Lexus - RX 400 - Workshop Manual - 2004 - 2004

RX400h New Technology Model Outline Performance • Power Train – 3MZ-FE engine [3MZ-FE] V6 3.3-liter, 24-valve, DOHC, w/VVT-i gasoline engine 155 kW @ 5,600 rpm 288 N·m @ 4,400 rpm 2 Model Outline Performance • Power Train – MG1 / MG2 [MG1] Alternating current permanent magnet synchronous type motor Max. System Voltage: AC 650V Max. Output: 109 kW @ 13,000 rpm Max. Torque: 80 N·m @ 0 13,000 rpm 3 Model Outline Performance • Power Train – MG1 / MG2 [MG2] Alternating current permanent magnet synchronous type motor Max. System Voltage: AC 650V Max. Output: 123 kW @ 4,500 rpm Max. Torque: 333 N·m @ 0 1,500 rpm 4 Model Outline Performance • Power Train – MGR (4WD model only) [MGR] Alternating current permanent magnet synchronous type motor Max. System Voltage: AC 650V Max. Output: 50 kW @ 4,610 5,120 rpm Max. Torque: 130 N·m @ 0 610 rpm 5 Model Outline Equipment • THS-II – DC 288V high-output HV Battery Rear Seat HV Battery 6 Model Outline Equipment • THS-II – Inverter MG MG ECU ECU Controls Controls inverter inverter components components Inverter Inverter AC AC DC DC Boost Boost Converter Converter DC288V DC288V DC650V DC650V DC-DC DC-DC Converter Converter DC288V DC288V 7 DC12V DC12V Model Outline Equipment • Combination meter – Power meter : Indication of total of engine & motor output – Multi-information : Indication of cruise information, energy monitor, etc.. Power Meter READY Light 8 Multi-information Display •Energy monitor, etc., … Model Outline Equipment • Multi display – New functions of multi display : Energy monitor Outside Temp. Instant Fuel Consumption 9 Change the display to fuel consumption screen : : : : Drive by Engine Drive by Motor Regenerate Not Activate Model Outline Equipment • Multi display – New functions of multi display : Fuel consumption Outside Temp. Average Fuel Consumption Instant Fuel Consumption Regenerated Energy Display Average Fuel Consumption (after resetting) Driving Distance (after resetting) Change the display to energy monitor screen 10 Engine Engine specifications Engine properties Engine Engine specifications • Outline – V6 (60-degree), 3.3-liter, 24-valve, DOHC, w/VVT-i gasoline engine Basic Basic construction construction and and operation operation are are same same as as 3MZ3MZFE FE on on RX330 RX330 12 Engine Engine specifications Item 3MZ-FE (RX400h) 3MZ-FE (RX330) 1MZ-FE (RX300) Destination -A, -W -A -W No. of Cylinders and Arrangement 6-Cylinder, V-type 24-Valve DOHC, Gear/Belt Drive, VVT-i Valve Mechanism Displacement 3311 2995 cm3 Bore x stroke mm Compression Ratio 13 92.0 X 83.0 87.5 X 83.0 10.8 10.5 Max. Output 155 kW @ 5,600 rpm 208 HP @5,600 rpm 172 kW @ 5,600 rpm 230 HP @ 5,600 rpm 150 kW @ 5,600 rpm Max. Torque 288 N·m @ 4,400 rpm 328 N·m @ 3,600 rpm 283 N·m @ 4,500 rpm Engine Engine specifications • Major Difference from 1MZ-FE (RX300) • THS ECU controls the engine • Cylinder bore diameter is increased • Same piston for right and left bank • Intake valve timing is changed (retarded) • ACIS is discontinued • Intake air control system is discontinued • Flat type knock sensor • Drive belt is discontinued 14 THS – II THS-II Overall THS-II Operation Motor / Generator Inverter assembly THS-II Overall • Basic components of THS-II Power Split Planetary Gear Unit MG1 MGR Engine HV Battery Inverter Motor Speed Reduction Planetary Gear Unit 16 MG2 THS-II MG (Motor Generator) • MG1, MG2 and MGR – Alternating current permanent magnet synchronous motor MG2 MG1 MGR Hybrid Transaxle 17 Rear Transaxle THS-II Overall • Power-dividing mechanism – 2 Planetary Gears Engine MG1 MG2 Counter Gear To Front Wheel 18 THS-II MG (Motor Generator) • Specifications Item MG1 Drive Front Wheels, Generator Drive Rear Wheels, Generator 109 / 13,000 123 / 4,500 50 / 4,610 ~ 5,120 80 / 0 ~ 13,000 335 / 0 ~ 1,500 130 / 0 ~ 610 Generator, Engine Starter Function System Voltage V Max. Output kW / rpm Max. Torque N·m / rpm 19 MGR Permanent Magnet Motor Type Cooling System MG2 Max. AC 650 Water-cooled Air-cooled THS-II Nomographic Chart + + rpm Torque - - Sun Gear (MG1) Carrier (Engine) Power Split Planetary Gear Unit • Vertical lines show rpm and direction of rotation • Spaces between vertical lines show gear ratios • Arrows show torque direction (Red: Discharge / Blue: Charge) 20 Ring Gear (Wheel) Carrier (Fixed) Sun Gear (MG2) Motor Speed Reduction Planetary Gear Unit - MG1, MG2 Condition Rotation Direction of MG + + Discharge Charge Torque Charge Discharge THS-II THS-II Operation • Engine starting – MG1 starts engine Vehicle Speed 0 Engine MGR MG1 MG2 21 Refer to chart HV Battery THS-II THS-II Operation • Idling – Engine turns MG1 to charge HV battery Vehicle Speed 0 Engine MGR MG1 MG2 22 Refer to chart HV Battery THS-II THS-II Operation • Vehicle start-off – Driving with MG2 & MGR Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 23 HV Battery THS-II THS-II Operation • Vehicle start-off with engine – MG1 starts engine for increase of drive torque – Engine turns MG1 to charge HV battery Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 24 HV Battery THS-II THS-II Operation • During slight acceleration with engine – Engine drives wheel and MG1 – Generated electricity is supplied to MG2 Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 25 HV Battery THS-II THS-II Operation • During low load & constant-speed cruising – Engine drives wheel and MG2 – MG1 is turned to keep an optimum gear ratio Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 26 HV Battery THS-II THS-II Operation • During full throttle acceleration – HV battery supplies electricity to MG2 and MGR Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 27 HV Battery THS-II THS-II Operation • Deceleration in D range – MG2 & MGR charge HV battery Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 28 HV Battery THS-II THS-II Operation • Deceleration in B range – MG1 drives the engine – The motive force of MG1 is used for engine brake Vehicle Speed 0 Fuel Cut Engine MGR MG1 MG2 29 Click! Movie HV Battery THS-II THS-II Operation • Driving in reverse – MG2 & MGR are reversing Vehicle Speed 0 Click! Movie Engine MGR MG1 MG2 30 HV Battery THS-II System diagram • System diagram of main components Shift Position Sensor Hybrid Transaxle MG1 Accelerator Pedal Position Sensor THS ECU Resolver (MG2) Rear Transaxle MG2 MGR* Inverter MG ECU Auxiliary Battery Boost Converter Engine DC – DC Converter Brake Actuator Skid Control ECU Speed Sensors 31 SMR1, 2 and 3 CAN DLC3 Battery Smart Unit HV Battery A/C Compressor with A/C Inverter THS-II Inverter assembly • General – 4 components MG MG ECU ECU Inverter Inverter Boost Boost Converter Converter DC-DC DC-DC Converter Converter Inverter assembly 32 THS-II Inverter assembly • System diagram THS THS ECU ECU MG MG ECU ECU Inverter Assembly MG1 Boost Boost Converter Converter Inverter Inverter •IPM •IPM (IGBT) (IGBT) •Reactor •Reactor •IPM •IPM (IGBT) (IGBT) HV Battery MGR DC DC -- DC DC Converter Converter A/C A/C Inverter Inverter 33 MG2 Auxiliary Battery A/C Compressor Motor THS-II Inverter assembly • Inverter – Converts DC AC Inverter Assembly DC Boost Converter Inverter MG1 DC IPM (IGBT) DC AC MG2 AC HV Battery AC MGR 34 THS-II Inverter assembly • Boost converter (Variable-voltage system) – converts DC 288V DC 650V DC DC 650V 650V DC DC 288V 288V Inverter Assembly AC MG1 Boost Converter DC 288 V •IPM (IGBT) •Reactor DC650 V Inverter (IPM) MGR HV Battery : Discharge 35 MG2 : Charge THS-II Inverter assembly • Boost converter (Variable-voltage system) – System diagram Boost Converter IGBT IPM Inverter Power Transistor IPM Reactor MG1 HV Battery MG2 MGR 36 THS-II Inverter assembly • DC – DC converter – Converts DC 288V DC 12V Inverter Assembly HV Battery MG1 Variablevoltage System DC 650V Inverter MG2 MGR DC – DC Converter DC 288V DC AC 288V AC AC AC 12V DC DC 12V Auxiliary Battery 37 THS-II Inverter assembly • Cooling – Separate cooling system from engine Receiver Tank Radiator (for Inverter) 38 Water Pump THS-II HV battery • General – Power supply 39 HV Battery Auxiliary Battery For MG1,MG2 and MGR etc. For headlight, audio, all