Presentation on theme: "ECB (ELECTRONICALLY CONTROLLED BRAKE) SYSTEM"— Presentation transcript:
1 ECB (ELECTRONICALLY CONTROLLED BRAKE) SYSTEM GeneralBasic construction and operation is same as LS460Regenerative Brake Cooperative Control FunctionBasic construction and operation is same as LS460.The LS600h has as the GS450h a Regenerative Brake Cooperative Control Function:Regenerative brake consists of a resistance force that is generated at the rotational axle in the reverse direction of the rotation of the generator (MG2) that is generating electricity. The greater the generated amperage (battery charging amperage), the greater will be the resistance force.The drive axle and MG2 are joined mechanically. When the drive wheels rotate MG2 and cause it to operate as a generator, a regenerative brake force of MG2 is transmitted to the drive wheels. This force is controlled by the THS II, which controls the generation of electricity.The regenerative brake cooperative control does not rely solely on the braking force of the hydraulic brake system to supply the brake force required by the driver. Instead, by effecting cooperative control with the THS II, this control provides a joint braking force provided by the regenerative brake and the hydraulic brake. As a result, this control minimizes the loss of the kinetic energy associated with the normal hydraulic brake, and recovers this energy by converting it into electrical energy.
2 ACTIVE STABILIZER SUSPENSION SYSTEM OverallEnhanced cornering ability to decrease an amount of roll by controlling twist of the front / rear stabilizer bars for the vehicle posture control during corneringTo decrease rolling angle during corneringTo change steering characteristic by driving conditionsActive stabilizer suspension system is equipped for all models except VIP??? Package model as STD.This system controls an amount of roll.AVS (Adoptive Variable Suspension System) controls a speed of roll: Stabilizer bar effect: Active stabilizer suspension system effect
3 ACTIVE STABILIZER SUSPENSION SYSTEM HV Battery UnitDC/DC Converter for EPS and Active stabilizerMain ComponentsAir Suspension ECURear Active Stabilizer ECUSteering Control ECURear Active Stabilizer ActuatorSkidControl ECUFront Active Stabilizer ActuatorFront Active Stabilizer ECUDamping Mode Select Switch
4 ACTIVE STABILIZER SUSPENSION SYSTEM Major Difference from GS450hLS600hL/LS600hGS450hPower SupplyHV BatteryExcusive BatteryDrive Voltage of Active Stabilizer ActuatorAC 46 V (Step down HV battery nominal voltage)AC 14 V (Battery voltage)DTCSome DTCs are newly added and discontinuedOutputCANSIL (Fr ECU)Reset MemoryNo requiredRequiredActive TestAvailableData List3 items are newly addedTest Mode(System Check)Reset memoryReset the current value and compensation value of the exclusive battery
5 ACTIVE STABILIZER SUSPENSION SYSTEM Steering Angle SensorYaw Rate SensorSteering Control ECUSuspension Control ECUDeceleration SensorSystem DiagramAC 46 VAC 46 VFront Active Stabilizer ActuatorFront Active Stabilizer Control ECURear Active Stabilizer Control ECURear Active Stabilizer ActuatorMotorMotorMotor Rotation SensorMotor Rotation SensorDC 46 VDC/DC Converter [EPS /Active Stabilizer Suspension]Function of Main ComponentsFront and Rear Active Stabilizer Control ECU: - Calculates the target twist angle of the active stabilizer actuator and actuates the active stabilizer actuator in accordance with the signals received from the sensors. - Converts the direct current from the DC/DC converter for EPS and active stabilizer suspension into three-phase alternating current. - Communicates with the front and rear active stabilizer control ECUs to keep optimally balancing the twist angles of both the front and rear active stabilizer actuators.Front and Rear Active Stabilizer Actuator: Twist the stabilizer bar in accordance with the signals received from the active stabilizer control ECU, in order to control the roll angle of the vehicle.DC/DC Converter for EPS and