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The energy crisis and rising gas price in the 2000s led to a growing popularity of hybrid vehicles. Hyundai-Kia Motors has been challenging to develop the new efficient eco-technology since introducing the mild type compact hybrid electric vehicle for domestic fleet in 2004 to meet the needs of the increasing automotive-related environmental issues. Now Hyundai has recently debuted a full HEV for global market, Sonata Hybrid. This system is cost effective solution and developed with the main purpose of improving fuel consumption and providing fun to drive. Presenter Seok Joon Kim, Hyundai Motor Company

A compact and high performance electric motor, called the 3D motor and designed to achieve output torque density of 100 Nm/L, was developed for use on electric vehicles and hybrid electric vehicles. The motor adopts an axial flux configuration, consisting of a disk-shaped stator sandwiched between two disk-shaped rotors with permanent magnets. It also adopts 9-phase current with a fractional slot combination, both of which increase the torque density. The rated torque output of this high power-density motor is achieved by applying a hybrid cooling system comprising a water jacket on the outer case of the stator and oil dispersion into the air gaps. The mechanical strength of the rotors against centrifugal force and that of the stator against torque exertion were confirmed in mechanical experiments. Several measures such as flux barriers, a chamfered rotor rim, parallel windings, and radially laminated cores were adopted to suppress losses.

There has been a growing need in recent years to further improve vehicle fuel efficiency and reduce CO2 emissions. JATCO began mass production of a transmission for rear-wheel-drive (RWD) hybrid vehicle with Nissan in 2010, which was followed by the development of a front-wheel-drive (FWD) hybrid system (JATCO CVT8 HYBRID) for use on a midsize SUV in the U.S. market. While various types of hybrid systems have been proposed, the FWD system adopts a one-motor two-clutch parallel hybrid topology which is also used on the RWD hybrid. This high-efficiency system incorporates a clutch for decoupling the transmission of power between the engine and the motor. The hybrid system was substantially downsized from that used on the RWD vehicle in order to mount it on the FWD vehicle. This paper describes various seal technologies developed for housing the dry multi-plate clutch inside the motor, which was a key packaging technology for achieving the FWD hybrid system.

In December 2006, Nissan announced its Nissan Green Program 2010 (NGP 2010), a mid-term environmental action plan that includes initiatives to reduce vehicle emissions. In line with this plan, the company intends to introduce a new and original hybrid system in fiscal year 2010. Specifically, this system-called the “Infiniti Direct Response Hybrid”-is a one-motor, two-clutch parallel hybrid system that eliminates the need for a torque converter. It will be featured in the 2012 Infiniti M35 Hybrid and provides the following advantages. 1 Significant improvement in fuel economy even in Highway driving 2 Better response and a more direct feeling 3 Lightweight and low cost This one-motor, two-clutch system without torque converter possesses a simple but highly capable architecture that is new to the passenger vehicle segment.

From the beginning of the 1990s, we have been vigorously investigating a high-performance power source system for application to environmental vehicles, focusing our research and development efforts specifically on lithium-ion batteries. In order to adapt a battery system to the requirements of the target vehicle, battery performance must be predicted and designed more accurately. In the case of hybrid electric vehicles, for example, battery power must be reliably assured. Improving battery power requires quantitative analytical methods as fundamental techniques for understanding the basic processes that take place in a battery. From this perspective, we began constructing a battery simulation model from scratch in the middle of the 1990s concurrently with our battery R&D activities. The model simulates electrode reactions and charge transport and has been used in investigating the influence of these factors on battery performance.

Aiming for an environmental vehicle, since the 1990s we have narrowed our focus to the development of an exclusive use lithium-ion battery, and we have strongly advanced our examinations into high-performance power supply systems. In order to adapt a battery to meet vehicle requirements, it is necessary to more accurately predict battery performance, and have the ability to design it. For example, in the applicability to HEVs(Hybrid Electric Vehicles), ensuring battery power with certainty is required, but in order to improve battery power, the basic process that occurs inside the battery was restrained, so it is possible that the quantitative analytical approach is the necessary fundamental technology.

Curbing emissions of carbon dioxide (CO₂), which is believed by many scientists to be a major contributor to global warming, is one of the top priority issues that must be addressed by automobile manufacturers. Automakers have set their own strategies to improve fuel economy and to reduce CO₂ emissions. Some of them include integrated approaches, focusing on not only improvement of vehicle technology, but also human factors (eco-driving support for drivers) and social and transportation factors (traffic management by intelligent transportation systems [ITS]). Among them, electric vehicles (EVs) will be a key contributor to attaining the challenging goal of CO₂ reduction. Mass deployment of EVs is required to achieve a zero-emission society. To accomplish that, new advanced technologies, new business schemes, and new partnerships are required.

