Toyota’s New Power Control Units Proven to Be a More Efficient Hybrid Solution

Probably not 4th gen Prius ready but a more efficient electric drivetrain is a huge plus.

Wayne Gerdes - CleanMPG - Jan. 29, 2015



Toyotas New SiC Power Semiconductor Technology.



Using a "Camry" hybrid prototype, Toyota is testing a brand new technology to evaluate the performance of silicon carbide (SiC) power semiconductors, which could lead to an efficiency improvements in hybrid vehicles with electric powertrains.



Power semiconductors is a device that is used as a switch or rectifier in power electronics. It is also a power device used in an integrated circuit. It is usually used in "commutation mode" i.e., either on or off.



Power control units (PCUs) are used to control motor drive power in hybrids and other vehicles with electric powertrains. PCUs play a crucial role in the use of electricity, supplying battery power to the motors during operation and recharging the battery using energy recovered during deceleration.



Power semiconductors account for approximately 20 percent of a vehicle's total electrical losses and by raising their efficiency, large gains it total efficiency can quickly increase overall powertrain efficiency.



The newly developed high quality silicon carbide (SiC) power semiconductors that Toyota is speaking about here creates less resistance when electricity flows through them and thus the large increase in efficiency.



The technologies behind these new SiC power semiconductors was developed jointly by Toyota, Denso Corporation, and Toyota Central R&D Labs as part of the results of a broader R&D project in Japan.



The Modified Toyota Camry Hybrid



In the Camry hybrid prototype, Toyota installed SiC power semiconductors (transistors and diodes) in the PCU's internal voltage step-up converter and the inverter that controls the motor(s). PCU voltage and current as well as driving speeds, driving patterns, and weather conditions are being collected. By comparing this information with data from the current units, Toyota will quantify the efficiency improvements of the new SiC power semiconductors.



Data from testing will be reflected in development, with the goal of putting the new SiC power semiconductors into practical use as soon as possible.

The all-new PCU.

While it appears this is to new for the 4th generation Prius, could there be similar advanced technologies within the upcoming 2016 Prius that has yet to be revealed? I cannot wait to hear about it myself. :)

Toyota’s New Power Control Units Proven to Be a More Efficient Hybrid Solution