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<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
<strong>Hybrid</strong> System Overview<br />
January 31, <strong>2004</strong><br />
1
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Chevrolet Silverado / GMC Sierra<br />
Models: Extended Cab Short Box, 2WD & 4WD<br />
Engine: VORTEC 5.3 Liter V-8<br />
Transmission: 4-speed auto transmission<br />
Power: 295 hp @ 5200 rpm<br />
Torque: 330 lb-ft @ 4000 rpm<br />
Battery: 42-V <strong>Hybrid</strong> Specific Design VRLA<br />
(Valve Regulated Lead Acid) Battery Pack<br />
GVWR: 2WD-6200 lbs 4WD-6400 lbs<br />
Payload: 2WD-1,050 lbs 4WD-950 lbs<br />
2
Technology Concept:<br />
Product Concept:<br />
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Electrohydraulic<br />
Power Steering Pump<br />
7-kW AC induction<br />
machine surrounding<br />
down-sized (258-mm)<br />
torque converter<br />
42-V “Advanced” Lead<br />
Acid Battery Pack<br />
No conventional<br />
starter or alternator<br />
Quiet<br />
start<br />
5.3-L Gen-III V-8 / 4L60E<br />
Delete from engine:<br />
Conventional starter<br />
Alternator<br />
P/S pump<br />
Modify transmission:<br />
Coast braking capability<br />
Auxiliary trans. oil pump<br />
Bell Housing<br />
Starter Generator Control Module<br />
120-V<br />
Electrical outlets<br />
120-V<br />
Electrical outlets<br />
+ 10% Composite fuel economy<br />
(+ 15% MPG City)<br />
3
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Unique Operating Differences<br />
Key Crank – Faster & Quieter<br />
Automatic Engine Start / Stop<br />
Different transmission operation<br />
– Up-shifts will happen at a lower RPM<br />
– Aggressive torque converter clutch (TCC) lock-up<br />
Aggressive decel fuel cut-off (DFCO)<br />
Regenerative braking<br />
– Active when Accelerator Pedal not depressed<br />
Rollback on incline<br />
4
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Auto Start/Stop Feature<br />
Engine shuts off when the driver is braking at speeds<br />
below 15 mph<br />
Oil pressure gauge and tachometer will go to zero<br />
The engine automatically restarts when:<br />
– Brake pedal is released<br />
– Accelerator is pressed<br />
– Tow/Haul mode is selected<br />
– Gear selector is moved out of Park<br />
– Door opens while in Park<br />
5
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Auto Start/Stop Feature<br />
The engine will remain running when the vehicle is at a<br />
complete stop, or will restart automatically when:<br />
– Climate control system is in front defrost mode<br />
– Outside temperatures are above 95°F and the climate<br />
control system is in the “Auto” mode<br />
– Shift lever is in Neutral, Reverse, Second or First<br />
– Tow/Haul mode is selected<br />
– 4WD-Lo is selected<br />
– Hood is open<br />
– The 42-volt lead-acid battery pack charge is low<br />
– A load greater than 1 kW is connected to the 120-volt<br />
auxiliary power outlets<br />
6
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Auxiliary Power Outlets – APO<br />
– 120-V AC, 2400 Watt<br />
– Ground-fault and overload protection<br />
– 2 outlets in truck bed,<br />
2 outlets under back seat<br />
– Activated with switch on instrument panel<br />
– 2 operation modes<br />
Normal: Vehicle moving<br />
Continuous: Vehicle stationary<br />
7
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Accessory Power Outlets<br />
8
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Accessory Power Outlets (APO)<br />
Normal Mode:<br />
– Activate by starting the engine and pressing the APO button<br />
– Disable by pressing the APO button, or turn off the ignition<br />
Continuous Mode:<br />
– Activate by starting the engine and place the transmission in<br />
Park. Press and hold the APO button for two seconds until<br />
the light begins to flash – turn the ignition to LOCK while the<br />
light is flashing. When the APO button stops flashing and<br />
remains on, the system is ready.<br />
– Disable by pressing the APO button, or turn the ignition to<br />
ACCY or ON<br />
9
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Vehicle & Component Overview<br />
10
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Starter Generator Control Module (SGCM)<br />
11
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Starter Generator Control Module<br />
Controls starter generator<br />
– 42-V DC 3-phase AC<br />
Generates 14-V power<br />
– 42-V DC 14-V DC<br />
Generates 120-V power<br />
– 42-V DC 120-V AC<br />
Electronics submerged in<br />
phase change liquid for cooling<br />
12
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
SGCM Location<br />
13
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
SGCM Cooling System<br />
Pump<br />
Heat Exchanger<br />
Fan and Radiator Assembly<br />
Coolant<br />
Reservoir<br />
14
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Starter Generator Integration<br />
15
Production<br />
Case<br />
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Starter Generator Integration<br />
SG Stator Assy.<br />
Compact<br />
Torque Converter<br />
5.3-L V-8 Engine Assy.<br />
SG Rotor Assy.<br />
Unique Flexplate<br />
Unique Bellhousing<br />
Stator Cooling Line<br />
16
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Electric Machine Stator Assembly<br />
Rear View<br />
3 Phase Cable Pass<br />
Through Location<br />
Removable Cover<br />
Front View<br />
17
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Engine and Transmission Modifications<br />
Modified Engine<br />
