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AM770 · Hybrid Drivetrains

Experimental Apparatus for the Study of Hybrid Drivetrains

A complete petrol-electric hybrid drivetrain, running, on a frame students can walk around. The petrol engine, both motor-generators, the automatic transmission, the high-voltage traction battery and the power electronics are the OEM parts of the Toyota Hybrid System II, in their production wiring, so a measurement taken on the apparatus is the measurement taken on a car.
Description
    The apparatus carries a functional petrol-electric hybrid drivetrain, built from the components a manufacturer fits to production cars. The petrol engine, the two motor-generators, the power-split automatic transmission, the traction battery, the inverter and DC/DC converter, the cooling and climate circuits and the full exhaust line are OEM parts of the Toyota Hybrid System II, wired as the vehicle wires them. Nothing is modelled and nothing is simulated.
What it shows
    Start it and the drivetrain behaves as it does on the road. The engine shuts down and restarts on its own, the electric machines take over and hand back, and the direction of energy flow between battery, motors and engine changes with load. Students watch that happen and read the sensor and actuator signals behind it at the same time, on a test panel wired to every measuring point in the system. The connections are 4 mm quick-connect, so a meter or a scope goes onto a circuit in seconds. All of it stays in view behind removable protective panels.
Fault simulation
    Every measuring point on the panel is also a break point. Pull the quick-connect link and the circuit behind it opens, which is exactly how an open circuit presents itself to the control unit and to the scan tool. There are 62 of them. An instructor sets a fault in seconds, without tools and without touching the harness, and the student works it the way the job is worked in a workshop: read the code, find the circuit, measure it, decide.
Experiments
  • Operating modes of a series-parallel hybrid drivetrain: electric, engine, combined and regeneration
  • Energy flow between traction battery, motor-generators and petrol engine under changing load
  • Structure and behaviour of the high-voltage energy storage system
  • The power-split transmission
    • how one epicyclic gearset and two motor-generators replace gear steps
  • Engine management on an Atkinson-cycle petrol engine
  • Signal measurement on every sensor and actuator circuit at the test panel
  • Fault finding on 62 switchable faults
    • from the fault code to the circuit to the measurement
  • OBD-II diagnostics: reading and clearing fault codes, live parameters, adaptations
  • Exhaust gas measurement before and after the catalytic converter
  • The engine cooling circuit and the automatic climate control circuit
Scope of Delivery
  • Hybrid drivetrain on a mobile frame, complete and functional
  • Petrol engine with its engine management
  • Two motor-generators and the power-split automatic transmission
  • High-voltage traction battery, inverter and DC/DC converter
  • Engine cooling circuit and power electronics cooling circuit
  • Automatic climate control with electric compressor, charged with R134a
  • Exhaust line with catalytic converter and a sampling point either side of it
  • Test panel with 4 mm quick-connect measuring points and 62 switchable faults
  • OBD-II 16-pin diagnostic connector and instrument cluster
  • Removable protective panels and emergency stop button
  • Wiring diagram set for measurement and fault finding
  • Set of instructional materials
  • Commissioning on site and initial operator training

All components and accessories listed under Scope of Delivery are supplied, whether or not they are visible in the photographs.

Options
  • Diagnostic scan tool
    • the apparatus works with generic OBD-II testers, multibrand workshop scanners and OEM-level software
  • Exhaust gas analyser
Safety
    Students work on a live hybrid drivetrain without being able to reach into it. Rotating and hot parts sit behind protective panels that come off for service and go back on for class. The engine wiring is secured and covered along its length, so no cable can be snagged or pulled apart in use. An emergency stop button shuts the apparatus down from anywhere around it. The frame rolls on locking castors and its mass sits low, so it will not shift or tip while the drivetrain is running. Every fluid and refrigerant circuit is the closed OEM circuit, and the exhaust is a sealed line to a single outlet.
230V
L 1750 W 1450 H 1350 mm
390 kg
Specifications