Introduction of new technologies Development of IPU for SPORT HYBRID i-DCD

Development of IPU for SPORT HYBRID i-DCD

Norihisa KOBAYASHI* Iori KANAMORI*

ABSTRACT
An Intelligent Power Unit for the 2014 model year FIT SPORT HYBRID i-DCD was developed.
The total height of the Intelligent Power Unit was reduced by the flat installation of its component battery and Power
Control Unit, while achieving miniaturization and reduced weight by modifying the frame and cooling duct structure.
By adopting a high-power, large-capacity, lithium-ion battery developed for the SPORT HYBRID, an energy performance 1.5
times greater than that of the conventional model was achieved. In addition, by reducing the volume of the Intelligent Power
Unit 23% compared to that of the conventional model, energy density was increased by a factor of two.
Reducing the total height of the Intelligent Power Unit allowed it to be installed in both 2WD and 4WD, which have limited
spare tire well volume, minimizing cargo room height and ensuring a sufficient cargo volume for practical use.

1. Introduction the engine is separated and the motor is the only power
supply; hybrid operation, which uses the motor to assist the
Amid rising crude oil prices and an increasing awareness engine; and engine operation, which uses only the engine as
of global warming and other environmental issues, the sales a power supply. In order to enable EV operation over a wide
ratio of fuel-efficient vehicles has increased, and automobile range, it was necessary to further improve battery output
corporations are competing fiercely to develop hybrid and capacity. Also, in order to install the IPU in a compact
technologies. vehicle, it was necessary to decrease its size and weight.
Previously Honda developed a lightweight, compact, Meanwhile, for the SPORT HYBRID i-DCD, it was
single-motor parallel hybrid system, the Integrated Motor also necessary to decrease the total height of the IPU to
Assist (IMA), which has primarily been installed in make the i-DCD suitable for the vehicle body combining
compact vehicles. In order to further improve the efficiency hybrid system and 4WD, which is Honda’s first, and to
of hybrid vehicles, the SPORT HYBRID intelligent Dual- ensure cargo room capacity. By developing an IPU capable
Clutch Drive (SPORT HYBRID i-DCD) was developed and of being used in both 2WD and 4WD, the number of parts
installed in the 2014 model year FIT (new FIT). Because for 4WD was decreased and costs were reduced.
the engine and the motor are separated by the clutch, this
system experiences less friction during EV operation 3. IPU Structure
than the conventional IMA system. In order to enable EV
operation over a broad range, the power and capacity of 3.1. Appearance
the battery were increased. This report introduces a high- Figure 1 shows the appearance and dimensions of the
power, compact Intelligent Power Unit (IPU) suitable for IPU as well as changes in dimensions compared to the 2011
the SPORT HYBRID i-DCD. model year FIT (previous FIT). The height of the IPU was
reduced by 20% compared to the previous FIT. Figure 2
2. Development Goals shows the changes in the volume and weight of the IPU
compared to the previous FIT. The IPU for the new FIT has
The conventional IMA system uses the engine as the been reduced in both size and weight.
primary source of power and has superior mountability
because it is compact and the motor is directly connected to 3.2. Configuration
the engine crank axis(1). In the SPORT HYBRID i-DCD, a Figure 3 shows the configuration of the IPU. The IPU
single motor is used to ensure compactness, and the engine comprises a battery module, Power Control Unit (PCU),
and motor were separated by integrating the clutch within Junction Board (J/B), Electronic Control Unit (ECU) and
the transmission. In this way, it became possible to provide cooling fan. There are four battery modules installed in
the following three operation modes: EV operation in which parallel, and the PCU is installed on the side of the battery
* Automobile R&D Center
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 Honda R&D Technical Review April 2014