Accessory Drive<br />
Transmission Auxiliary Oil Pump<br />
18
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
<strong>Hybrid</strong> Control Module<br />
19
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
<strong>Hybrid</strong> Control Module (HCM)<br />
Controls hybrid functions<br />
– Auto Start/Stop events<br />
– Controls energy into/out of 14-Volt and 42-Volt<br />
batteries<br />
– Auxiliary Power Outlet (APO) mode<br />
– Power maintain relay<br />
– Hood ajar<br />
Diagnostics for HCM component<br />
20
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Electro-Hydraulic Power Steering Pump<br />
21
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Electro-Hydraulic Power Assist (EHPA)<br />
Controls power steering assist<br />
Controls power brake assist<br />
Powered by 42V system<br />
Provides power steering and brake<br />
assist while the engine is off<br />
Diagnostics for EHPS system<br />
22
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
EHPS In Vehicle<br />
23
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Energy Storage Box<br />
24
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
42-V Energy Storage Box (ESB)<br />
– Three 14-V Valve-Regulated Lead Acid (VRLA) batteries<br />
– Air Circulation Fan<br />
– Manual and automatic battery cut off switches<br />
– 400-A fuse<br />
– Energy Storage Control Module (ESCM)<br />
25
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Energy Storage Control Module (ESCM)<br />
Manages State of Charge (SOC)<br />
Communicates battery pack status<br />
Controls battery cut off switch<br />
Controls Energy Storage Box (ESB) fan<br />
Diagnostics for ESB components<br />
26
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
ESB Location<br />
27
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
ESB Interior<br />
28
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
42-Volt System Isolation<br />
– 42-V battery charged through 12-V terminals<br />
– Service disconnect<br />
– Battery cutoff switch<br />
Activated when Airbags are deployed<br />
Can be activated via Tech 2<br />
29
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Powertrain Control Module (PCM)<br />
Performs base vehicle engine & transmission<br />
functions<br />
Stores ESCM, EHPS, HCM, & SGCM fault<br />
codes<br />
Translate service data between Class 2 &<br />
GMLAN buses<br />
30
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Driver Information Center Messages<br />
42V SWITCH OFF – Service Disconnect, BCO, or ESB Fuse is open<br />
BATTERY NOT CHARGING – 12V or 42V battery is not charging<br />
120V READY – Entrance into APO Continuous Mode<br />
120V DISABLED – APO disabled due to over temperature condition<br />
ENGINE AUTOSTART MODE – Auto-Stop is active while in Park<br />
SERVICE 42V BATTERIES<br />
SERVICE STEER SYSTEM<br />
SERVICE BRAKE SYSTEM<br />
HOOD AJAR<br />
31
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Electric Powertrain Subsystem Overview<br />
Electric Machine<br />
(3Ø AC Induction)<br />
(Between Engine &<br />
Transmission & Outside<br />
of Torque Converter<br />
Starter Generator<br />
Control Module<br />
(Underhood)<br />
AC DC<br />
Inverter<br />
DC DC<br />
Converter<br />
Downsized<br />
14V Battery<br />
(Engine Compartment)<br />
EHPS (On Engine)<br />
42 VDC<br />
DC => AC<br />
Inverter 120 VAC<br />
Energy Storage Box<br />
ESCM<br />
14V<br />
Battery<br />
14V<br />
Battery<br />
14V<br />
Battery<br />
(Under Rear Seat)<br />
120 VAC<br />
(Pickup Bed)<br />
14V Vehicle Electrical Systems<br />
32
HVAC Sensors & Switches<br />
Wheel Speed Sensors<br />
THROTTLE<br />
BY WIRE<br />
ABS<br />
HVAC<br />
TACM<br />
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Electrical Mechanization<br />
IPC<br />
Horn<br />
Key Information<br />
Class 2 Bus<br />
UART Bus<br />
APO Switch & LED<br />
TBC<br />
HCM<br />
PCM<br />
Electric<br />
Machine<br />
Aux. Coolant Pump<br />
Aux. Transmission Pump<br />
Hood Ajar<br />
Power Maintain Relay<br />
Transmission<br />
CAN Bus<br />
SGCM<br />
EHPS<br />
Brake Apply Sensors<br />
Steering Wheel Sensor<br />
ESCM<br />
42 V Battery Pack<br />
33
Fuel Rate<br />
(g/s)<br />
Vehicle Speed<br />
(mph/10)<br />
4.0<br />
3.0<br />
2.0<br />
1.0<br />
0.0<br />
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
<strong>PHT</strong> Drive Profile<br />
Auto-Start<br />
Surge Smoothing<br />
(TCC Lock-up)<br />
326 346 366 386 406 426<br />
Time (s)<br />
Coastdown Regen &<br />
Downshift Assist<br />
Auto-Stop<br />
Vehicle Speed<br />
<strong>PHT</strong> Fuel Rate<br />
34
<strong>2004</strong> <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong> (<strong>PHT</strong>)<br />
Acronyms – <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong><br />
ABS – Antilock Brake System<br />
APO – Auxiliary Power Outlets<br />
DFCO – Decel Fuel Cut-Off<br />
EHPA – Electro-Hydraulic Power<br />
Assist<br />
ESB – Energy Storage Box<br />
ESCM – Energy Storage Control<br />
Module<br />
HCM – <strong>Hybrid</strong> Control Module<br />
HVAC – Heating Ventilation Air<br />
Conditioning<br />
IPC – Instrument Panel Cluster<br />
PCM – Powertrain Control<br />
Module<br />
<strong>PHT</strong> – <strong>Parallel</strong> <strong>Hybrid</strong> <strong>Truck</strong><br />
S/G – Starter Generator<br />
SGCM – Starter Generator<br />
Control Module<br />
TACM – Throttle Actuator<br />
Control Module<br />
TBC – <strong>Truck</strong> Body Computer<br />
TCC – Torque Converter Clutch<br />
35
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