Hybrid Regenerative Braking Systems PDF
Hybrid Regenerative Braking Systems PDF
OpenSIUC
Presentations Department of Automotive Technology
Spring 4-13-2010
Eugene Talley
Southern Illinois University Carbondale, [email protected]
Recommended Citation
Janello, Timothy and Talley, Eugene, "Hybrid Regenerative Braking Systems" (2010). Presentations. Paper 16.
http://opensiuc.lib.siu.edu/auto_pres/16
This Article is brought to you for free and open access by the Department of Automotive Technology at OpenSIUC. It has been accepted for inclusion
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Tim Janello & Eugene Talley
Southern Illinois University Carbondale
Ron Henningsen
Undercar Specialists Inc.
Shoreview, MN
Topics
Manufacturers:
Toyota
Ford
Honda
GM
Hybrid Brake System Overview
Hybrid Communication Network
Hybrid Brake Components
Hybrid Regen/Hydraulic Brake Interaction
Hybrid Safety
Hybrid Foundation Brake Service/Issues
2
Brake Pad Delamination
Do You
“Know”
why this is
a Hybrid
Issue?
3
Brake Rotor Friction
Do You
“Know”
why this is
a Hybrid
Issue?
4
Brake Fluid………..
Do You
“Know”
why this is
a Hybrid
Issue?
5
“Ready” Mode
Hybrid Drive System/ICE On
6
Hybrid Brake System Overview
7
Toyota Hybrid Systems (THS & THS II)
Generation I
’01 – ’03 Prius
Generation II
’04 – ’09 Prius
’06 –’09 Highlander (4WD)/Camry
Ford Escape ’05-’09
Nissan Altima ’07 – ‘09
8
Toyota System Comparisons
’01 – ’03 Prius ’04 & later Prius Highlander Hybrid
Regenerative Brake Regenerative Brake Regenerative Brake
Cooperative Control Cooperative Control Cooperative Control
- - TRAC
- -
9
Regeneration/Motor Functions
MG 1
Recharges HV battery (w/ICE running)
Provides Power for MG 2
Control CV output to wheels
ICE starter motor
MG 2
Regeneration Braking/Charging HV Battery
Drive Wheel Motor
10
Honda Integrated Motor Assist
IMA
Generator/Motor
Assembly
11
12
Hybrid Regeneration
13
14
AUX. Battery
ABS 1 Relay ABS 2 Relay Brake Control
ABS 1 Motor Relay Power Supply
ABS 2 Motor Relay
Parking Brake
Pump Motor Switch
Master Cylinder
ECU Hybrid ECU
Steering Angle
Pressure Sensor Sensor
Yaw/Decel Sensor
Actuator
Gateway
Master Cylinder Stroke ECU
Simulator Cut-valve
Instrument
Speedometer
Brake Fluid Reservoir Skid Control
Buzzer
Panel Warning
Indicators
Warning Switch 15
16
17
18
Brake Pedal Stroke Sensor
19
Stroke Simulator
Cut Valve
Closed
Cut-valve open
20
’08 Highlander Skid Control ECU
21
22
23
Fluid Reservoir Normal Brake Actuation
RR Dump RF Dump LR
LF Dump Solenoid Solenoid Dump
Solenoid Solenoid
LR
LF Wheel RR Wheel RF Wheel Wheel
Pressure Pressure Sensor Pressure Sensor Pressure
Sensor Sensor
RR
RF LR
LF Caliper
Caliper Caliper
Caliper 24
Fluid Reservoir
Closed Fail Safe Mode
RR Dump RF Dump LR
LF Dump Solenoid Solenoid Dump
Solenoid Solenoid
LR
LF Wheel RR Wheel RF Wheel Wheel
Pressure Pressure Sensor Pressure Pressure
Sensor Sensor Sensor
RR
RF LR
LF Caliper
Caliper Caliper
Caliper 25
Ratio of Regen to Hydraulic
“Normal Stop”
26
Ratio of Regen to Hydraulic
“Panic Stop”
27
28
Ford Escape Hydraulic Brakes
29
30
Honda Integrated Assist Braking
Master Cylinder is
operated by hydraulic
boost.