Every fuel injection system for DI gasoline engines has a DC-DC converter to provide high, stabile voltage for opening the injector valve more quickly. A current control circuit for holding the valve open is also needed, as well as a large-capacity capacitor for pilot injection. Since these components occupy considerable space, an injector drive unit separate from the ECU must be used. Thus, there has been a need for a fuel injection system that can inject a small volume of fuel without requiring high voltage. To meet that need, we have developed a dual coil injector and an opening coil current control system. An investigation was also made of all the factors related to the dynamic range of the injector, including static flow rate, fuel pressure, battery voltage and harness resistance. Both efforts have led to the adoption of a battery voltage-driven fuel injector.

Recent environmental concerns such as atmospheric pollution and energy conservation have intensified the need to develop pollution-free, energy-efficient vehicles. One such solution is the electric automobile which draws its power from rechargeable batteries. There are few vehicles on the road today because present batteries can store very little energy compared with that of a tank of gasoline. To obtain adequate range, this concept vehicle adopts a new battery which can be recharged to 40% of capacity in six minutes. This super quick charging system makes it possible to recharge the batteries at an electric recharging station just as gasoline-powered vehicles are refilled at service stations. The electric concept vehicle also has improved aerodynamics, reduced rolling resistance and a lighter curb weight, which help to assure adequate range.

This paper describes the motor and inverter of Nissan's newly developed parallel hybrid system for rear-wheel-drive hybrid vehicles. The new system incorporates a high-power lithium-ion battery and a one-motor-two-clutch powertrain to achieve both highly responsive acceleration and better fuel economy. As the main components of the hybrid system, both the motor and the inverter have been developed and are manufactured in house to attain high power density for providing responsive acceleration, a quiet EV drive mode and improved fuel economy. Because the motor is located between the engine and the transmission, it had to be shortened to stay within the length allowed for the powertrain. The rotary position sensor and clutch actuator are located inside the rotor to meet the size requirement. High-density winding of square-shaped wire and a small power distribution busbar also contribute to the compact configuration.

An electrically-driven, intelligent brake unit has been developed, to be combined with a regenerative braking system in electric vehicles (EVs) and hybrid electric vehicles (HEVs) which went into production in 2010 - 11. The brake pedal force is assisted by an electrically driven motor, without using vacuum pressure, unlike conventional braking systems. The actuator can be implemented to coordinate with a regenerative braking system, and to have adjustable pedal feel through use of a unique pressure-generating mechanism and a pedal-force compensator. In this paper, we describe features of the actuator mechanism and performance test results

Hydraulic power steering is applied for petrol and diesel models of Infinity M series to provide supreme feeling of steering. Power assist of hydraulic power steering (here after called HPS), however, does not work when hybrid vehicle is in EV drive mode because the engine, which is the power source stops and the power is not supplied. Electric Power Steering (hereafter called EPS), therefore, “MUST” be installed to assist the power. Here comes the need that Nissan has developed our Hybrid EPS for Infinity M Hybrid model to keep providing supreme feeling of steering of hydraulic power steering without huge packaging change from the standard packaging of petrol & diesel models with hydraulic power steering. Our Hybrid EPS is the 1st hybrid EPS system in the world that is effectuated by oil pressure, and succesively realized by unique and excellent technology of Nissan.

HEV and EV markets are in a rapid expansion tendency. Development of low-cost regenerative cooperation brake system is needed in order to respond to the consumers needs for HEV and EV. Regenerative cooperation brake system which HEV and EV are generally equipped with has stroke simulator. We developed simple composition brake system based on the conventional ESC unit without the stroke simulator, and our system realized a low-cost regenerative cooperation brake. The key technologies are the quiet pressurization control which can be used in the service application, which is to make brake force depending on brake travel, by gear pump and the master cylinder with idle stroke to realize regenerative cooperation brake. Thanks to the key technologies, both the high regenerative efficiency and the good service brake feeling were achieved.