Active Stabilizer Suspension: Steps down the nominal voltage of the HV battery from DC 288V into DC 46 V and supplies electrical power to the active stabilizer control ECUs.Steering Angle Sensor: Detects the steering angle of the steering wheel and transmits them to the active stabilizer control ECUs.Yaw Rate Sensor: Detects the yaw rate and the longitudinal and lateral acceleration and deceleration of the vehicle body and transmits them to the active stabilizer control ECUs.Steering Control ECU: Transmits VGRS actuator operating angle signals to the active stabilizer control ECUs.Suspension Control ECU: Transmits the damping force mode (NORMAL, COMFORT or SPORT) signals to the active stabilizer control ECUs.Damping Mode Select SwitchDC 288 VSpeed SensorsCenter Console Switch ModuleHV BatterySkid Control ECUDriver Side Switch ModuleMain Body ECUMeter ECUMulti-information DisplayMaster Warning LightBuzzerDLC3
6 ACTIVE STABILIZER SUSPENSION SYSTEM Vehicle Roll AngleAmount of twisting the stabilizer bar are controlled based on signals of actual turning angle of tire, vehicle speed, lateral acceleration, and AVS modeOPERATING CONDITIONSShift position except “R” and “N” rangeVehicle speed is satisfied following conditionCHARACTERISTIC OF ROLL ANGLELateral AccelerationVehicle Roll AngleONActive stabilizer system stops operation, when the following conditions occur:Vehicle speed dropped to 5 km/h (3.2 mph)Shift lever in “R” or “N” rangeMalfunction occurred in this system or high-voltage circuitOFF5 km/h (3.2 mph)20 km/h (12.5 mph)Vehicle Speed: with System: without System
7 ACTIVE STABILIZER SUSPENSION SYSTEM Active Stabilizer ActuatorEach stabilizer bar position is kept to the neutral position by the vehicle’s weight, when system is OFFEach stabilizer bar position is not fixed, however is not freeMotor Short Relay is located in the active stabilizer actuator to fix each stabilizer bar position, when the malfunction occurs in this systemMotor Characteristic:When the motor is driven from output side while having short circuit the motor terminal, the counter electromotive force is generated in the motor, and as result, it becomes difficult to rotate the motor.CONDITIONSACTIVE STABILIZER ACTUATOR[STABILIZER BAR CONDITIONS]System OFFNot fixed, not freeSystem ONNot satisfied operating conditionsFixed (Controlled by ECU)Satisfied operating conditionsActive (Controlled by ECU)In fail-safeFixed (Controlled by motor short relay)
8 ACTIVE STABILIZER SUSPENSION SYSTEM Warning MessageSystem condition check by multi-information displaySYSTEM CONDITIONMULTI-INFORMATION DISPLAYMASTERWARNING LIGHTNOTESSystem MalfunctionONMalfunction detected in this systemDiagnosis ModeNo DTCOFFSystem normalStored DTCDTC stored in ECUDiagnosis Mode: Using SST, connect terminals TC (13) and CG (4) of the DLC3.
9 SERVICE POINT (ACTIVE STABILIZER SUSPENSION SYSTEM) Active TestIn active test mode, each active stabilizer control ECU operates each active stabilizer actuator automatically.SELECT: CHASSIS > FRONT STABILIZER OR REAR STABILIZER > ACTIVE TESTTESTER DISPLAYTEST PARTCONTROL RANGEDIAGNOSTIC NOTEStabilizer CheckFront active stabilizer actuatorThe following operation is operated every one second automaticallyFront side of the vehicle leans to the rightKeep above conditionReturn normalFront side of the vehicle leans to the leftReturn normal againIf operation is prohibited through fail-safe control, Active Test cannot be performedRear active stabilizer actuatorRear side of the vehicle leans to the rightRear side of the vehicle leans to the left
10 SERVICE POINT (ACTIVE STABILIZER SUSPENSION SYSTEM) Active TestIf Active Test does not operate, test mode DTCs are outputDTC FOR ACTIVE TESTDTC NO.DIAGNOSIS ITEMSINSPECTION ITEMSC194FOperation of Static Test Mode is Incomplete (Test Mode DTC)Test mode operation errorSteering angle sensorC1950Front Stabilizer Target Angle Not Attained (Test Mode DTC)Active stabilizer actuatorsActive stabilizer ECUsWire harnessC1951Rear Stabilizer Target Angle Not Attained (Test Mode DTC)If this system malfunction DTCs are already stored, test mode DTCs re not stored
