PLUG-IN CHARGE CONTROL SYSTEM


  1. FUNCTION OF MAIN COMPONENTS

    Component Function
    Electric Vehicle Charger Assembly

    • Communicates with the charging cable or plug-in charger and sends signals such as the charging current, charging voltage, etc., to the hybrid vehicle control ECU.

    • Performs plug-in charging based on signals sent from the hybrid vehicle control ECU.

    • Illuminates or flashes the charging indicator (EV charger lid indicator assembly) and SOC indicator (indicator lamp assembly).

    • When plug-in charging, supplies voltage to the auxiliary battery via the sub DC-DC converter.

    • Boosts the AC voltage from the external power source and converts it into DC power to charge the HV battery.

    • Sends lock and unlock request signals to the fuel lid with motor lock assembly.

    • Illuminates the charge lid light (spot light assembly).
    Hybrid Vehicle Control ECU

    • Sends charger operation signals to the electric vehicle charger assembly.

    • Receives the plug-in charge permission signal from the electric vehicle charger assembly and sends a charger relay turn-on request signal to the battery ECU assembly.
    Battery ECU Assembly

    • Receives the charger relay turn-on request signal from the hybrid vehicle control ECU and turns on the charge (CHR) relay.

    • When the battery heating system is operating, turns on the HV battery heater relay.
    Inverter with Converter Assembly When the battery heater system is operating, supplies power to the battery heater at a reduced voltage.
    Charge Cable (Electric Vehicle Charger Cable Assembly)

    • When the charging connector is connected to the charger inlet, supplies voltage from the external power source.

    • Has a CCID (Charging Circuit Interrupting Device) that automatically performs an electrical leakage test when the charging connector is connected.

    • Has a CCID (Charging Circuit Interrupting Device) that cuts off the voltage of the external power source if electrical leakage is detected while performing an electrical leakage test when plug-in charging. Reconnects the power when the system returns to normal.
    Combination Meter Assembly Allows scheduled charge times to be added, confirmed or changed, and immediate charging or next scheduled charge time to be confirmed or changed via the multi-information display.
    SOC indicator (Indicator Lamp Assembly) Displays the HV battery SOC by illuminating or flashing the 3 indicators.
    Charge inlet (AC Charger Inlet Cable) When the charging connector of the charge cable is connected, supplies voltage from the external power source to the electric vehicle charger assembly.
    Charge Lid Light (Spot Lamp Assembly) Illuminates when the charger lid is open.

    EV Charger Lid Indicator Assembly


    • Charging indicator

    • Charging Connector Lock Switch

    • Illuminates or flashes to indicate the plug-in charging status.

    • Locks or unlocks the charging connector during manual operation.
    EV Charger Lid Switch Assembly Sends the charging port lid open or closed signal to the electric vehicle charger assembly.
    Cable EV Charger Lock Assembly Locks and unlocks the charging connector and charge inlet based on request signals from the electric vehicle charger assembly.
    Timer Charging Switch (Fuel Control Switch) When the switch is operated, displays the timer charging screen on the multi-information display.

  2. FUNCTION

    Control Function
    Charging Control Depending on the status of the HV battery, the electric vehicle charging assembly optimally adjusts the amount of power. When nearing full charge, gradually reduces the voltage until the battery is fully charged.
    Charging Timer By registering a charge event, charging can be started at the desired time. Furthermore, a preferable charging method such as completing the charging according to the set departure time, starting the charging on the specified day and time every week, etc., can be set.
    Battery Heating Control When the HV battery is being charged and the HV battery temperature is low, the HV battery temperature is raised using the built-in heater in order to enhance the drivability of the vehicle driven by motor.
    Pre-charging Battery Cooling Control When the temperature of the HV battery is high and charging is performed, by using the air conditioning system to cool the battery before charging begins, battery deterioration is suppressed.

    1. Charging Timer


      1. When registering a charge event, each of the following functions can be set:


        1. Charge Mode

          Charge mode can be selected from the following 2 modes.
          Charge Mode Detail
          Start Time Starts charging at the set time and ends charging when the HV battery is fully charged.
          Departure Time

          Starts charging so that charging is completed by the departure time.

          When this setting is selected, the air conditioning-linked setting is available.

        2. Repeated Setting


          • By selecting the desired day of the week, the charge event can be set to repeatedly be performed.

