CHARGING SYSTEM


  1. SYSTEM CONTROL


    1. This system lowers the generated voltage when the vehicle is not decelerating, and raises the generated voltage when the vehicle is decelerating. This reduces the load applied to the engine by the generator assembly while it is generating electricity, resulting in improved fuel economy. During idle or constant-speed driving, this system regulates the generated voltage in order to bring the amperage estimation value closer to the target value.

    2. This control consists of the power management control ECU, ECM, battery current sensor assembly with a built-in battery temperature sensor, generator assembly, various sensors and switches.

    3. The ECM detects the driving conditions based on the signals output by various sensors and switches. To give voltage instructions to the generator assembly, the power management control ECU performs calculations based on battery voltage as well as the signals output by the battery current sensor and the battery temperature sensor.

    4. The power management control ECU stops the charging control and the generator assembly switches to normal power generation mode under the following conditions:


      1. Low battery capacity

      2. Low or high battery temperature

      3. Wipers operating or blower motor operating (over high load) or taillight relay on

      4. Battery current sensor assembly or battery temperature sensor malfunctions

      5. Communication failure (Local communication between power management control ECU and ECM)

      6. Generator assembly malfunction

      7. Engine started

      8. Battery charged for approximately 2.25 to 3 hours

      9. Accumulated driving time becomes approximately 20 hours

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  2. CONSTRUCTION


    1. Generator Assembly


      1. This generator assembly has a joined segment conductor system in which multiple segment conductors are welded together to form the stator. Compared to the conventional winding system, the electrical resistance is reduced due to the shape of the segment conductors, and their arrangement helps to make the generator assembly compact.

        A004585E12
        Text in Illustration
        *1 Segment Conductor *2 Stator
        *3 Conductor Wire - -
        *a Segment Conductor Type Generator *b Conventional Type Generator
        *c Joined Segment Conductor System *d A-A Cross Section
        *e Winding System *f B-B Cross Section
        *g Cross Section - -

      2. The starter coil for the cSC0 type generator assembly uses a dual winding system to reduce both electrical noise (ripple and spike) and magnetic noise (a hum that is heard as generator assembly load is increased). This system consists of 2 sets of three-phase windings whose phases are staggered by 30°. Both electrical noise and magnetic noise are reduced because the electromagnetic waves that the respective windings generate have opposite polarities. However the electrical power generated does not cancel itself out, due to the use of separate rectifiers. The opposite polarities that are generated can be seen below.

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    2. Auxiliary Battery


      1. A European Norm (EN) battery for the auxiliary battery is provided.

      2. The ISS* type auxiliary battery is a suitable battery for the repeated engine starts that are performed by the stop and start system.

        CAUTION:

        When replacing the auxiliary battery, replace it with an ISS type battery or an equivalent battery intended for use with the stop and start system. It is dangerous to use a battery not intended for use with the stop and start system, as the engine may not stop/start correctly, or the battery could burst.

        Tech Tips

        *: ISS refers to the stop and start system.

        Auxiliary Battery Specification
        Item Specification
        Battery Type*1 LN1*2 LN2-ISS*3 LN2*4
        Rated Voltage (V) 12 12 12
        20 Hour Rate Capacity (20HR) (Ah) 45 60 60
        Cold Cranking Ampere (CCA)*5 (A) 325 540 356
        Exhaust Method All Cells Combined Each Cell All Cells Combined
        Indicator Nothing Nothing Nothing

        Tech Tips

        *1: For European Norm (EN) batteries, this refers to the battery size.

        *2: Standard equipment.

        *3: Models with stop and start system.

        *4: Destination package models for Germany without stop and start system.

        *5 Value indicates low-temperature starting performance.

    3. Battery Current Sensor Assembly


      1. Installed on the negative terminal of the battery, this sensor detects the amount of charging and discharging amperage of the battery and sends signal to the ECM. Based on this signal, the ECM calculates the battery capacity.

      2. A Hall IC is used for detecting the amount of charging and discharging amperage. The changes that occur in the magnetic flux density in the core as a result of the charging and amperage of the battery are converted and output as voltage.

        A004575E07
        Text in Illustration
        *1 Negative Terminal of the Battery *2 Charge/discharge Current
        *3 Battery Current Sensor Assembly *4 Magnetic Field
        *5 Core *6 Hall IC
        *7 Charge/discharge Amount Signals - -
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        Characteristic of Battery Current Sensor Assembly
        *1 Output Voltage
        *2 Current

    4. Battery Temperature Sensor


      1. The battery temperature sensor is built into the battery current sensor assembly.

      2. The battery characteristic (battery internal resistance) of taking in current for charging varies according to battery electrolyte temperature. If the electrolyte temperature is too low or too high, the battery internal resistance will increase, resulting in early deterioration. To prevent this, the battery temperature sensor changes its resistance as shown below to detect the temperature.

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        Text in Illustration
        *1 Battery Current Sensor Assembly *2 Battery Temperature Sensor Portion
        *a Battery Current Sensor Assembly Cross Section - -
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        Characteristic of Battery Temperature Sensor
        *1 Resistance
        *2 Battery Temperature