www.cargeek.

ir

w
SONATA HEV Motor
w
w
.C
ar
G
ee
k.
www.cargeek.ir ir
 www.cargeek.ir

HEV Motor 2

Overview Engine Wheel

Motor

w
Clutch

w
Engine A/T

w
Wheel
Battery

.C
HSG

ar
G
HSG
ee
k.
ir
Theta Ⅱ Hybrid
Hybrid Engine Drive Motor 6 Speed A/T

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 3

Specifications

w
w
Item

w
Drive Motor HSG
Number of Mag. Polarity/Core 16 / 24 Slots 6 / 36 Slots

.C
Max 30kW@1.4k~6krpm (5s) 8.5kW@1.87k~12krpm (5s)
Output
Continuous 10kW@1.54k~4krpm (40min) 6.4kW@4.25k~12krpm (40min)

ar
Output
Spec. Max RPM 6300rpm 15750rpm
Max Torque 205Nm(@245A) 43.2Nm(@125A)

G
Max Output 95% ↑ 95% ↑

ee
Core (Stator) Split Core/0.35t/Sheet Type Unibody Core/0.35t/Sheet Type
Permanent Magnet High Energy Rare-earth Type High Energy Rare-earth Type
Position Sensor Resolver Resolver

k.
Category
High Voltage
100A Connector Type 40A Connector Type
Connector

ir
8P Integrated Type (position and 10P Integrated Type (position and
Sensor Connector
temperature sensors) temperature sensors)

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 4

Composition of Drive Motor

w
Drive Motor Ass’y Stator Ass’y

w
Rotator Stator
· matching engine/transaxle
· motor cooling function (oil cooling type)

w
Resolver · power cable connection
· terminal

.C
ar
Transaxle Engine

G
ROTOR Ass’y

ee
generate/deliver power
PM (16 polarities)

k.
high voltage terminal stator resolver

ir
(connector type) (concentrat (position sensor)
rotor core PM (ND series) ed winding)
(16 polarities, - detects magnet
IPM) position

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 5

HSG Configuration

w
HSG Ass’y Stator Ass’y

w
· Emergency power generation
· HSG cooling

w
· Power cable terminal

.C
ar
G
Resolver Stator

ee
Rotor Ass’y

· Engine start

k.
· PM PM (ND series)
· Rotating magnetic field

ir
Housing
bearing pulley bearing rotor
Copyright ⓒ 2010 All rights reserved. www.cargeek.ir
 www.cargeek.ir

HEV Motor 6

Motor Operating Principle

w
0˚

w
Magnetic Torque

w
N
S

.C
S
N

ar
G
Permanent Magnet

ee
k.
Copyright ⓒ 2010 All rights reserved. www.cargeek.ir ir
※PMSM : Permanent Magnet Synchronous Motor
 www.cargeek.ir

HEV Motor 7

Motor Operating Principle

w
w
Inverter

w
(MCU)

.C
ar
3 Phase
Current

G
Inverter

ee
k.
ir
HSG Motor Drive

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 8

Role of the Drive Motor

w
Electric Motor
Power Source for HEV

w
 Starting and low-speed/cruising: motor power only

w
 Acceleration: supplement engine power
 Deceleration and braking: store electric energy

.C
ar
G
ee
k.
ir
 Elec. Mode: electric motor only  Hybrid Mode: engine + motor  Regenerative Brake mode:
stores electric energy

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 9

Role of HSG
 Engine Start Control: Starts the engine when HEV mode is engaged.

w
 Engine Speed Control: Raises the engine RPM to equal the motor speed

w
when the engine clutch is activated.
 Soft Landing Control: Minimizes engine vibration when the engine is turned off.

w
 Alternator: Starts the engine when the SOC is low and charges the high voltage battery.

.C
② Instantly raise
Engine + Electric motor ① Minimize engine ① Start the engine and
speed to equal
① motor vibration when turning recharge the high voltage
motor speed

ar
speed OFF the engine battery when the SOC is low

G
High Speed Accelerating

ee
k.
③ engage when both
speeds are equal

Engine Start Control

Copyright ⓒ 2010 All rights reserved.

