Analysis of key technologies of Honda i-MMD hybrid system

At present, many domestic automobile manufacturers are actively developing their own hybrid vehicles, with the Honda i-MMD hybrid system being a notable example. This article delves into the key technologies that make this system stand out in the automotive industry. One of the core components of the system is the Honda Accord i-MMD hybrid structure. The i-MMD system is configured with an Atkinson cycle engine, a clutch, and two motors arranged in a three-axis layout. The engine is connected to the engine output shaft via a clutch, while it is also linked to a generator through a gear before the clutch. The motor is directly connected to its output shaft, and there is a third shaft between the engine and motor output shafts, which transmits power to the wheels. The system supports multiple driving modes, including pure electric mode (EV), series hybrid mode, and parallel hybrid mode. In EV mode, the engine remains inactive, and the motor directly delivers torque through the gear mechanism. In series hybrid mode, the engine generates electricity through the generator, and the motor provides the necessary torque. In parallel hybrid mode, the engine directly drives the vehicle, and the motor simultaneously contributes to the torque output. These driving modes represent the multi-mode capabilities of the Accord i-MMD system, where the "i" stands for intelligent control strategies developed by Honda. The system's control strategy is optimized to enhance fuel economy in two main ways: first, by maximizing efficiency within each operating mode, and second, by intelligently switching between modes to improve overall performance. In the hybrid or engine drive mode, the controller adjusts the engine and motor operating points to optimize efficiency. For instance, the engine's operating point can be fine-tuned to work at a more efficient location on the engine map. In hybrid mode, the engine and wheels are virtually decoupled, allowing the engine to operate at its most economical point while the battery compensates for the required power. In engine drive mode, both the engine and motor work together, with the generator and motor helping to adjust the engine’s operating point for better fuel economy. Switching between modes also plays a crucial role in improving fuel efficiency. For example, the intermittent hybrid mode between EV and hybrid drive allows the battery to assist under low-speed and low-load conditions, potentially increasing speed by up to 50%. However, under high-speed and high-load conditions, the benefits are less significant, and some scenarios may even result in lower energy efficiency. The i-MMD system also features an Atkinson cycle engine, known for its excellent fuel economy but limited power output. This makes it ideal for hybrid systems, as the electric motor can compensate for the lack of power. The engine uses dual cams—power cam and economic cam—to switch between Otto and Atkinson cycles, optimizing performance based on driving conditions. Regarding the motor design, the i-MMD system has undergone several improvements. The first generation of the permanent magnet synchronous motor was enhanced by increasing reluctance torque, raising the voltage to 700V, and increasing motor speed to boost power density. Additionally, structural changes such as grooves on the rotor and improved cooling systems were introduced to ensure safe operation at high speeds. In the new generation of motors, the stator winding was redesigned using square thick wires, improving groove fill rate and reducing motor size. Enhanced insulation techniques, such as powder coating, were applied to increase mechanical strength and durability. Other innovations included transitioning from single-layer to double-layer winding, reducing the axial length of the motor end, and optimizing the distribution of rotor magnet steel. These improvements led to a 23% reduction in weight and volume, along with increased maximum torque and power output, while maintaining near-unchanged efficiency. Overall, the i-MMD system represents a significant advancement in hybrid technology, offering superior fuel economy, performance, and intelligence.

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