ABS HCU/foundation
brakes work the same
as any other.
31
Brake Pedal Input
32
Master Cylinder Regulation
33
Fail-Safe
34
35
GM Mild Hybrid Hydraulic Brakes
V
BEC
Sol Enable
+ BAT
Line Res.
Booster
M/C
P
SOL1 PWR
SOL2 PWR
PEB
Sol 1 Sol 2
GM LAN SOL 1 Control
ECM
PWM SOL 2 Control
Sec Pri
ABS
Module
Sol 1 – Left front, Right rear
RF (sec) LF (PRI)
Sol 2 – Right front, Left rear
LR RR
36
GM Hill Hold System
Used to halt Vehicle
movement until
Accelerator pedal is
applied.
37
GM Two-Mode Hydraulics
38
39
DO NOT FORGET! Turn the ignition Off.
On Toyota/Ford type systems, the engine may not be
running when you pull the vehicle in, but may start at
any time.
Can you imagine the surprise for a tech who has
the oil drained and the engine decides to start?
40
Tip: If you encounter a 2004 and newer Toyota Prius
that will not shut down, it may be due to a malfunction
in the shift control actuator. Appling the parking
brake, something we should do anyway, should allow
the vehicle to shut down while in park or neutral.
41
The High Voltage system is marked by the orange
cables, but should be discharged after five (5) minutes
with the ignition off. They are sealed to prevent
contact, but always look for insulation damage before
touching.
With the Ignition “Off” and the key or I-key removed
(stored 15 feet away from vehicle) the High Voltage is
normally disabled.
Blue Cables are 36-42 Volt Systems.
Always Wear “HV” Safety Equipment when
disconnecting service plugs just to be Safe!
42
2009 Silverado Hybrid Inverter
43
44
Toyota Prius
HV Service
Disconnect.
Located in front
left of rear
cargo area.
45
Toyota Highlander
HV Service
Disconnect
Located
under left
side of rear
seat.
46
Honda Civic
HV Service
Disconnect
Located behind
rear seatback.
To gain access,
Remove metal
cover plate.
HV Battery
cover removed.
47
Ford Escape
HV Service
Disconnect
Located under
right rear of
cargo mat.
48
GM Vue Hybrid
49
2009 GM Two-Mode Hybrid
50
Brake Issues
Brake Service
Brake Bleeding
51
All use Standard DOT 3 Fluid.
Honda Civic Escape Highlander
52
Ford Escape Hybrid Brake Issues
53
Service Safety Procedures
Because the Regenerative Braking System can
check/checks the integrity of the brake system at
various times when the vehicle is parked.
And it develops brake pressure for short periods of time
when doing so.
You should realize that opening the door may/usually
triggers this check.
You must to enter the Pad Service Mode to service
brakes & disable the self check mode.
This prevents brake pressure from being applied.
54
Ford Escape Hybrid Brake Service
57
Ford Escape Hybrid Brake Service
Other ways of entering the Pad Service Mode
continued:
Use a scan tool and the correct software to enter “Pad
Service Mode” selection of menu.
58
Ford Escape Hybrid Brake Service
To exit the pad service mode
59
Ford Escape Hybrid Conventional
Foundation Brakes Bleeding
Provided you have not opened the
hydraulic system i.e.. Caliper
replacement, run dry, blown hose etc.
you can bleed the system in a regular
manner.
61
Screw
Clamps
Other
clamps
leaked?
62
Brake
Fluid
Filter
63
HCU Bleeding Using the Ford Special Tools
65
65
Replacing the HCU With Original Module
Available
1. Connect the WDS or IDS and ID the vehicle as normal.
2. From Toolbox , Select & Highlight Module Programming
3. Press the check mark.
4. Select & Highlight Programmable Module Installation.
5. Follow the on-screen instructions, turn the ignition key to the
OFF position, and press the check mark.
