Toyota Aqua (Prius c) teardown: Part 2
Hybrid systems behind the 35.4km/liter (53 mpg city) car
Disassembly of Toyota's New Aqua Hybrid (dubbed "Prius c" in the U.S.) was organized for public viewing by the Saitama Automotive Industry Support Center. The key part suppliers and battery components of the Toyota Aqua were posted in the previous report.
Cutaway model of the drive unit that was exhibited
at the Tokyo Motor Show 2011
* Click on the photo for a larger image.
Engine room before disassembly
Power control unit (PCU) with a boost converter
|Air filter||Exhaust pipe|
|The air cleaner with the case disassembled. "Toyoda Gosei" is written outside the case (right) and "Denso" on the filter element. The black item in the front right of the case at the left of the photo is the plug-in type airflow meter of the intake air temperature sensor (built-in).||Sango's exhaust heat recovery system (not shown) may be fitted as a factory option to the pipe assembly. According to Toyota announcement, the system increases fuel efficiency in cold areas by 9% since it shortens the time needed for warming the engine.|
The transaxle consists of the motor and the generator, and the gear train assembled between them. The motor and the generator were removed first.
|Transaxle as viewed from the vehicle left (motor side). The high-voltage cable at the top of the transaxle connects to the generator, and the high-voltage cable at the right connects to the drive motor. The section (center) identified by a red arrow contains the oil pump. The section identified by a white arrow contains the motor resolver. The transaxle designed specifically for the Aqua is shorter in length by 21mm and weighs 8kg less than the current Prius due to the fewer parts count along with downsizing and weight reduction efforts.||The drive motor appears when the outer cover in the left-side photo is removed. The whitish cable at diagonally upper right of the motor is the temperature sensor. The pale red cable extending from the cover center is the motor resolver (angle sensor). The motor coil is made of rectangular wire co-developed by Furukawa Electric and Furukawa Magnet Wire. It consists of rectangular conductor, enamel layer and extruded resin layer. The use of the rectangular wire reduces the resistance of the coil winding and increases the electric current running in the coil. This, in turn, increases the motor power. Furthermore, it allows regularly pitched swirl-like winding that results in 15% shorter coil height (coil end) compared to the current Prius.|
|Drive motor rotor|
|Side view of the rotor removed from the drive motor.|
|Engine side of the transaxle|
|The contact point between the engine and the transaxle. The generator is located behind it. The shaft projecting at the center is part of the power split mechanism that transmits driving force from the engine.|
Gear train disassembly
"Gear train" serves four functions of power transmission, power splitting, motor reduction and parking.
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