2016 - 2022 Toyota Prius Inverter with Converter
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- čas přidán 9. 07. 2024
- This episode covers the 4th generation Toyota Prius Inverter with Converter. Internal components and service procedures are discussed. The theory of operation and diagnostics will be covered in the next video in this series.
TIMELINE:
0:00 Start
0:50 External features
0:56 Liquid cooling
2:34 Safe removal procedures
3:12 A/C compressor connection
3:40 High voltage DC battery connection
4:30 Contactor functions
5:12 3-Phase cable connections
5:56 HV interlock circuit connection
6:57 Cover removal and seams
9:38 Motor Generator Control Computer
10:19 Electro-static discharge prevention procedures
11:00 Safety precaution - Capacitor discharge at
12:50 Motor Generator Control Computer removal
13:00 Vibration dampening electrical connectors
13:50 Special Service Tool (SST) 09905-00040
16:30 Vibration dampening grounding screws
17:39 Alignment dowels
18:40 Delicate terminal pins and connections
22:00 Cooling pipes
26:35 DC-DC Converter and removal
29:40 DC-DC Converter lift out
30:40 What is serviceable?
31:30 The forbidden zone, what is inside?
33:40 Reactor (Buck/Boost Converter)
34:48 HV battery connections
35:00 14 Insulated Gate Bi-Polar Transistors (IGBTs)
35:41 IGBT to Motor Generator 1 (MG1) and Motor Generator 2 (MG2)
35:48 Smoothing capacitor
35;52 Capacitor drain resistor
36:40 IGBT Cooling
38:11 Conclusion
ABOUT US:
Weber State University (WSU) - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab. This episode covers High Voltage Hybrid Electrical Systems - Specifically the 4th generation Toyota Prius Inverter with Converter. Internal components and service procedures are discussed. The theory of operation and diagnostics will be covered in the next video in this series.
W.S.U is a leader in Hybrid and Electric Vehicle education. This topic is taught as part of our 4-year bachelor's degree program. For information on joining the Weber Automotive program, visit: www.weber.edu/automotive
This video helps cover content related to the 2017 National Automotive Technicians Education Foundation (NATEF) Master Automobile Service Technology (MAST) Standard task 1.A.9 "Identify service precautions related to service of the internal combustion engine of a hybrid vehicle."
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see www.weber.edu/automotive/J_Kel...
QUESTIONS FOR TEACHERS:
1. How is the inverter with converter cooled?
2. What is the safe procedure for disconnecting the electrical circuits from the inverter with converter?
3. What electrical precautions must a service technician take before removing the motor-generator control computer?
4. What is the correct method of releasing the vibration dampening electrical connectors?
5. What can be easily damaged if extreme care is not used when removing the motor-generator control computer?
6. What mistake can lead to coolant getting inside the inverter with converter?
7. Where is the DC-DC converter located?
8. How are the DC-DC converter coolant passages sealed?
9. What inverter with converter parts are serviceable?
10. How many IGBTs are used in this inverter with converter?
11. What is the purpose of the smoothing capacitor?
12. What component discharges the smoothing capacitor?
ADDITIONAL TRAINING FOR YOU
Join us for hybrid and electric vehicle training with two online courses and in a 5-day on-campus boot camp with Professor John D. Kelly. See www.weber.edu/evtraining
DONATE TO OUR DEPARTMENT
Please consider a donation to the Department of Automotive Technology at Weber State University here: advancement.weber.edu/Automotive
Between Professor Kelly and AMD of "Car Car Nut" videos, I've learned a whole lot about my 2020 Toyota Camry Hybrid SE. Everything from how to service, how systems work, and the mechanical and electrical details about the excellent details that goes into my Toyota. These have been a great education for me to understand what goes into my favorite car. Thanks!
These hybrid videos are such a generously provided and useful resource. Thankyou.
Thank you!
"I like to take things apart further than I'm supposed to whenever I can."
Me too. :)
Fun stuff (usually) ;)
As far as possible, is the best policy! Just like honesty ; , ℅¢
My salutes to you sir for producing such a comprehensive video!
Brilliant video, thank you so much. A really well designed Inverter too, beautiful engineering.
This is a really well done video. Very clearly presented and very informative. Thank you for taking the time to make it!
Thank you very much!
Thank you professor. I am my own super tech to 07 Prius. I have replaced inverter/converter unit, 4 years ago. I have also replaced high voltage battery modules several times. It’s very dangerous work but it’s worth it. I am so proud of myself.