11 SERVICE POINT (ACTIVE STABILIZER SUSPENSION SYSTEM) Initialization and Calibration ItemsAfter disconnecting auxiliary batteryPARTSPROCEDUREIF INITIALIZATION DOES NOT OPERATE, THE FOLLOWING FUNCTIONS ARE NOT WORKEDSteering Angle SensorDrive vehicle on a straight road at 35 km/h (22 mph) or more for 5 sec. or moreActive stabilizer control functions are not working (Roll angle may not decrease during cornering)
12 STEERINGOverallVehicle speed sensing type EPS system and VGRS system are used for all models as STDMAJOR DIFFERENCE FROM LS460L / LS460, GS450hLS600hL / LS600hLS460L / LS460 (Model with VGRS/ 19-inch wheels)GS450hSteering Gear TypeRack and PinionGear Ratio (Overall)12.4 to 19.311.6 to 16.712.4 to 17.2No. of Turns Lock to Lock2.5 to 3.92.4 to 3.53.16Drive Voltage of EPS MotorAC 46 V (Step down HV battery voltage)AC 46 V (Boost up Battery voltage)AC 14 V (auxiliary battery voltage)Power Supply DeviceDC/DC Converter for EPS and Active StabilizerBoost Converter (for EPS)Rack assist type EPS is usedMechanical construction of the steering gear unit and the VGRS actuator are the same as the LS460L / LS460 and GS450h.Power tilt and power telescopic mechanism with memory function is used.
13 STEERING System Diagram AC 33 – 46 V DC 33 – 46 V DC 12 V DC 288 V Steering Gear UnitRotation AngleSensorEPS MotorTorque SensorLock SolenoidSystem DiagramVGRS ActuatorMotorAC 33 – 46 VRotation AngleSensorSteering Control ECUPower Steering ECUParking Assist ECUDC 33 – 46 VDLC3DC/DC Converter [EPS /Active Stabilizer Suspension]HV ECUEPS SystemPower steering ECU, steering control ECU, steering angle sensor, skid control ECU, speed sensors, parking assist ECU (model with intelligent parking assist system), HV ECU and combination meter (PS warning light, multi-information display, master warning light and buzzer)VGRS SystemSteering control ECU, power steering ECU, suspension control ECU, yaw rate and deceleration sensor, skid control ECU, speed sensors, steering angle sensor, driving support ECU (model with pore-collision system) and combination meter (multi-information display, master warning light and buzzer)Combination MeterDC 12 VDC 288 VAuxiliary BatteryHV BatterySkid Control ECUSuspension Control ECUSpeed SensorsSteering Angle SensorYaw Rate SensorDriving Support ECUDeceleration Sensor
14 STEERING Layout of Main Components HV Battery Unit DC/DC Converter for EPS and Active stabilizerParking Assist ECUAir Suspension ECUAuxiliary BatterySteering Control ECUPower Steering ECUDriving Support ECUSkid Control ECUHV ECUSteering Gear UnitTorque SensorEPS MotorRotation Angle SensorVGRS ActuatorMotorRotation Angle SensorLock Solenoid
15 STEERING DC/DC Converter for EPS and Active Stabilizer Usually, DC/DC converter steps down the HV battery voltage from DC 288 V to DC 46 V and supplies electrical power to the power steering ECU.EPS MotorHigh-voltage use permission signalDC/DC CONVERTER [EPS /Active Stabilizer Suspension]AC 46 VHV ECUPower Steering ECUDC/DC converter supplies electrical power of DC 46 V to the Fr/Rr active stabilizer ECU in the same way.HV BatteryDC 288 VStep Down CircuitShut Down CircuitDC 12VBoost Converter CircuitAuxiliary BatteryTo Fr/Rr Active Stabilizer ECUBoost Circuit
16 STEERING DC/DC Converter for EPS and Active Stabilizer When there are any HV battery voltage problems, the DC/DC converter temporarily converts the auxiliary battery voltage from DC 12 V to approx. DC 33 V and supplies electrical power to the power steering ECU.EPS MotorHigh-voltage use permission signalDC/DC CONVERTER [EPS /Active Stabilizer Suspension]AC 46 VAC 33 VHV ECUPower Steering ECUHowever, during fail-safe operation, DC/DC converter does not supply electrical power to the Fr/Fr active stabilizer ECU.When the DC/DC converter changes to the fail-safe operation mode, power steering ECU will output the DTC C1546 or C1562 and PS warning light illuminates. - C1546: Malfunction in HV ECU - C1562: DC / DC Converter PIG Power Supply VoltageHV BatteryDC 288 VStep Down CircuitShut Down CircuitAuxiliary BatteryDC 12VBoost Converter CircuitTo Fr/Rr Active Stabilizer ECUBoost Circuit
