HYBRID CONTROL SYSTEM


  1. CONSTRUCTION


    1. An FC converter assembly that boosts the FC stack assembly output voltage to a maximum of 650 V has been adopted. The FC converter assembly is composed of the FC boost control ECU, IPM (Intelligent Power Module) for boosting, reactor, and capacitor.

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      *1 FC Converter Assembly *2 FC Stack Assembly

    2. The FC boost control ECU follows the output request value from the EV control ECU, and drives the boosting IPM, controls the FC output power value, and boosts the voltage to a maximum of 650 V.

    3. The FC converter assembly includes sensors such as the reactor current sensor and reactor temperature sensor.

    4. The FC converter assembly uses coolant to directly cool the boost IPM and reactor.

    5. FC converter

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      1. The FC converter consists of 4 phase reactors, IGBTs, and capacitor.

      2. The ON/OFF operation of the IGBTs is used to perform FC output power control and voltage boosting. By changing the number of operating IGBTs based on vehicle conditions, fuel efficiency is improved.

    6. Reactor current sensor


      1. The reactor current sensors are located at the FC converter reactors, and detect each FC output current value. Based on these output current values, the FC boost control ECU performs feedback control of the IGBT ON timing.

      Figure 1. Characteristics of Current Sensor:

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      *a Sensor Output Voltage (V)
      *b Current (A)

    7. Reactor temperature sensor


      1. The reactors inside the FC converter are equipped with temperature sensors.

      2. Based on the information sent from the temperature sensors via the FC boost control ECU, the EV control ECU controls the EV cooling system and FC system.

    8. FC boost control ECU


      1. The FC boost control ECU is located inside the FC converter, and operates the IGBT according to the output request value from the EV control ECU, and thus controls the output of the boost converter. The FC boost control ECU sends the FC converter input current value, voltage value, and other information necessary for vehicle control to the EV control ECU.

      FC Boost ECU Main Controls
      Control Function
      FC Converter Control While controlling the output power of the FC stack assembly, also boosts the output voltage to a maximum of DC 650 V, and outputs it to the inverter with converter assembly.