Thank you, Good job!
Thank you for yet another excellent and informative presentation.
Thank you and much appreciated Professor.
I'm more aware and confident working on hybrid cars.
Thank you so much for posting.
Appreciate you , the way of explation , and talents . you are a good teacher, what we lost from the teachers nowadays.
Thank you very much!
Excellent informative channel !! Thank you for sharing your knowledge Professor Kelly!
Thanks for these absolutely fascinating and educational videos!
Thank you so much for all your videos. You do great.
Thank you!
Amazing video.
Thanks mate.
I watched most of your videos and plan to watch them all. Everything I've seen from you is excellent. My personal interest is in making electric and hybrid drive trains for bikes but I plan to repair/rebuild existing ones also. I'll try to be more helpful when I can. Keep up the great work you're doing. God bless you.
Thank you very much!
I like watching your videos a lot! 👍 I work with several brands of electric cars and all these things are familiar to me, but it is very interesting to see other manufacturers' ideas for the same purpose. You make very good and educational videos! Keep up the good work
man want to be an electric vehicle tech looking for a tech team mate i am auto lock smith and automotive technician for combustion engines 16 year experiance
always informative, thanks ...
Thank you!
Very Good Explanation...
Thank sr for your teaching, very instructive. God bless you
Very good explanation. Thank you.
Thank you
Thanks very much for enlighting us in this scary hybrid technology.
Thank you for the effort and technical information you put out, Salute from the UK, By the way I achieved 171 miles from 11litres of E10 petrol (UK litres ) ,recently on 3rd gen engine, Toyota Auris these are excellent engineered cars.
Thank you sir. All your videos are very very helpful :)
Thank you!
You are doing a great job
Thank you
Love his videos it’s so helpful
Thanks for watching
Great video and very informative thanks 😀
Thank you
What an amazing channel! I am absolutely stoked with an amount of technical data in greate detail here!
I am planning on purchasing Accord with i-MMD, and it's currently virtually impossible to find any technical information about it.
It would be so awesome to take a look at the transaxle and HV Inverter. I will not buy any hybrid car before I can see it inside. This lets me get some understanding about longevity and how serviceable it is. I like my cars, and I keep them forever, so I need to know what's inside!
Merry Christmas and a happy new year and thank you master
thank you for efforts of this video production from Emil Ruducha @ NYC
Thank you for the videos
Thank you!
awesome.thank you professor.
Thank you!
thank you very nice video .
Ok.
thanks for the answer.
感恩了解，謝謝分享！
Thank you very much
Great video, great channel and great teacher! I would like to suggest you to include some drawings and schemes during the explanions, it would be very useful. Thank you so much for content you provide for us.
What I'd like to see is him putting it all back together !! :) :) :)
Here it is czcams.com/video/ErC7MpWGsgI/video.html
Wow, wow. Professor... I did not expect a reply, especially from you. I am indeed honoured. I prostrate before you !!
Thank you!
thank you.
Thank you very much for your videos. Special thanks for showing good culture working in the right way!
Thank you very much!
Dear Professor,
May I ask you to make the disassembling the European cars (BMV, AUDI, VW Renault ) interesting how they do the EVs. All the cars you do the inventors are from Japan. Thank you in advance.
@@nikodimaleshkin7689 Thank you for your suggestion. I would like to do that, but have limited access to those vehicles
The German car makers do , I think many things different. For example they do different style of the batteries from Tesla. Not the round one but flat windings. I think that the investors are also are different. Once again thank you for your great educational videos! We watch you with my son. Even at work I show your videos as an example. I am from the electronic components side.
@@nikodimaleshkin7689 Thank you, have a good day
Fascinating to see the internal structure of this unit (being an owner of a Toyota Hybrid; in my case a 2017 Yaris, with a 144V d.c. NiMH battery). In practice, if there is an internal fault, it’s most likely that a servicing dealer would replace the whole unit, but it’s good to see what it’s like inside.
One of the points to note is that they have managed to simplify a lot of things outside the unit, in effect. E.g. these cars do not have any belt driven alternators, air con pumps, nor any d.c. starter motors. The advent of IGBTs and variable frequency traction motors has been a major development for electric traction - for both on and off the road.
Very very thsnks
Thank you a very very much.. you must be awesome totally! Yes, do please good job forever.
SUPER SIR
Thank you!