module. Also, by using a flat-installation package in which package with a low total height. Each component is held
the J/B is installed on the front of the battery module and by two IPU frames that pass horizontally over the front and
a cooling fan is installed on the rear of the PCU, it was rear of the module.
possible to minimize the height of the IPU to achieve a
3.3. Battery Module
Figure 4 shows the configuration of the battery module.
A single module comprises 12 cells stacked in series. This
module was also used in the 2014 model year Accord
SPORT HYBRID i-MMD(2).
217 mm
(-20%)
3.4. PCU
Figure 5 shows the configuration of the PCU. The
PCU comprises an inverter, DC/DC converter, and electric
965 mm current sensor. Installing the inverter and DC/DC converter
(-9%) 572 mm vertically allowed the PCU to be installed in the space
(-15%) beside the battery module.

Fig. 1 Dimensions of IPU 3.5. Frame Structure

Figure 6 shows the frame structure of the previous FIT.
2011 model year FIT The battery module and PCU are attached using the battery
frame and PCU frame, and a structure that uses two IPU
23% less
frames to suspend the battery module and PCU was utilized.
Volume

New FIT
End plate
Frame

5% less Cell

End plate

Weight

Fig. 2 Volume and weight of IPU

Holder
IPU cover

Frame
Cooling fan
ECU Spring
Outlet duct
IPU rear frame
Upper duct Fig. 4 Configuration of battery module
Right side
frame
PCU cover

Battery module Inverter

PCU
3-phase current sensor
Left side
J/B frame PCU case

Lower duct IPU front frame

PCU duct

PCU frame

IPU case DC/DC converter

Fig. 3 Configuration of IPU Fig. 5 Configuration of PCU

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 Development of IPU for SPORT HYBRID i-DCD

In contrast to this, the frame structure of the new FIT Figure 8 shows the flow of cooling air. The cooling air
SPORT HYBRID i-DCD holds the component units with taken up from the air-intake grill installed on the right side
only two frames as shown in Fig. 3: the IPU front frame of the rear seat passes through the air-intake duct placed on
installed in the front of the module and the IPU rear frame the trunk side and flows into the IPU from the rear of the
installed in the rear of the module. It was therefore possible vehicle. Cooling air is evenly distributed to the four battery
to not only reduce the number of parts and the cost but modules from the upper duct installed on top of the battery.
also to simplify assembly. Figure 7 shows the shape of the After passing through the battery, the cooling air flows into
IPU front frame. The main frame is a press-formed product the lower duct, cooling the inverter and DC/DC converter.
without joints. Also, a lower patch and an upper patch were Then, it passes through the cooling fan and is expelled into
welded to both ends of the main frame, the part that attaches the spare tire well via the outlet duct.
to the vehicle, forming a closed section and increasing
stiffness. The IPU rear frame has the same structure as that 3.7. 4WD Installation
of the front frame. Figure 9 shows the appearance of the IPU for 4WD.
In addition, a side frame that joins and attaches the In 4WD, the rear differential is installed below the
front and rear frames was installed on each side of the IPU spare tire well, so the tire well is shallower than that for
frame. This side frame minimized vibration by increasing the 2WD. Therefore, by attaching the IPU stay during
the stiffness of the IPU in the longitudinal direction, thereby 4WD installation, the IPU is elevated 65 mm above the
improving vehicle steering stability. installation position of the 2WD. As far as the points in the
IPU that were changed in the 4WD compared to the 2WD,
3.6. Cooling Structure
The battery module, inverter, and DC/DC converter
must be efficiently cooled and controlled to within the
optimal operating temperature range. Intake duct

IPU front frame IPU rear frame

PCU frame PCU

Outlet duct
Cooling fan Z

Battery frame Inverter Upper duct

Ni-MH Battery

Fig. 6 Frame structure of 2011 model year FIT

PCU duct Lower duct
DC/DC converter
Right collar Left collar
View Z
Fig. 8 Cooling air flow