        3. Air Conditioning-linked Setting


          • When charge mode is set to departure, the air conditioning-linked setting (Climate Prep) in which the air conditioning system automatically starts according to the set time (approximately 10 minutes before the set departure time) can be set.

        4. ON/OFF of Immediate Charging


          • When the charging cable is connected to the vehicle, if one or more charge events have been registered, charging does not start until the set time of the charging event. To start charging immediately without changing the registered contents of the charge events, set "Charge Now" to ON and the scheduled charge times will temporarily ignored and charging will begin as soon as the charge cable is connected.

        5. Changing Next Scheduled Charging


          • Without permanently changing the content of the next scheduled charging event, the next scheduled charging event can be temporarily changed.

    2. Battery Heating System


      1. When plug-in charging, if the temperature of the HV battery drops, the 5 battery heaters located under the battery stacks are operated to raise the battery temperature to improve the drivability of the vehicle when in EV mode.

      2. The power for the HV battery heater is supplied from the HV battery at a lower voltage via the DC-DC converter.

      3. The battery heating system can be set to on or off via the multi-information display.

    3. Pre-charging Battery Cooling System


      1. Straight after driving, if the HV battery temperature is high when charging begins, the air conditioning system is operated to efficiently cool the HV battery to prevent high battery temperatures, especially when the SOC is high, and to minimize deterioration of the HV battery.

      2. The pre-charging battery cooling system can be set to on or off via the multi-information display.

      3. When the battery heating system is operating during charging, the charging time is longer than usual.

      4. When the charging timer is scheduled (departure time) and the ambient temperature becomes higher than estimated, charging may complete early.

  3. SYSTEM CONTROL


    1. Battery Heating System


      1. When scheduled charging is not set or immediate charging is performed.


        1. When the charging connector is connected, the temperature of the HV battery is automatically controlled to be above 36°F and is stopped when the charging connector is disconnected or after 3 days have elapsed.

          A003ISTE01

      2. When scheduled charging (start time) is set.


        1. The temperature of the HV battery is automatically controlled to be above 36°F at the scheduled charging start time and is stopped when the charging connector is disconnected or after 3 days have elapsed.

          A003J53E01

      3. When scheduled charging (departure time) is set.


        1. According to the set departure time, the temperature of the HV battery is raised to 41°F. If the vehicle departure time is exceeded, the temperature of the HV battery is automatically controlled to be above 36°F and is stopped when the charging connector is disconnected or after 3 days have elapsed.

          A003JEFE01
        Charging Status Display
        Operating Charging indicator (EV charger lid indicator assembly) SOC indicator (indicator lamp assembly) CCID Indicator
        Charging Only Illuminated Illuminated Illuminated
        Battery Heating Only Illuminated Not illuminated Illuminated
        Charging and Battery Heating Illuminated Illuminated Illuminated

    2. Pre-charging Battery Cooling System


      1. When the power switch is turned off and user requested HV battery cooling is enabled, the air conditioning system operates in cooling mode before charging starts.

      2. Operates when scheduled charging is not set and the temperature of the battery is above the required temperature. When scheduled charging is set, operates based on the time calculated 30 minutes prior to the start of charging if the temperature of the battery is above the required temperature.

      3. The pre-charging battery cooling system goes into standby mode 5 minutes prior to operating.

      4. When the pre-charging battery cooling system is enabled and the HV battery SOC is high, to ensure precise charging, the pre-charging battery cooling system does not operate.

      5. When the pre-charging battery cooling system is enabled, if the HV battery is excessively discharged, the pre-charging battery cooling system does not operate.

      6. Pre-charging battery cooling system suspension conditions


        • The engine hood or any door is opened.

        • The power switch is turned on (ACC) or on (IG).

        • The power switch is pressed.

        • The alarm system is sounding.

        • A shift state other than park (P) is selected.

        • The scheduled charge time has air conditioning cooperative control.

        • When immediate charging is performed.

  4. FAIL-SAFE


    1. The electric vehicle charger assembly has a self-protection function and automatically limits or stops power output in the event of overvoltage, overcurrent or excessive-temperature.


      1. If overvoltage or overcurrent is detected, charging is suspended.

      2. If an abnormal temperature is detected, the charging power is reduced.