Thanks teach
If you bought a Prius in japan in 2018 there are chances that you’re using an inverter I helped assemble :)
Great video, very well done.
Thank you for the information, that is cool!
C'mon...you have worked at Toyota city? How was it like?
Good work bro like the way u bo thinks, I in Trinidad I work on hybird toyato and nissan vehicles and all. New vehicles 1990 up 2018 and more, in my work shop i will enplement the ways u bo think keep up the good work
Thank you
Thank you very much for your amazing video about prius professor. Can you please post some videos on e wheel drive... It will be the next future...
Thank you. Are you referring to individual wheel motors when you say e wheel drive?
Yes you are correct.. Electric motor are kept inside each wheels..
called "outrunner"
A very enjoyable & informative video, as always. Thank you Prof. I have the feeling that as E.V.s become more abundant and production increases, then the serviceable parts will become fewer as more functions are integrated into one big black unserviceable mass produced lump.
Thank you. Most hybrid vehicle manufacturers do not have serviceable inverters. Toyota is different; their batteries, inverters, and converters all have serviceable components. I believe it is to reduce warranty expenses. It is less expensive to repair them than to replace the entire unit at this time. I hope, as EVs become more plentiful, that they have serviceable components as well.
A moot point, those very delicate interconnections between electronic processing stages is unsustainable in a practical commercial world. The smoothing regenerative braking capacitors have already been subjected to integration. Thank you for your professionalism in your videos & thoughtful response to all the comments. I look forward to your future videos.
Thank you!
Has always a very informative video there sir. A very well built pieces of hardware from toyota.
About part being unserviceable; I would say probably not.
Smaller and more integrated (implying more special tools and training) definitly.
I can attest about that, for example the best selling EV in France is the Renault ZOE.
The first Gen used a set of 3 large wire with heavy duty connectors between the inverter and the motor.
Now the new Generation has a smaller inverter with 3 copper bar that goes from the inverter straight down into the backplate of the electric motor. So unplugging the inverter from the motor require to open the inverter to gain access to the bolts holding the copper tabs.
Thank you zeus194, your observations are entirely relevant regarding the future of EV electronics. Who knows?
Dear Professor thanks a lot for wealth of information given in your videos. The best I have seen so far. Any chance of doing a video on the Prius gen 3 braking system overview?
Thank you! That is a good idea. I will add it to my list
Thanks for your prompt response
Thank you for the great videos I have a 2017 complete engine, inverter, and trans-axle with computer. Is there any way to get it to work with a gen 3 2011 Prius?
thank you
Nice
Thank you
Very informative. Thank you.
One question, Why do you call converter instead of plain voltage reducer? I don't see any conversion there.
very clear all I want is hold your hand kiss your hand and thank for your priceless lessons thank you very much professor and thank you UTUBE
Thank you!
hope to see you in person professor you are the best, and Utube will grow strong forever I will try my best just to be part of what you have done professor god bless you, sir
Dear Professor, Thank U for ur informative lectures. Great learning. I just wanted to know which is this "Electric screw driver" that you are using in this video. Company and model ??
Hi,
Can the DC-DC convert be upgraded? I've heard for grew 3rd gen Plug-in. The DC-DC convert puts out 14.4v @ 100amp. Any way to bump the amperage to 200-250 amp?
Thank you so much. Everything is very interesting and useful. Is it possible to make a similar material about the electric vehicles of Tesla?
Thank you! Some day I hope to get my hands on a Tesla
Toyota is awesome for coming out with hybrids. That's why I'll only buy Toyotas from now on.
I'm learning a lot. Thanks Prof. Now there's a point where you mentioned that IGBTs are serviceable but any replacement calls for repogramming. Where does one go for the programming?
A Toyota dealership is the best place. Although it is possible for anyone to purchase a Toyota scan tool, programming software subscription, and training, it is very expensive to do so.
my parents told me when i was still a baby until 5 y/o they'd buy me toys that moves and produces sounds.i'd play with them toys for awhile,like a minute or two then i'll go to my Dad's garage and i'll start dissecting the toy ^_^ my parents said i'm the strangest little girl they've ever seen in their life.i love toolboxes and what's inside toys ^_^
That is awesome!
Melania Trump You’re going to be an engineer!!
great video professor!!!! What is Vibrational Dampinning Electrical Connections? what they do?
Hello Professor,
That was really a good overview of Toyota Prius Power control Unit. I gained a lot of knowledge from the video.