17 SERVICE POINT (STEERING) Initialization and Calibration for Steering System*: Straight-ahead judgment conditions are requiredEPSVGRSInitializationCalibrationBattery reconnection*-ReplacementPower Steering ECUSteering Control ECURemoval/installation, replacement or adjustment of steering system partsSteering Gear UnitInitialization and Calibration for Steering System is the same as the LS460L / LS460.EPS System - Calibration: Means the rotation angle sensor value initialization and torque sensor zero point calibrationVGRS System - Initialization: Means the steering angle sensor initialization - Calibration: Means the actuator angle initialization and actuator angle adjustment - Relation pats for initialization and calibration: VGRS: Steering column, steering intermediate shaft, steering wheel (off-center)
19 ACTIVE STABILIZER SUSPENSION SYSTEM Active Stabilizer ActuatorDC brushless motor and reduction gear twist stabilizer bar on both sidesNOTE: Active stabilizer actuator is non-disassemble partsStator CoilRotor GearReduction Mechanism (Strain Wave Gearing Mechanism)Front Stabilizer Bar (LH)The motor is high power output, brushless type motor that is driven by a voltage of 46 V.FrontFront Stabilizer Bar (RH)Brushless MotorMotor Rotation Sensor (3 Hall ICs)
20 ACTIVE STABILIZER SUSPENSION SYSTEM Active Stabilizer ActuatorReduction mechanismBoth stabilizer bar shifts 2 teeth per wave generation 1 rotationFront Stabilizer Bar (RH)402 teeth400 teethFront Stabilizer Bar (LH)Reduction mechanism is the same as the mechanism for VGRS on LS460L/LS460.Rotor GearWave GeneratorFlexible GearCircular GearGear Ratio : 1/200
21 REFERENCE (ACTIVE STABILIZER SUSPENSION SYSTEM) Reduction MechanismConstructionStator GearFlexible GearWave GeneratorBall Bearing is between flexible gear and wave generatorMeshingFlexible gear is oval shaped by wave generatorNOTE: Indicate this is the reduction mechanism as VGRS system for GS430 exampleView from stator gear side(Steering wheel side)Not meshing
22 REFERENCE (ACTIVE STABILIZER SUSPENSION SYSTEM) Reduction MechanismOperation of strain wave gearingMotor ShaftFlexible Gear(100 teeth)Wave GeneratorBall Bearing(Between flexible gear and wave generator)Stator Gear(102 teeth)View from stator gear side(Steering wheel side)
23 REFERENCE (ACTIVE STABILIZER SUSPENSION SYSTEM) Reduction MechanismOperation of strain wave gearing[Operation of strain wave gearing]1. Flexible gear is flexed into an oval shape by wave generator2. Flexible gear teeth meshes with stator gear teeth and driven gear3. During wave generator rotation, the meshed area of the flexible gear and stator gear / driven gear moves in sequence4. After the wave generator makes one turn, the flexible gear is shifted by 2 teeth because the flexible gear has 2 fewer teeth than the stator gear5. The driven gear and flexible gear have the same number of teeth, so their rotational movements are identical6. The flexible gear is shifted by 2 teeth = The driven gear shifted by 2 teeth (= Actuator output)Stator gear fixedView from stator gear side(Steering wheel side)
24 STEERING VGRS Actuator VGRS actuator is relocated and spiral cable is discontinuedInputStrain Wave GearingOutputMotorLock MechanismVGRS actuator is relocated at pinion shaft. (On the EPS torque sensor)By the relocation, spiral cable is discontinued.TorqueSensor(for EPS)Torsion BarPinion Shaft
25 STEERING VGRS Actuator Strain wave gearing LS460 GS430 [ ]: Number of teethStator GearSpecification of the strain wave gearing is changed from GS430.- Driven gear is changed from “output” to “input”- Stator gear is changed from “input” to “output”- Reduction Ratio of strain wave gearing is 51Driven GearLS460GS430Flexible Gear
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