ECUs, etc. (when the READY OFF) THS-II HV battery • General – Located under the rear seat HV Battery Assembly Rear Seat Service Plug 40 THS-II HV battery • Layout of Main Components Junction Block Cooling Fan Battery Smart Unit Modules 41 Service Plug Connector THS-II HV battery • Layout of Main Components – Junction block SMR1 SMR2 SMR3 42 Amperage Sensor Resistor THS-II HV battery • Features Plug-in Type SMR 3 Cooling Fans DC 288V 114V Metallic Battery Case 60V 114V 3 Portions 43 THS-II HV battery • Battery smart unit – Transmit the HV battery information to the THS ECU THS ECU SOC* SOC* Control Control Cooling Cooling Fan Fan Control Control Cooling Fan Relay Diagnosis Diagnosis Function Function for for HV Battery HV Battery Serial Communication Battery Smart Unit HV HV Battery Battery Condition Condition Detection Detection HV Battery + Amperage Sensor Short Short Circuit Circuit Detection Detection for for HV HV Battery Battery Voltage x 16 Cooling Fan Motors (3) Temp. x 8 Temp. Sensors (Thermistor) 44 *: State of Charge THS-II HV battery • SOC control – The SOC is maintained at target SOC 45 THS-II HV battery • SOC control – THS ECU controls the SOC Battery Smart Unit HV Battery Information THS ECU SOC SOC Drive Voltage (SOC) Charging Charge MG1 Drive HV Battery Engine 46 THS-II HV battery • SMR (System Main Relay) – Turns ON / OFF high voltage circuit SMR1 SMR2 SMR3 Resistor 47 THS-II HV battery • Service plug – Service plug cut the high voltage circuit Cover Rear Seat Service Plug 48 THS-II HV battery • Service plug – Power is shut off at HV battery midpoint 49 THS-II Auxiliary battery • Auxiliary battery – Supplies 12V power Auxiliary Battery 50 THS-II Power cable • Power cable – High-voltage, high-amperage cable Junction Connector A/C Compressor Rear Transaxle (MGR) Inverter DC-DC Converter for EPS Front Transaxle (MG1, 2) EPS ECU HV Battery MGR (W, U, V) 51 HV Battery (+, -) EPS (DC-DC Converter) THS-II THS-II control system • Motive force calculation – Target motive force - Engine motive force = MG2 motive force Shift Position Sensor Accelerator Pedal Position Sensor THS ECU Target Target Motive Motive Force Force Calculation Calculation Engine MG1 MG1 Generation Generation Calculation Calculation Speed Sensor (Resolver) SOC SOC Calculation Calculation HV Battery 52 Engine Engine Motive Motive Force Force Calculation Calculation MG2 MG2 Motive Motive Force Force Calculation Calculation MG1 MG2 Hybrid Transaxle THS-II THS-II control system • Motor traction control Each wheel Speed Sensors Skid Control ECU Brake Request High Speed THS ECU Speed Sensor MG2 Hybrid Transaxle Traction Control Brake Force MGR Brake Actuator 53 Speed Sensor Inverter Rear Transaxle THS-II THS-II control system • 4WD system – Electric 4WD system Rear Transaxle •MGR 3MZ-FE Engine 54 Hybrid Transaxle •MG1 •MG2 THS-II THS-II Control System • 4WD system – Skid control ECU calculates the front / rear wheel torque distribution 4 Speed Sensors THS ECU Target Target Motive Motive Force Force Calculation Calculation SOC SOC Calculation Calculation Target Motive Force, Shift Position Front Front Motive Motive Force Force MG1 Engine 55 Rear Rear Motive Motive Force Force MG2 Torque Distribution MGR Skid Control ECU Calculates Calculates front front / / rear torque rear torque distribution distribution Steering Angle Deceleration Sensor Rate Sensor THS-II THS-II control system • 4WD system – 2WD / 4WD Operation Accelerat ion Start-off, Low Load Normal Driving 4WD (82N>m) D 4W >m) 0N 3 1 ( 2WD On slippery load 4WD (130N>m) 56 Decelerat ion 4W D Tight Turn 4WD (23N>m) (): MGR Max. Torque THS-II THS-II control system • 4WD system – 4WD warning on multi information display 4WD Warning Combination Meter 4 Skid Control ECU Communication Malfunction Warning Request THS ECU Sensor Malfunction Sensor 57 MGR Gateway ECU MGR Malfunction Meter ECU Chassis Hybrid Transaxle Rear Transaxle Steering Brake Control system Chassis P310 Hybrid Transaxle • General – A new “P310” hybrid transaxle Front 59 Chassis P310 Hybrid Transaxle • Features 