I was also interested in Power control unit construction of Toyota C-HR Battery electric vehicle.
To understand the difference in design for a hybrid and pure electric.
If possible, Could you please provide some information about it.
Thank you very much😀
to make it easier to open the halves or covers i use permatex gasket remover ...but this does not work as it says in the instructions 15 -30 minutes ... I wetted two days where the silicone ...
It would be great if you could compare and contrast this I/C unit with the one used in the Prius Prime- different component and conductor sizes and ratings, etc.
Thx for the video. What are these vibration dampening connectors?
They are there because the connections to the other parts inside the inverter are through solid connections (no flexible wire harnesses to absorb vibrations while driving).
Hello professor, thanks for another interesting video!
I have one question concerning the A/C system, on this Inverter/Converter there's not anymore the inverter dedicated to the A/C compressor, and the connection uses only 2 wires (so HV DC) has this moved on the compressor itself?
I remember that in the previous Toyota Inverter/converter there was a dedicated output with 3 wires, so and AC one, am I wrong?
Thank you! You are correct. If the A/C compressor has only two wires connected to it, the inverter is built into the A/C compressor. If it has three wires, it is elsewhere. Most modern hybrid and electric vehicles use the 2-wire A/C compressor.
มีสายกราวด์ รัดข้อมือด้วย thank you.
Thank you
Wonderful video! My 2012 Prius lost power several times recently and the error code is P0A08, which is DC-DC Converter Fault Circuit / Open. According to your video, there should be something wrong the DC-DC Converter at the bottom of the inverter assembly. Unfortunately I can't find any used separate DC-DC Converter module sold on ebay. Only the whole inverter assembly is sold.
What do you think about the levels of EMF in hybrid cars ?
Professor, please can you confirm what happens in Sport Mode on a Lexus CT200H (P410). I think I read or heard that it merely increases to voltage to the traction motor.
Hello! Those electronic plates are very tricky to disassemble. What is purpose of this thin pins and vibration damping contactors: for high frequence AC voltage? I've learned already so much. Thanks a lot!
Good question. I do not know. I suspect it is to accommodate for thermal expansion
Is it possible to connect your Prius to your home in case of a black out?
Thanks professor I find an compatible unit at an use salvage yard parts for a fraction of the price from dealer
Good to hear, sometimes that is a good way to go. Thanks for your feedback
Good day sir, I was taking my ase l3 and failed it by two points. However I ran to a question with a diagram.
When you check the voltage on the terminal and it doesn't discharge is it the resistor that has a problem?
My 2024 corolla hybrid is faulty. The voltage sent to the 12 volt battery is not 14.5v but 20v. Do you think the problem might be the DC to DC converter? If not the DC to DC, what else could it be? The dealer replaced 1 12v batt. because it couldn't pass a load test. Any help you could provide would be much appreciated. Thanks. BTW, I watched your video from beginning to end; excellent!
Why are there 7 banks of IGBTs? I was expecting 6, ie one per phase of the MG1 and MG2 stators.
Excellent video professor, as always. What is the power rating of the Prius Prime electric motor?
Thank you very much! MG1 = 23kW, MG2 = 53kW
When will you do a video on Honda’s newer hybrid system? I just bought the new 2019 insight and I’m totally fascinated and curious.
Thanks for your feedback, that would be fun
Dear Professor, I have Prius V 2012 not getting to ready mode all I tried switching the Converter, Checking the Red Service Plug but the car still not starting the ready light blink twice and 2 or 3 click sounds from the HV battery. Please help
Hi Mr. Kelly is there a difference in Prius, Auris or Yaris inverters. They look much the same except top cover or P/N. Do you maybe know about the rating for the traction IGBTs inside?
If the part numbers are different, the inverters will be different as well. It may just be the upper board, but I do not know.
It will be very interestig to see how Toyota solve the manage of the heat of IGBT and how is made the coooling system in between IGBTs
Thanks for watching
Professor please make a vedio on HVIL switch.....also what is the make and part number of this HVIL switch
Hej Professor Det er meget interessant og meget fint beskrivelse, selv de mindste fragmenter bliver tydeligt gjort for os elbil interesseret,.
Jeg kan bruge det, til køb af brugte elbiler samt vedligeholdelse, men bliver bedre klædt på til at tale med forhandlerne og værkstedet.