Engine Speed Control

www.cargeek.ir ir
Soft Landing Control Alternator Control
 www.cargeek.ir

HEV Motor 10

Temperature Sensor’s Role

w
Drive Motor HSG

w
PIN NO PIN ASSIGN
PIN NO PIN ASSIGN

w
1 REZ +
1 REZ +
2 REZ S1 2 REZ S1
3 REZ S2

.C
Temp Sensor
3 REZ S2 온도 센서
4 TEMP 4 TEMP
5 REZ ㅡ 5 SHIELD
6 REZ S3 6 REZ ㅡ

ar
7 REZ S4 7 REZ S3
8 TEMP GND 8 REZ S4
9 TEMP GND

G
10 SHIELD

ee
1 2 3 4

5 6 7 8

k.
ir
Temp.
Pin 4-8 126.8 ㏀±5% @20℃ Temp.sensor Pin 4~9 143~71 ㏀
sensor

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 11

Resolver’s (Position Sensor) Role

w
Drive Motor HSG

w
Position sensor Position sensor PIN NO PIN ASSIGN
(Resolver) PIN NO PIN ASSIGN

w
(Resolver) 1 REZ +
1 REZ +
2 REZ S1 2 REZ S1
3 REZ S2

.C
3 REZ S2
4 TEMP 4 TEMP
5 REZ ㅡ 5 SHIELD
6 REZ S3 6 REZ ㅡ

ar
7 REZ S4 7 REZ S3
8 TEMP GND 8 REZ S4
9 TEMP GND

G
10 SHIELD

ee
1 2 3 4

5 6 7 8

k.
Pin 1-5 11.7 Ω±10% Pin 1~6 14.2~17.4 Ω

ir
Position Position
Sensor Pin 2-6 32 Ω±10% @20~30℃ Sensor Pin 2~7 26.1~32 Ω @20~30℃
(resolver) Pin 3-7 27 Ω±10% (resolver) Pin 3~8 26.1~32 Ω

Copyright ⓒ 2010 All rights reserved www.cargeek.ir

 www.cargeek.ir

HEV Motor 12

Resolver’s (Position Sensor) Waveform

w
w
w
.C
↓ HSG ON

ar
G
↑ IG ON
ee
k.
Copyright ⓒ 2010 All rights reserved. www.cargeek.ir ir
 www.cargeek.ir

HEV Motor 13

Motor Cooling

ATF Oil Cooling Type

w
w
w
.C
ar
G
ee ATF is filled in the lower section of

k.
the motor up to the oil level

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir ir

 www.cargeek.ir

HEV Motor 14

HSG Cooling

w
Cooling System Configuration

w
w
.C
R
A
D
I EWP

ar
A
Reservoir
T
Tank
O

G
R
HPCU ▶Elec.

ee
W/Pump

k.
HSG is cooled via water cooling of EWP System

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir ir

 www.cargeek.ir

HEV Motor 15

Precautions when replacing motor

w
Drive Motor HSG

w
w
.C
ar
G
ee
When the IPM is removed, it may affect your mobile phone, credit cards, or other

k.
magnetic devices. Therefore, when conducting motor maintenance, make sure you
remove mobile phone and credit cards from your possession before you start the

ir
task

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 16

Inspecting Drive Motor

w
PIN NO PIN ASSIGN

w
1 REZ +
2 REZ S1
3 REZ S2 1 2 3 4

w
4 TEMP
5 REZ ㅡ
5 6 7 8 Test item Test part spec note

.C
6 REZ S3
7 REZ S4 U-V
8 TEMP GND Power Average±5% @10Arms
V-W
(Line-Line) mΩ @20~30℃

ar
W-U
Temp.
Resistance Pin 4-8 126.8 ㏀±5% @20℃

G
sensor
Pin 1-5 11.7 Ω±10%
Position

ee
Sensor Pin 2-6 32 Ω±10% @20~30℃
(resolver)
Pin 3-7 27 Ω±10%

k.
10 ㏁↑ @DC500V, 1min
U, V, W
5 mA↓ @AC1500V, 1min
Cover

ir
Insulation
W (ground) Resolver 10 ㏁↑
V
Temp. @DC500V, 1min
U
10 ㏁↑
sensor

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 17

Inspecting HSG

w
② Sensor connector

w
1 2

w
V 1
U Test item Test part spec note

.C
① High Power
U-V
Voltage @10Arms
(Line- V-W 95~106 mΩ
connector @20~30℃

ar
Line)
W-U
2
Temp. Pin 4~9 143~71 ㏀

G
PIN NO PIN ASSIGN Resistance @20~30℃
1 REZ +
sensor U-V-W 1 ㏁↑
2 REZ S1 Pin 1~6 14.2~17.4 Ω

ee
Position
3 REZ S2
Sensor Pin 2~7 26.1~32 Ω @20~30℃
4 TEMP
(resolver)
5 SHIELD Pin 3~8 26.1~32 Ω

k.
6 REZ ㅡ 10 ㏁↑ @DC500V,1min
7 REZ S3 U-V-W
Housing 5 mA↓ @AC1500V,1min

ir
8 REZ S4
Insulation /Cover
9 TEMP GND
(ground) Resolver 1 ㏁↑
10 SHIELD @20~30℃
Temp.sensor 1 ㏁↑

Copyright ⓒ 2010 All rights reserved. www.cargeek.ir

 www.cargeek.ir

HEV Motor 18

Resolver Calibration

w
w
 Conduct Calibration after replacing;
- Drive Motor

w
- HSG

.C
- MCU

ar
G
ee
k.
Copyright ⓒ 2010 All rights reserved. www.cargeek.ir ir