2 Planetary Gear Units Compound Gear No Drive Chain 60 3 Axes Chassis P310 Hybrid Transaxle • Transaxle Unit Power Split Planetary Gear Motor Speed Reduction Planetary Gear Engine Compound Planetary Gear Unit Oil Pump Transaxle Damper MG2 Compound Gear MG1 Counter Gear Difference Gear Unit 61 Final Gear Chassis P310 Hybrid Transaxle • MG1 – Operates as generator and starter motor Item MG1 Type Permanent Magnet Motor Generator, Engine Starter Function System Voltage V Max. Output kW / rpm Max. Torque N·m / rpm Max. rpm Cooling System 62 Max. AC 650 109 / 13,000 80 / 0 ~ 13,000 13,000 Water-cooled Chassis P310 Hybrid Transaxle • MG2 – Drives front wheels – Operates as generator when braking Item MG2 Type Permanent Magnet Motor Drive Front Wheels, Generator Function System Voltage V Max. Output kW / rpm Max. Torque N·m / rpm Max. rpm Cooling System 63 Max. AC 650 123 / 4,500 335 / 0 ~ 1,500 12,400 Water-cooled Chassis P310 Hybrid Transaxle • Power split planetary gear – Sun gear = MG1 – Planetary carrier = Engine – Ring gear = Wheel Power Split Planetary Gear Engine MG1 MG2 To Front Wheel 64 Chassis P310 Hybrid Transaxle • Motor speed reduction planetary gear – Sun gear = MG2 – Planetary carrier = Fixed – Ring gear = Wheel Motor Speed Reduction Planetary Gear Engine MG1 MG2 To Front Wheel 65 Chassis P310 Hybrid Transaxle • Motor speed reduction planetary gear – Reduction of MG2 speed & increase of torque Reduction Reduction Ratio Ratio :: 2.478 2.478 66 Chassis Reference (P310 Hybrid Transaxle) Motor speed reduction planetary gear Without Reduction Mechanism Torque (Motor Size) With Reduction Mechanism Compact and light weight 0 Motor Speed Necessary Performance for MG2 Chassis Q211 Rear Transaxle • General – Rear transaxle Front 68 Chassis Q211 Rear Transaxle • Construction MGR Speed Sensor Counter Gear Ring Gear Differential Gear Unit 69 Chassis Q211 Rear Transaxle • MGR Item MGR Type Permanent Magnet Motor Drive Rear Wheels, Generator Function System Voltage V Max. Output kW / rpm 50 / 4,610 ~ 5,120 Max. Torque N·m / rpm 130 / 0 ~ 610 Max. rpm Cooling System 70 Max. AC 650 10,750 Air-cooled Chassis Shift Lever • Shift pattern 71 Chassis Steering • EPS (Electric Power Steering) – Direct drive between motor & rack Resolver Type Torque Sensors [Specifications] Type Gear Ratio (Overall) No. of Turns Lock to Lock Rack Stroke [mm ] 72 Rotational Angle Sensor Vehicle Speed Sensing Type 15.6 : 1 2.90 145.0 Steering Gear Unit • Brushless Motor • Reduction Mechanism Chassis Steering • Layout of main components Steering Gear Unit EPS ECU 73 Steering Column HV Battery DC-DC Converter Chassis Brake control system • VDIM (Vehicle Dynamics Integrated Management) – Conceptual diagram of control management Vehicle Cornering Driving Cornering Braking VDIM 74 Smooth Vehicle Control Driving Cornering Cornering Braking Conventional Chassis Reference (Brake control system) • VDIM (Vehicle Dynamics Integrated Management) – Example VSC or ABS Control VDIM Control Braking VDIM 75 Smooth Vehicle Control Braking Conventional Chassis Brake control system • VDIM (Vehicle Dynamics Integrated Management) – Functions Regenerative Regenerative Brake Brake Cooperative Cooperative Control Control ECB System EBD EBD ABS ABS Brake Brake Assist Assist 76 TRAC TRAC VSC VSC Power Power Steering Steering Cooperative Cooperative Control Control Chassis Brake control system • Regenerative brake cooperative control Brake Pedal Depression Regenerative Brake Brake Force 77 Hydraulic Brake Chassis Brake control system • Regenerative brake cooperative control – Operation Skid Control ECU Demand Demand Braking Braking Force Force Regenerative Regenerative Brake Brake Force Force Calculation Calculation Hydraulic Hydraulic Brake Brake Control Control THS ECU Regenerative Regenerative Brake Brake Control Control Actual regenerative brake force Electricity MG2 78 MGR* *: 4WD model only Chassis Brake control system • ECB system – Total brake force (hydraulic®enerative) matches the required braking power Hydraulic Brake Regenerative Brake 79 80 81