System Description
HYBRID / BATTERY CONTROL: PLUG-IN CHARGE CONTROL SYSTEM: SYSTEM DESCRIPTION
1. FUNCTION OF MAIN COMPONENTS
(a) The main components of the plug-in charge control system have the following functions:
2. SYSTEM CONTROL
(a) Control List
(1) The plug-in charge control system consists of the controls listed below:
3. OPERATING CONDITION
(a) After turning the power switch off, the plug-in charge control ECU assembly transmits a charge start request signal to the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly by connecting the electric vehicle charger cable assembly to the charge inlet.
(b) The plug-in charge control ECU assembly receives charge enable signals from CCID and the electric vehicle charger assembly and drives the electric vehicle charger assembly, charge relay, SMR, DC-DC converter and charges the HV battery pack with HV battery voltage that has been boosted by the electric vehicle charger assembly.
4. FUNCTION
(a) Plug-in Charge Control ECU Assembly
(1) The plug-in charge control ECU assembly controls the plug-in charge control system based on information sent from the electric vehicle charger assembly, such as charger operation condition, output current, output voltage and input voltage. The plug-in charge control ECU assembly also controls the charging timer function, which enables the plug-in charging operation start time or finish time to be set.
(2) When the power switch is turned off and the charging cable (electric vehicle charger cable assembly) is connected to the charging inlet (electric vehicle charger cable), the plug-in charge control ECU assembly transmits a charge start request signal to the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly.
(3) After receiving a plug-in charging operation enable signal from the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly, the plug-in charge control ECU assembly activates the electric vehicle charger assembly, charging relay, and SMR (system main relay). The electric vehicle charger assembly outputs power, charging the HV battery. At this time, the charging indicator displays the HV battery charging state.
5. CONSTRUCTION
(a) Electric Vehicle Charger Assembly
(1) The case of the electric vehicle charger assembly is made of aluminum. This in conjunction with cooling fins and cooling blowers ensures heat radiation performance.
Text in Illustration
(2) The electric vehicle charger assembly converts the AC power supplied from the external outlet to DC power, boosts it to the HV battery voltage and charges the HV battery.
(3) The plug-in charge control ECU assembly actuates and stops the electric vehicle charger assembly, and requests it to charge.
(4) The electric vehicle charger assembly changes the AC 120 V*1 or AC 208 to 240 V*2 input power from the external power source to DC power and boosts it to the HV battery voltage. It then outputs it at 1.2 kW*1 or 2 kW*2 respectively.
*1: When charging via a home outlet using the charging cable (electric vehicle charger cable assembly).
*2: When charging at a charging station.
(5) The electric vehicle charger assembly has self-protection functions, such as over voltage protection, over current protection and over heat protection, so it will stop automatically and regulate the power, if needed. It also sends information about operating conditions to the plug-in charge control ECU assembly.
(6) Using an air-cooling method which employs the built-in cooling fan, temperature increases due to the electric vehicle charger assembly operation will be reduced.
(b) Charging Cable (Electric Vehicle Charger Cable Assembly)
(1) The charging cable (electric vehicle charger cable assembly) consists of a charging connector, Charging Circuit Interrupting Device (CCID) and plug.
Text in Illustration
(2) When the charging connector is connected to the charging inlet (electric vehicle charger cable), it starts supplying electrical power from the external power source to the vehicle. The micro switch that detects the connecting condition of the charging connector and charging inlet (electric vehicle charger cable assembly) is built into it, and it transmits the connection condition to the plug-in charge control ECU assembly.
CAUTION:
Keep the connecting portion of the charging connector clear of foreign matter. If any foreign matter is present, problems may result such as an increase in charging time.
(c) Charging Circuit Interrupting Device (CCID)
(1) The CCID monitors electrical leakage while the vehicle is being charged from an external power source. If leakage or other problems are found, the built-in relay will cut off the power supply.
(2) The power indicator turns on while being connected to a 120 V outlet, and the error warning indicator will turn on if problems, such as a malfunction in which the built-in relay is forced to turn off, are detected.
Text in Illustration
CCID Functions
Resuming Built-in Relay
(d) Charging Relay
(1) The charging relay is integrated in the hybrid vehicle junction block assembly.
(2) During plug-in charging, based on signals from the plug-in charge control ECU assembly, the charging relay opens or closes the circuit that supplies the power from the electric vehicle charger assembly to the HV battery.
Text in Illustration
(e) Charging Indicator
(1) The plug-in charge control ECU assembly illuminates, flashes or turns off the charging indicator to inform the user of the battery charging state.
Text in Illustration
Charging Indicator Operating Conditions
(f) Charging Timer Switch (Satellite Switch Set)
(1) The charging timer switch (satellite switch set) is a momentary type switch. By pressing this switch, the charging operation start time or finish time can be set. The set time is displayed on the multi-information display. The timer function can be reset.
6. SYSTEM DIAGRAM