6. Install the new module and press the check mark.
7. Follow the on-screen instructions, turn the ignition key to the
ON position, and press the check mark.
8. The module configuration is complete.
9. Test the module for correct operation
66
Replacing the HCU With Original Module
Not Available
1. Internet Connection Necessary and Access to Ford As-Built Data.
2. Connect the WDS or IDS and ID the vehicle as normal.
3. From Toolbox , select and highlight Module Programming.
4. Highlight the module that was installed and press the check mark.
5. Select Programmable Module Installation. Highlight the module that was
installed and press the check mark.
6. Follow the on-screen instructions, turn the ignition key to the RUN position and
press the check mark.
7. WDS/IDS tries to retrieves the module data.
8. Screen stating “Contact the As-Built Data Center”. Retrieve the data from
WWW.FMCDEALER.COM at this time and press the check mark.
9. Enter the module data (the module address and line are displayed to the left of
the 3 entry boxes) and press the check mark.
10. The WDS/IDS uploads the data into the new module and displays Operation
Successful — Programming Complete.
11. Test the module for correct operation.
67
May 08, 2001
Introduction of Prius to North America
600,000 Prius Vehicles Sold.
Toyota Prius
Pad Replacement
Frequently (always) the Brake/ABS light will be
illuminated after pad replacement.
Knowing why is important
Knowing how to clear the problem is even more
important
Knowing an alternative method is Important.
69
Toyota Prius Pad Replacement
Knowing Why:
The Prius has pressure sensors at the master cylinder
and the outputs for the wheels.
Any difference between the sensors will set a fault
code/light
When replacing the pads you push the caliper pistons
back in the caliper bores
A pressure difference is then sensed when pumping out
the pistons to seat the pads
70
Toyota Prius Gen 1
Pad Replacement (continued)
Knowing Why: (continued)
This pressure difference set a code causing the ABS light
to come on.
If the ABS light was not during the initial test drive
before performing brake work it was set because of the
pressure difference sensed during pumping out the
pistons.
71
Toyota Prius
Pad Replacement Code Clearing
Malfunction Codes: C1341 (RF), C1342 (LF), C1343 (RR),
C1344 (LR) may be present after pad replacement
Clear w/scan tool
Clear w/special service tool
Clear w/jumper wire
72
Toyota Prius
Pad Replacement Code Clearing
Jumper Wire
Procedure
Connect terminals
TC and CG of the
DLC3 connector
Turn Power Switch to ON/Ready
Depress the brake pedal 8 times within 5 seconds.
Warning light should display normal code.
Remove jumper
73
Alternative Method to Prevent
Setting a Code
After relining brakes:
Remove “I” key from area.
Suggested distance of 15 feet.
“Slowly” pump pedal to move caliper pistons to force
pads to contact rotors.
74
Toyota Prius Hybrid
General Brake Information
Part time brake by wire to front wheels
Hydraulic for is usually applied in normal
braking until below 9/10 mph. Regenerative
braking is taking place.
Hard stops & ABS stops use hydraulic pressure
not regenerative braking.
Driver feed back on the brake pedal is through
the “stroke simulator”. The driver can’t tell any
difference in pedal feel between regenerative
and conventional braking.
75
Toyota Prius Hybrid
General Brake Information
When in a engine off parked mode hydraulic
pressure is still in the brake system.
Prius can/does drive without using the ICE.
The ICE may start at any time to charge the HV
battery or operate the HVAC.
Remove electronic key away from vehicle during
service (oil change especially!)
76
Toyota Prius Hybrid
General Brake Information
Gen I (’01-03)used the same wheel brakes as other
Toyota models.
Rear drum brakes always operate and are not part of
the regenerative braking system.