MVH Henrik p. Nielsen
Bonjour ,vos vidéos sont vraiment bien .J'aimerais suivre une formation sur les prius dans votre atelier.
Sir I request you to please make videos on car sensor, and their test.
Thanks for your request
can we add a "RAT " air turbuine to recharge the battery pack while driving at the highway or solar panels or generators installed in every tire?
Only if you want to suck more power from the battery to run them
Hi professor you know where I can buy the dc dc converter? Because the dealer don't know nothing about this piece!!
The dealer is the only place besides a salvage yard that sells it. Try a different parts person. It is under the inverter in the same housing.
👏🏽👏🏽👏🏽👏🏽👏🏽
Hello Professor, I am new to the automotive world and I am very interested with your explanation about everything about vehicle, but I need your advice to guide me where should I start to learn about vehicle as a beginner. Thanks for your time to reading this.
Hello, I recommend starting at a local trade school and learning the basics of automotive technology and then moving on to more advanced topics like this. Best wishes!
No problem Professor!! Thanks a lots for your recommendation and such a huge gift to find your channel for me. May God bless you and have a nice day!!
I have a cuestion teacher.
what happens when hibrid cars and trucks have accidents?.
There in any device or system to disconnect the high voltage in case of an accident?.
Good question. The high voltage system is automatically shut down in an accident that deploys an airbag or results in loss of isolation of the high voltage circuits. Turning off the key (power switch) or disconnecting the 12 volt battery power supply will do the same thing. I have owned hybrid and electric vehicles for 10 years now, I am not concerned at all with the high voltage system in an accident. Best wishes.
I recently had an accident in my Gen2 Prius (2007) and the whole front of the car was smashed in from a head on collision. However the airbags did not deploy as it seems the 'crumple zones' absorbed the majority of the impact. While the dashboard lit up like a Christmas tree including the main warning triangle, the car could still move under its own power on the electrics alone, which was impressive considering the front of the car was half the length that it was supposed to be. The ICE could not start due to damage but I was able to drive it a short distance to an emergency stopping area on battery power alone, which I thought was quite impressive considering the extensive damage. I was even able to turn it back on a little later so I could back it up and make room for the tow truck, which makes me wonder whether the car knows when it's been in an accident and lets you drive it in a situation when normally it wouldn't let you. The insurer deemed the damage as unrepairable and wrote the car off.
Hi quick question why when
My Toyota battery on my 2014 fielder hybrid reaches 2 bars when I drive and mash brakes the idle drops and after raises up after
Good question, I do not know
Hi that video was interesting.in toyato. U have any on Nissan.thanks
Hy sir, how are you? You are great full professor.I watch your videos and get a lot of lessons. I want to come to your country for work in hybrid cars,can it's possible sir?
The grate vedio..i have one qustion..why use in vibration dampar?
Thermal expansion of the parts causes them to shift positions slightly.
WeberAuto .thankyou proffeser..now we need immedietly regarding the powertrain of nissan leaf and tesla vehicle..i am hope it soom..
what's the normal running temperature of the cooling oil?
Good question. The reservoir cap has the same pressure rating at the engine coolant reservoir, It could get as hot as engine coolant. The main source of heat is not the inverter, it is the transaxle stator windings. Thank you!
hi ...
do you have video of 3rd Generation Toyota Prius Inverter with Converter ????
thanks ...
Not yet, but I hope to this summer.
Thanks for your feedback!
Hi folks, may I know which video is talking about resolver? Thank you very much!
This one does czcams.com/video/MZf_BUuW5Qg/video.html
Thank you very much!
What is the difference between this and the prius prime converter
This is called silicon carbide mosfet because of a faster switching than igbt.
Granted you are supposed to use a anti static Mat with the wrist strap. I work on all kinds of static sensitive components all the time. without all of that. Granted I ground myself out on some metal first. from the video it looks like they put plenty of under fill on the board. so you don't have to be too paranoid taking that apart. the sad part is. those components on that board are not expensive at all. but just because they have been pre assembled inside something for a module like that. I bet it sells for 1,000 or more. I always enjoy either watching a tare down or doing the tare down myself. Most of all I love learning new things. And how they put stuff together. I am very much into electrical and mechanical devices.
Thanks for your feedback. The mat and wrist strap are Toyota service requirements.
Yea any service manual will have that requirement in it. do you know if the Crostrek Models have the same or similar setups as the Prius Models? for the trans axle, battery etc..