1. Inverter Assembly

2. Inverter Assembly Components Inverter DC  AC high voltage
Variable-voltage System
DC201.6V stepped up to max. DC500V
DC-DC Converter
DC201.6V stepped down to DC 12V
A/C Inverter
DC  AC to drives the A/C compressor
Components:
- Inverter: Converts DC to AC (AC to DC)
- Variable-voltage system: DC201.6 stepped up to max. DC500V
- DC-DC converter: DC201.6 stepped down to DC12V
- A/C inverter: Converts DC to AC to drive electric inverter compressor

3. Variable-voltage System
Inverter Assembly
Components
Inverter Assembly
MG1
Inverter
Variable-voltage System
MG2
HV Battery
A/C Inverter
DC - DC Converter

4. Variable-voltage System
Inverter Assembly
Variable-voltage System
DC 201.6V  Max. DC 500V conversion
Max. DC 500V
 
DC 201.6V
Inverter Assembly
Inverter
(IPM)
MG1
Variable-voltage System
IPM (IGBT)
Reactor
DC 201.6V
DC500V
AC500V
Variable-voltage System uses IGBT(Insulated Gate Bipolar Transistor = semiconductor switching device) and the reactor to boosts voltage. This device is 20% smaller than the similar device used in THS (’03 model) and has achieved low heat generation and high efficiency.
MG2
HV Battery
: Discharge
: Charge

5. Inverter Assembly Variable-voltage System System Diagram
Power Transistor
Boost Converter
Inverter
IGBT
IPM
IPM
Reactor
MG1
HV Battery
MG2
IPM: Intelligent Power Module
IGBT: Insulated Gate Bipolar Transistor

6. Variable-voltage System
Inverter Assembly
Variable-voltage System
Voltage boost-up operation
Variable-voltage System
Inverter
201.6V ON
HV Battery

7. Inverter Assembly Variable-voltage System Voltage boost-up operation
HV Battery
Inverter
Variable-voltage System
HV Battery
201.6V ON
Inverter V
OFF

8. Variable-voltage System
Inverter Assembly
Variable-voltage System
Voltage reduction operation (when charging)
Variable-voltage System
Inverter ON
HV Battery

9. Inverter Assembly Variable-voltage System
Voltage reduction operation (when charging)
Variable-voltage System
HV Battery
Inverter ON
Variable-voltage System
HV Battery
Inverter
OFF

10. Voltage is regulated by IGBT duty
Inverter Assembly
Variable-voltage System
Voltage reduction operation (when charging)
Variable-voltage System
Inverter ON
HV Battery
Voltage is regulated by IGBT duty

11. Inverter Assembly MG Inverter Operation Motor drive U V W V W W V
IPM
IPM MG ON U V W V W W
Inverter creates 3-phase alternating current when the motor drive. (DC to AC) V ON

12. Inverter Assembly MG Inverter Operation Motor drive V W U V W U U W V
IPM
IPM MG ON ON V W U V W U U W V ON

13. Inverter Assembly MG Inverter Operation Motor drive V U V U U W V
IPM
IPM MG ON V U V U U W V ON

14. Inverter Assembly MG Inverter Operation Motor drive V W U V W U U W V
IPM
IPM MG ON V W U V W U U W V ON ON

15. Inverter Assembly MG Inverter Operation Motor drive U W V Inverter ON
IPM
IPM MG ON U W V ON

16. Inverter Assembly Inverter Operation Motor control
Motor Torque is controlled by the current value
Motor Speed is controlled by the frequency
High Speed
High Torque
Motor Torque is controlled by the current value.
Motor Speed is controlled by the frequency.
Low Torque
Low Speed

17. Inverter Assembly MG Inverter Operation Regeneration U V W V W W V
Regenerative Voltage
Inverter
to Variable-voltage System
IPM
IPM MG U V W V W W
Inverter creates DC current when the generation. (AC to DC) V

18. Inverter Assembly MG Inverter Operation Regeneration V W U V W U U W V
Regenerative Voltage
Inverter
to Variable-voltage System
IPM
IPM MG V W U V W U U W V

19. Inverter Assembly MG Inverter Operation Regeneration V U V U U W V
Regenerative Voltage
Inverter
to Variable-voltage System
IPM
IPM MG V U V U U W V

20. Inverter Assembly MG Inverter Operation Regeneration V W U V W U U W V
Regenerative Voltage
Inverter
to Variable-voltage System
IPM
IPM MG V W U V W U U W V

21. Inverter Assembly MG Inverter Operation Regeneration W U W U U W V
Regenerative Voltage
Inverter
to Variable-voltage System
IPM
IPM MG W U W U U W V

22. Variable-voltage System
Inverter Assembly
DC – DC Converter
DC201V  DC 12V
Inverter Assembly
HV Battery
MG1
Variable-voltage System
Inverter
MG2
DC – DC Converter
DC201.6V to DC12V conversion to charge the auxiliary battery. DC  AC
AC 201.6V 
AC 12V AC  DC
DC 12V
DC 201.6V
Auxiliary Battery

23. Inverter Assembly DC – DC Converter Operation DC – DC Converter
DC 201.6V
DC 12V
Rectifier Diode
Smoothing Circuit
DC  AC
Transformer
Auxiliary Battery

24. Inverter Assembly A/C inverter DC201.6V  AC201.6V conversion
A/C ECU
HV ECU
DC 201.6V 
AC 201.6V
Target Compressor Speed
AC 201.6V
DC 201.6V
A/C Inverter
DC 201.6V to AC 201.6V conversion to supplies the AC voltage to electric inverter compressor.
HV Battery
Electric Inverter Compressor
Inverter Assembly

25. Inverter Assembly Cooling System
Cooling circuit is used for inverter assembly
Separate cooling system from engine
Reservoir
Pump
MG1 / 2
Radiator
Inverter
Reservoir Tank
Coolant Type: SLLC
Coolant maintenance schedule is same as engine coolant.
Electric Water Pump
Radiator