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LIST OF FIGURES
Figure Page
1.1. Flow diagram of baseline benchmarking approach. .............................................................................. 3
2.1. 2010 Toyota Prius [7]. ........................................................................................................................... 4
2.2. Comparison of PCUs (which include motor and generator inverters). .................................................. 6
2.3. PCU of the 2010 Prius. .......................................................................................................................... 7
2.4. Compartments of the 2010 Prius inverter and converter assembly. ....................................................... 8
2.5. Circuit diagram of 2010 Prius PCU. ...................................................................................................... 9
2.6. 2010 Prius PCU separated.................................................................................................................... 10
2.7. Controller and driver circuitry for dc-dc convert and inverters. .......................................................... 11
2.8. DC, motor, and generator connection terminals. ................................................................................. 11
2.9. Underside of power module/cooling structure (top) and bottom compartment (bottom) .................... 12
2.10. Bottom compartment containing inductor, capacitors, and dc-dc converter. ..................................... 12
2.11. 2004 Prius bottom compartment containing compressor inverter and 12V dc-dc converter. ............ 13
2.12. 2010 Prius main capacitor module removed from housing. .............................................................. 15
2.13. X-ray of 2010 Prius main capacitor top view (left) and side view (right). ........................................ 16
2.14. X-ray of 2010 Prius 0.562 µF (left) and 0.8 µF (right) filter capacitors. ........................................... 16
2.15. 2010 Prius PE module. ....................................................................................................................... 17
2.16. Cross section of 2010 PE module. ..................................................................................................... 18
2.17. Thermistor located on coolant input port. .......................................................................................... 18
2.18. Comparison of Toyota PE modules. .................................................................................................. 19
2.19. Close-up of 2010 Prius PE module. ................................................................................................... 20
2.20. Cross-section of boost converter modules 2010 Prius. ...................................................................... 20
2.21. Boost converter modules from Camry (left) and 2004 Prius (right). ................................................. 21
2.22. LS 600h PCU cooling and PE assembly. ........................................................................................... 21
2.23. LS 600h PE module. .......................................................................................................................... 22
2.24. Dimensions (mm) of inverter PE devices from Camry (left), 2004 Prius (middle), and 2010 Prius
(right). ................................................................................................................................................. 22
2.25. Dimensions (mm) of inverter PE devices from 2008 LS 600h. ......................................................... 23
2.26. Dimensions (mm) of bi-directional boost converter PE devices of 2010 Prius. ................................ 23
2.27. Side (left) and top (right) cross-sectional views of extracted 2010 Prius PE module. ....................... 24
2.28. Comparison of thermal conduction path in 2004 Prius (left) and 2010 Prius (right). ........................ 25
2.29. SEM image of IGBT and adjacent solder layer. ................................................................................ 25
2.30. SEM image of reaction layer and nickel plating on solder layer. ...................................................... 26
2.31. SEM image of insulator. .................................................................................................................... 26
2.32. SEM image of aluminum layers between insulator and cooling channels. ........................................ 27
2.33. 2010 Prius 888 μF capacitor module equivalent capacitance vs. frequency. ..................................... 28
2.34. 2004 Prius 1,130 μF capacitor module equivalent capacitance vs. frequency. .................................. 29
2.35. 2010 Prius 888 μF capacitor module equivalent capacitance variation with ambient temperature. .. 29
2.36. 2010 Prius 888 μF capacitor module ESR vs. frequency. .................................................................. 30
2.37. 2004 Prius 1,130 μF module ESR vs. frequency. .............................................................................. 30
2.38. 2010 Prius 888 μF capacitor module ESR vs. temperature. ............................................................... 31
2.39. 2004 Prius 1,130 μF capacitor module ESR vs. temperature. ........................................................... 31
2.40. 2010 Prius 888 μF capacitor module DF frequency response. .......................................................... 32
2.41. 2004 Prius 1,130 μF capacitor module DF frequency response. ...................................................... 32
2.42. 2010 Prius 888 μF capacitor module DF temperature response. ....................................................... 33
2.43. 2004 Prius 1,130 μF capacitor module DF temperature response. ................................................... 33
2.44. Previous ripple current test schematic. .............................................................................................. 34
