Toyota Aqua (Prius c) teardown: Part 1

Part suppliers and battery components

2012/11/27

Summary

Toyota Aqua
Toyota Aqua exhibited at the Tokyo Motor Show 2011
* Click on the photo for a larger image.

 Disassembly of Toyota's New Aqua Hybrid (dubbed "Prius c" in the U.S.) was performed on November 6-7 at the maintenance shop of the Saitama Institute of Automotive Technology (SIAT) in Ina, Kita Adachi Gun, Saitama Prefecture. The event was organized for public viewing by the Saitama Automotive Industry Support Center.

 The first day of the two-day event was spent for removing the power control unit (PCU) affixed with a boost converter (located under the engine hood), the drive unit (consisting of the engine and the hybrid transaxle), drive battery and associated components located under the rear seat. On the second day, the hybrid transaxle and the PCU were disassembled and other components were separated from the engine room.

 Reported below (Part 1) is a summary of the key component suppliers and battery-related components. The drive unit and the PCU with a boost converter will be introduced under "Toyota Aqua (Prius c) teardown: Part 2" as soon as it is ready.


 

Related reports: 
"Nissan Leaf teardown" 1 (posted in March 2012), 2 (posted in September 2012), 3 (posted in November 2012)

 



Main specifications of the Toyota Aqua (click for more details)

Model name DAA-NHP10
Body type 5-seat 5-door hatchback
Platform B-platform shared with Vitz (Yaris)
Dimensions 3,995 (L) by 1,695 (W) by 1,445mm (H) with 2,550mm wheelbase
Weight Curb weight:1,050kg, GVW:1,325kg
Fuel efficiency 35.4km/liter (JC08 mode)

 

 



Key component suppliers

Component Supplier
Drive unit 1.496-liter in-line 4-cylinder Atkinson cycle gasoline engine
(max. output: 54kW/74ps, max. torque: 111Nm/11.3kgfm),
model name: 1NZ-FXE
Toyota (in-house)
Electric water pump (for engine cooling) Aisin Seiki
AC synchronous (permanent magnet synchronous type)
motor (max. output; 45kW/61ps, max. torque: 169Nm/17.2kgfm),
model name: 1LM
Toyota (in-house)
Rectangular wire (for motors and generators) Furukawa Electric,
Furukawa Magnet Wire
Motor core Mitsui High-tec
Drive motor angle sensor (resolver) Tamagawa Seiki
Shift lever position sensor Panasonic
Battery Nickel metal hydride battery pack Primearth EV Energy
Battery voltage sensor (BMS: battery management system) Denso
Relays (hybrid battery junction block)
Small cooling blower Toyota (in-house)
Auxiliary battery GS Yuasa Battery
PCU Power control unit (PCU) Toyota (in-house)
Inverter
ECU
DC-DC converter Toyota Industries
Safety Disk brake ADVICS
Disk brake harness Hitachi Cable*
Airbag inflator Daicel Safety Systems
Brake booster accumulator NHK Spring
Seatbelts Takata
Air conditioning Electric compressor Denso
Condenser
Radiator, radiator fan
Interior, exterior Combination meter
Door trim Toyoda Gosei
Front side glass Nippon Sheet Glass
Rear side glass, front/rear glass Asahi Glass
Side mirror Tokai Rika
Headlight Koito
Rear combination lamp Stanley Electric
Back door stay KYB
Windshield wiper system ASMO
Others Electric power steering JTEKT
Engine air filter element Denso
Engine air filter Toyoda Gosei
Exhaust heat recovery system (optional) Sango

* An agreement was reached in November 2012 regarding business merger with Hitachi Metals, effective as from April 1, 2013.