Right IPU stay

Top view
IPU
Upper patch
Main frame

Lower patch

Front view Left IPU stay

Fig. 7 IPU front frame of new FIT Fig. 9 Configuration of IPU for 4WD

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 Honda R&D Technical Review April 2014

only the position of the collar on both ends of the IPU frame Table 1 Specifications of battery
was changed in order to attach the IPU stay, while the other
2011 model New FIT
parts are the same as in the 2WD. year FIT

Battery type Ni-MH Li-ion

3.8. IPU Vehicle Installation
Figure 10 shows the IPU mounted in the vehicle. Voltage 100 V 173 V
Adopting an IPU package with a low total height prevents Output 10 kW 22 kW
increasing the height of the cargo room in the 4WD. As a
result, the height of the trunk is below the lower edge of
the trunk rear gate opening, ensuring convenient use of the 50% UP
cargo room.
65 mm higher

Battery energy
Rear differential
2WD 4WD
Fig. 10 Mounting of IPU
2011 model New FIT
year FIT (Li-ion)
(Ni-MH)
4. IPU Performance
Fig. 11 Comparison of battery energy
4.1. Battery Performance
Table 1 shows a comparison of the battery High-load
Low-load
specifications of the previous FIT and the new FIT, and driving cycle driving cycle
Fig. 11 shows the results of an energy comparison. In the (LA4) (US06)
new FIT, the separation of the engine and the motor by the

Good
Cooling capacity/Calorific value

clutch allows EV travelling over a broad range as well as

increased regeneration energy during deceleration. As a
result, the new FIT requires more battery output and energy
Cooling capacity
than the conventional FIT. While a Ni-MH battery was > Calorific value
used in the previous FIT, a Li-ion battery is used in the new 50% UP
FIT, increasing rated voltage and system output to increase
energy performance by approximately 1.5 times.
Cooling capacity
4.2. Cooling Performance < Calorific value
Figure 12 shows the results of a comparison of the
previous and new FIT models in terms of battery cooling 2011 model New 2011 model New
capacity in relation to battery-generated heat in the LA4 year FIT FIT year FIT FIT
(Ni-MH) (Li-ion) (Ni-MH) (Li-ion)
and US06 representative operation modes. Note that
the maximum quantity of cooling air is established by Fig. 12 Cooling capacity
considering NV during cooling FAN operation.
In the new FIT, the cell cooling capacity improvement
due to the adoption of a square cell and the pressure loss
reduction due to optimization of intake and outlet duct 5. Conclusion
shape and cooling air flow path inside the IPU improved the
cooling capacity performance by approximately 1.5 times An IPU for the 2014 model year FIT SPORT HYBRID
over that of the previous FIT. As a result, it became possible i-DCD was developed. By utilizing an IPU package with a
to decrease the output limitation frequency by increasing low total height, the IPU was made capable of being used in
the temperature of the battery in US06 mode, which is the both 2WD and 4WD, while ensuring sufficient cargo room
high-heat-generating battery mode. Also, it is predicted space even in 4WD.
that the cooling capacity will be capable of adequately In addition, using a lithium-ion battery improved energy
supporting derivative models in which this IPU is planned performance by 1.5 times, and reducing the volume of the
to be installed. IPU by 23% allowed a two-fold increase in energy density.

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 Development of IPU for SPORT HYBRID i-DCD

The newly developed IPU will be installed not only in

the new FIT, but also in the 2014 model year VEZEL.

Reference
(1) Ochiai, S., Uchibori, K., Hara, K., Tsurumi, T., Suzuki,
M.: Development of a Motor Assist System for a Hybrid
Car – INSIGHT, HONDA R&D Technical Review, Vol.
12, No. 1, p. 7-14
(2) Ohnuma, Y., Takahashi, K., Matsuda, T.: Development
of Li-ion Battery for SPORT HYBRID, Honda R&D
Technical Review, Vol. 25, No. 2, p. 49-53

Author

Norihisa KOBAYASHI Iori KANAMORI

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