Gen I uses a standard proportioning valve & vacuum
booster
77
Toyota Prius Hybrid
General Brake Information
Generation II (’04-07) Parking Brake Problem
Parking Brake light remains on after parking brake has
been released.
TSB BR002-07 (replace parking brake pedal assembly).
78
Toyota Prius Hybrid
General Brake Information
Gen II does not have a vacuum booster
Larger accumulator and pump system provide pedal
boost.
Wheel brakes are same as non-hybrid but pads are
constructed differently for corrosion resistance.
79
Toyota Prius Hybrid
General Brake Information
Major Components of the system.
Brake pedal stoke sensor
Dual voltage signal device input to Skid Control Electronic
Control Unit (SCECU)
Calculates braking effort and speed of apply
80
Prius Hybrid
Stroke
Simulator
(SS)
81
Toyota Prius Hybrid
General Brake Information
Major Components of the system.
Stroke Simulator (SS)
Located in hydraulic line between MC and brake actuator (RR of
eng. Compartment)
Absorbs fluid volume/pressure gives the pedal a “normal” feel.
Two stage two spring operation
Inlet has a two-position solenoid valve “cut valve”
SCECU controlled valve
On-fluid flows into simulator.
Off-fluid flows into brake actuator (de-energized, fail safe mode)
Note: Highlander and Camry vehicles have the SS attached to the
MC.
82
Prius Hybrid Brake Actuator
83
Toyota Prius Hybrid
General Brake Information
Major Components of the system.
Brake Actuator
Located between the SS and the Calipers. Bolted to firewall
mid area.
Contains the high pressure pump, accumulator, pressure
sensors & solenoid valves (linear and changeover).
Functions Control:
ABS, Vehicle Stability Control, Brake Assist Controller.
84
Toyota Prius Hybrid
General Brake Information
Major Components of the system.
SCECU (Skid Control Electronic Control Unit)
i.e. Brake controller/computer
85
86
Advanced Hydraulic Booster (AHB) MC – Servo w/ECU
HCU/ABS
87
87
Follow Conventional Replacement
Procedures
Honda Recommendation:
Use of an on-car, steering knuckle-
mounted lathe is critical because it
corrects run-out of the hub and disc
as an assembly.
88
88
Advanced
Hydraulic
Booster
Located on
RH side of
engine
compartment
Brake pedal
doesn’t directly
control the MC.
91
Servo Unit with MC. Pg. 2, Civic 2006 handout info.
NO normally
open
NC normally
closed
RNO (regen)
normally
open
RNC (regen)
normally
closed
92
Conventional Brakes (calipers, master cylinder, etc.)
1. Ignition off
2. Pump pedal until hard to release accumulator pressure
3. Pump pedal and bleed traditionally (LF-RF-RR-LR)
93
1. Attach a clear hose to the bleeder under the servo
assembly.
2. Open the bleed screw about 180 degrees.
3. Turn the ignition to run.
4. Allow Pump to discharge brake fluid from the
reservoir for one (1) minute.
5. Note: Don't operate the pump for more than 110
seconds, or you can overheat it.
6. Tighten bleeder screw once no air is found
discharging through the tube.
7. Turn the ignition switch off.
8. Fill the fluid reservoir to the middle line.
94
9. Turn the ignition switch to run.
10. Make sure the brake lights in the IP cluster turn OFF.
11. Turn the ignition switch off.
12. Press the brake pedal 20 times or until the pedal
becomes hard.
13. Wait about five (5) minutes.
14. Repeat steps 6 - 11 two times.
15. Inspect the brake fluid level.
16. Check the brake pedal stroke.
17. Clear the DTCs if necessary.
95
Questions???
E-mail:
Tim Janello <[email protected]>
Eugene Talley <[email protected]>
Ronald Henningsen <[email protected]>
Presentation Location:
www. siucautomotive.com
http://opensiuc.lib.siu.edu/auto_pres/
References:
Ford Motor Co.
American Honda Motor Co, Inc.
Toyota Motor Sales, Inc.
General Motors