizes vehicle-level and subsystem-level test results obtained for the 2004 Prius and various electrical and mechanical subassemblies of its hybrid electric drive system. The primary objective of these tests was to (1) characterize the electrical and mechanical performance of the 2004 Prius, and (2) map the performance of the inverter/motor system over the full design speed and load ranges.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V). FreedomCAR and Vehicle Technologies (FCVT) Program
- Contributing Organization:
- Oak Ridge Inst. for Science and Education (ORISE), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
- DOE Contract Number:
- AC05-00OR22725
- OSTI ID:
- 890029
- Report Number(s):
- ORNL/TM-2006/423; TRN: US200620%%208
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
33 ADVANCED PROPULSION SYSTEMS
AUTOMOBILES
COOLANTS
EFFICIENCY
ELECTRIC MOTORS
ENGINES
EVALUATION
FABRICATION
FUEL CONSUMPTION
INTERNAL COMBUSTION ENGINES
MOTORS
PEAK LOAD
PERFORMANCE TESTING
PROPULSION
ROTORS
TESTING
VELOCITY