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There are two primary technical issues in the application of position sensorless control to generators for 100% electric-drive hybrid vehicles. The first is the risk of losing control when position sensorless estimation methods are changed in accordance with the generator speed, while. The second is the reduction in the maximum torque if the rate of change in the generator speed is extremely large in a relatively low-rotation-speed area. This study proposes countermeasures for each issue and their effects examines them via simulations and experiments.

A hybrid system that has been put on the market by Nissan Motor Company was configured by removing the torque convertor with a lockup clutch from a conventional 7-speed automatic transmission and installing a clutch and a motor in its place. This hybrid electric vehicle (HEV) has a simple structure and is expected to improve fuel economy and responsiveness because it eliminates the torque convertor. One issue for this system is that an abrupt change in the input torque could cause torsional vibration of the drive shaft, resulting in a severe degradation of ride comfort. To solve this problem, an original vibration control system that was adapted for the mass-produced LEAF electric vehicle was also adapted for use on this HEV fitted with an engine and a 7-speed automatic transmission. This control system enables the hybrid vehicle to generate maximum motor torque at launch and also provides significant advantages for vehicle design.

At Nissan we have developed a new parallel hybrid system for rear-wheel-drive hybrid vehicles. As the main components of the hybrid system, both the motor and the inverter have been developed and are manufactured in house to attain high power density for providing responsive acceleration, a quiet EV drive mode and improved fuel economy. Because the motor is located between the engine and the transmission, it had to be shortened to be within the length allowed for the powertrain. Therefore, new technologies have been developed such as high-density, square-shaped windings and an optimized magnetic circuit specially designed for concentrated winding motors. The inverter is sized to a 12V battery, which it replaces in the engine compartment. Despite its compact size, the inverter must have rather large current capacity to drive a high-power motor. Heat management is critical to the design of a small but high-power inverter.

The one-motor, two-clutch hybrid system adopted by Nissan requires high control performance for the entire system, because the single motor provides the various functions of a drive motor, generator and engine starter depending on the driving situation. An especially challenging problem is to prevent the motor torque variation caused by engine start while transmitting driving torque to the drive wheels in a situation where the engine is started in response to the driver's demand for acceleration during motor-only operation. In this case, it is effective to let the clutch on the driving side slip until engine start is completed. For that purpose, we designed the slip control system described here. This system controls driving torque by the clutch while controlling the slip speed by means of the motor speed control. The slip speed can be controlled with high accuracy because the motor speed is controlled by the motor torque which is easily controllable.