400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org 2005-01-0275 Development of the Intelligent Power Unit for the V6 Hybrid Midsize Sedan Noboru Yusaku and Hiroshi Kosaka Honda R&D Co., Ltd. Tochigi R&D Center Reprinted From: Advanced Hybrid Vehicle Powertrains 2005 (SP-1973) 2005 SAE World Congress Detroit, Michigan April 11-14, 2005 SAE TECHNICAL PAPER SERIESDownloaded from SAE International by University of Edinburgh, Saturday, August 25, 2018The Engineering Meet ings Board has approved th is paper for publication. It has successfully completed SAE’s peer review process under the supervision of the session organizer. This process requires a minimum of three (3) reviews by industry experts. All rights reserved. No part of this publication ma y be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electroni c, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licen sing requests contact: SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: [email protected]: 724-772-4028Fax: 724-772-4891 For multiple print copies contact: SAE Customer ServiceTel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-1615 Email: [email protected] ISSN 0148-7191 Copyright © 2005 SAE International Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE. The author is solely responsible for the content of the paper. A process is available by which discussions will be printed with the paper if it is published in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publication by SAE should send the manuscript or a 300 word abstract to Secretary, Engineering Meetings Board, SAE. Printed in USADownloaded from SAE International by University of Edinburgh, Saturday, August 25, 20182005-01-0275 Development of the Intelligent Power Unit for the V6 Hybrid Midsize Sedan Noboru Yusaku and Hiroshi Kosaka Honda R&D Co., Ltd. Tochigi R&D Center Copyright © 2005 SAE International ABSTRACT The Intelligent Power Unit (IPU) of the Integrated Motor Assist (IMA) system was developed with the dual objectives of increased output and reduced size. To realize miniaturization and to reduce energy losses, fine patterning of IGBT chips in the inverter was conducted, transfer mold power modules were used, and film capacitors were integrated in the unit. Parts integration by digital control was performed in the 12V DC-DC converter. The internal resistance was reduced and the output increased of the IMA battery by changing the construction of the current collector and increasing the length of the electrodes. The battery box was made of a new design enabling easy assembly. The cooling system construction of the box was modified, and the pitch between the modules was reduced, enabling the battery box to be made more compact. Thanks to the technological developments mentioned above, an increase in output of 20% and a reduction in size of 20% were achieved simultaneously for the new IPU, ensuring adequate running performance and cabin space befitting mid-size four-door sedans. INTRODUCTION Low fuel consumption and low emissions are being increasingly demanded in vehicles from the perspectives of maintaining the global environment and bringing about savings in petroleum fuels. Thus, low fuel consumption vehicles equipped with hybrid system are the focus of attention in recent years, and such vehicles have been growing in number. Honda marketed the two seater "Insight" in 1999 and the compact sedan "Civic Hybrid" in 2002, in response to these demands. Honda has endeavored to further enhance the performance of the Integrated Motor Assist (IMA) system based on the conventional system fitted in "Civic Hybrid" as part of the development of the mid-size sedan "Accord