 



Before disassembly

Before disassembly Before disassembly
SIAT students looking into the engine room prior to commencing disassembly Rear view of the Aqua before disassembly
Bottom view of the front floor Bottom view of the rear floor
Bottom view of the front floor with exhaust pipe (left) and high-voltage cable (right) Bottom view of the rear floor with fuel tank (black container, center left)

 

 



Battery and associated parts

Cutaway model of the nickel metal hydride battery pack that was exhibited at the 2012 Automotive Engineering Exposition

Cutaway model showing under the rear seat Cutaway model of the nickel metal hydride battery
Cutaway model showing under the rear seat with the nickel metal hydride battery pack in a protective frame. A 12V auxiliary battery is identified by a red cover next to the battery pack (more details later). Cutaway model of the nickel metal hydride battery. The black round component (left) is a small cooling blower.

 

Battery and associated parts

Battery and associated parts before disassembly Covering over the battery under the rear seat
Battery and associated parts before disassembly Covering over the battery under the rear seat
Battery and associated parts under the rear seat as viewed from the cargo room (seat was removed before disassembly).
The battery pack has been reduced by 11kg in weight and 20% in volume from the current Prius to fit in the space under the rear seat.
The nickel metal hydride battery is stowed in the central silver case shown with the auxiliary battery (right) and a blackish compact exhaust ducting in the foreground.
Covering in the rear seat leg room.
The current Prius has its nickel metal hydride battery pack fitted under the floor of the luggage space behind the rear seat. The New Aqua has its battery pack under the rear seat. The battery is protected by covering that has an inlet opening (the gridded section to the right) for the small cooling blower.

 

Nickel metal hydride battery pack
Nickel metal hydride battery pack Nickel metal hydride battery pack
Nickel metal hydride battery pack supplied by Primearth EV Energy.
The black case in white covering at the center of the left-side photo is the hybrid battery junction block (containing relays).
The black part at the left of the battery in the right-side photo is the service plug grip. A high-voltage cable connecting the nickel metal hydride battery pack to the PCU is inserted in the service plug grip. The power supply is shut off when the high-voltage cable is pulled out. The white rectangular part (covered) to the left of the service plug grip is the coupler with the battery voltage sensor.
The black ducting under the battery in the left-side photo is the air inlet port from the small cooling blower. The air flows from bottom to top between the battery modules and finally exits from the small exhaust duct seen above the battery in the right-side photo.

 

Small cooling blower Auxiliary battery, small exhaust duct
Small cooling blower Auxiliary battery, small exhaust duct
A small cooling blower for forcing air to cool the battery. Air is drawn into the battery from the rectangular opening at the bottom left. The blower measures 200 (H) by 150 (W) by 150mm (D). Top view of the 12V auxiliary battery (supplied by GS Yuasa Battery) fitted under the rear seat at the right side of the vehicle.
A small exhaust ducting (the black item at the center running alongside the auxiliary battery) provides exiting passage for air after cooling the nickel metal hydride battery pack.

 

Hybrid battery junction block Battery voltage sensor
Hybrid battery junction block Battery voltage sensor
An enlarged image of Denso's hybrid battery junction block consisting of relays. The white item at the bottom of the photo is the resistor. The black items from left to right are the current sensor, SMRP (pre-charge relay), SMRG (positive side main relay) and SMRB (negative side main relay). An enlarged image of Denso's battery voltage sensor. The white square item is the coupler (connector) located at the right-hand side of the nickel metal hydride battery pack.

 

Nickel metal hydride battery pack uncovered
the nickel metal hydride battery pack the nickel metal hydride battery pack
Photos showing the nickel metal hydride battery pack uncovered with the arrow pointing to the vehicle front.
The battery pack houses 20 battery modules (as compared to 28 modules in the current Prius) with six cells per module, 120 cells in total. Three temperature sensors are located at the center of the battery pack to monitor the temperature of the modules at both ends and at the center.
The battery pack measures 300 (D) by 600 (W) by 100mm (H). Each module is about 20mm wide. The Aqua has 48 fewer cells and the battery pack is smaller by 29% in volume than the current Prius.

 

 



Radiator removal

Radiator
Radiator
Denso's integrated radiator for the engine and the inverter is fitted behind the front grille together with the fan (right) and the air conditioning condenser (top).

<Automotive Industry Portal MarkLines>