New technologies are needed to reduce cold-start emissions in order to meet the more stringent regulations that will go into effect in Europe (EC2000 or EC2005) and in California (ULEV), especially for larger engines such as 6- and 8-cylinder units. One new technology in this regard is the electrically heated catalyst (EHC). However, the use of EHCs alone is not sufficient to achieve the necessary reduction in emissions. This paper discusses techniques for effectively combining the elements of an EHC system, including the introduction of secondary air into the exhaust, improved control of the air/fuel ratio, and an electric power supply method for EHCs. It is shown that it is more effective to promote exothermic reactions in the exhaust manifold than at the EHC. A suitable method for this purpose is to introduce secondary air into the exhaust near the exhaust valves.

The performance capabilities which hold the key to the acceptance of electric vehicles (EVs) includes range and acceleration. Range can be effectively extended by increasing the size of the batteries used, but it requires a trade-off with acceleration performance which deteriorates due to the increased weight. The FEV-II and Prairie Joy EV exhibited at the 1995 Tokyo Motor Show were equipped with high-performance lithium-ion batteries that achieve both high energy and power densities, to provide an excellent balance of range and acceleration. Futher more, the batteries exceptionally high charging efficiency enables them to accept regenerative energy effectively. This feature improves range, and also allows the battery state of charge (SOC) to be determined accurately. This characteristic was used to develop a highly accurate battery model which was incorporated in a simulation program for predicting EV performance.

This paper presents a lightweight, high-performance Lithium-ion Battery System developed jointly by Nissan Motor Co. and Sony Corp. for electric vehicle (EV) use. Electric vehicles are generally powered by a battery pack consisting of numerous cells connected in a series. Management techniques to elicit the maximum performance of the battery pack are needed, including a function for monitoring individual cells to prevent them from over-discharging. Because of high cell voltage, lithium-ion batteries enable the number of cells in a battery pack to be greatly reduced compared with other types of battery systems. They also allow accurate detection of the battery State of Charge (SOC) based on the battery voltage. These characteristics are conducive to the application of battery pack management technology. These concepts provided the basis for the development of a Lithium-ion Battery System for EV application.

A key factor influencing the performance of a hybrid electric vehicle (HEV) is how the engine and motor-generator (MG) are combined with the vehicle. There have been several types of combinations such as power transfer by using the mechanical transmission of conventional vehicles or the electrical transmission originally designed for HEVs. The objectives of this research were to clarify fuel economy characteristics according to the type of power transfer system used and to identify the requirements for MG system development by analyzing MG operation conditions in each power transfer mode. HEV systems for passenger car use were modeled on the basis of a functional classification. Simulations were conducted using the characteristics of the power transfer systems as parameters to evaluate fuel economy tendencies under several driving modes. The mechanism of the fuel economy tendencies was then analyzed to evaluate quantitatively the effect of each power transfer system on fuel economy.

This paper describes a high-power lithium-ion battery system that has been newly developed for application to hybrid electric vehicles (HEVs). The battery system was designed on the premise of an underfloor location so as to avoid sacrificing interior spaciousness while providing the power output and recharge performance required by the hybrid propulsion system. To meet these requirements, efforts were made to increase the specific power and to reduce the heat generation of the battery to previously unattained levels. As a result, exceptionally high specific power of 1,200 W/kg per cell, battery pack power of 25kW at 20% state of charge (SOC), and high charge/discharge efficiency of more than 95% in the urban driving schedule has been achieved. The battery pack is composed of two box-shaped modules designed with a low height in consideration of underfloor mountability.

Nissan has recently developed and begun driving tests of a fuel cell vehicle equipped with a methanol reformer that produces hydrogen through the use of a catalyst to induce chemical reactions between methanol and water. With this onboard fuel cell system, only methanol in the form of a liquid fuel needs to be supplied, making the system highly practical as an automotive powertrain for near-future application. The Nissan Fuel Cell Vehicle (FCV) adopts a high-efficiency neodymium magnet synchronous traction motor combined with lithium-ion batteries that enable the vehicle to achieve optimum electric power by switching between a fuel cell-powered driving mode and a battery-powered driving mode. This presentation will cover the current status of the FCV development program and driving test results.

Technologies applied to the Nissan Tino Hybrid, marketed in March 2000, in Japan, are expected to evolve into the core powertrain technologies of the future, for the following technical advantages inherent to hybrid EVs: 1 Regeneration of deceleration energy 2 Motor driven propulsion at low speed, combined with power-assisted operation in the mid- and high-load ranges. It is expected that a number of models will be introduced to the market in the future, which pursue these advantages in various forms, resulting in HEV technologies to accelerate the use of electric power for the vehicle. Fuel cell vehicles will be included in this future scenario. In this paper, our view on the future HEV technologies will be described. In addition, the latest technologies applied to the Nissan Tino Hybrid will be introduced.