400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2006-01-1342 Development of Intelligent Power Module for Hybrid Electric Vehicle Makoto Imai Toyota Motor Corporation, Electronics En gineering Division 2, De sign Department No. 23 Reprinted From: Advanced H ybrid Vehicle Powertrains 2006 (SP-2008) 2006 SAE World Congress Detroit, Michigan April 3-6, 2006 Downloaded from SAE International by North Carolina State Univ, Sunday, September 16, 2018The Engineering Meetings Board has approved this paper for publication. It has successfully completed SAE's peer review process under th e supervision of the session organi zer. This process requires a minimum of three (3) reviews by industry experts. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licensing requests contact: SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: [email protected]: 724-772-4028 Fax: 724-776-3036 For multiple print copies contact: SAE Customer Service Tel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-0790Email: [email protected] ISSN 0148-7191 Copyright © 2006 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 th e paper. A process is available by which discussions will be printed with the pap er if it is publishe d in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publicat ion by SAE should send the manuscript or a 300 word abstract to Secretary, Engineering Meetings Board, SAE. Printed in USADownloaded from SAE International by North Carolina State Univ, Sunday, September 16, 2018ABSTRACT Toyota developed the first-generation Intelligent Power Module (hereinafter referred to as IPM) that is the key part of the system for Hybrid Electric Vehicles (hereinafter referred to as HEV). It was installed in the inverter for Prius, which was launched in Japan in 1997, and recently, the demands for not only mileage performance but also power performance in an HEV have been increasing. For the inverter for Prius that was launched in 2003, we developed a new IPM for the high voltage and high power that is applied in the second generation Toyota Hybrid System (hereinafter referred to as THSII). In the second-generation IPM, the boost converter that raises the power-supply voltage was added in the inverter, and a low electric current in the IPM was achieved based on “Power = Voltage ˜ Electric Current”. The IPM for the motor and the IPM for the generator were integrated by using the merits of the system. Additionally, as for the circuit portion, the power supply circuit and the current sensor that were different circuit portions originally, were integrated and consequently miniaturization of the IPM was realized. The second-generation 120kw-class IPM for RX400h, in addition to the 50kw-class IPM for Prius, was developed. INTRODUCTION The inverter is used in various applications for a power converter. In the HEV, the inverter converts the direct current (hereinafter referred to as DC) from the in-vehicle battery into the alternating current (hereinafter referred to as AC) and activates the AC motor (hereinafter referred to as MG). Also, the IPM is installed inside the inverter and it is the key device that implements the conversion of DC Њ AC in response to the signal from ECU with PWM control method. The recent trend in the HEV is not only to achieve the improvement of mileage performance, but to achieve a balance between that and the improvement of power performance, which uses the characteristics of t