1 Hybrid System Overview January 31, 2004
2 Chevrolet Silverado / GMC Sierra Models: Extended Cab Short Box, 2WD & 4WD Engine: VORTEC 5.3 Liter V-8 Transmission: 4-speed auto transmission Power: 295 hp @ 5200 rpm Torque: 330 lb-ft @ 4000 rpm Battery: 42-V Hybrid Specific Design VRLA (Valve Regulated Lead Acid) Battery Pack GVWR: 2WD-6200 lbs 4WD-6400 lbs Payload: 2WD-1,050 lbs 4WD-950 lbs
3 Technology Concept: Electrohydraulic Power Steering Pump 7-kW AC induction machine surrounding down-sized (258-mm) torque converter 42-V Advanced Lead Acid Battery Pack 5.3-L Gen-III V-8 / 4L60E Delete from engine: Conventional starter Alternator P/S pump Modify transmission: Coast braking capability Auxiliary trans. oil pump Bell Housing Starter Generator Control Module 120-V Electrical outlets Product Concept: No conventional starter or alternator 120-V Electrical outlets Quiet start + 10% Composite fuel economy (+ 15% MPG City)
4 Unique Operating Differences Key Crank Faster & Quieter Automatic Engine Start / Stop Different transmission operation Up-shifts will happen at a lower RPM Aggressive torque converter clutch (TCC) lock-up Aggressive decel fuel cut-off (DFCO) Regenerative braking Active when Accelerator Pedal not depressed Rollback on incline
5 Auto Start/Stop Feature Engine shuts off when the driver is braking at speeds below 15 mph Oil pressure gauge and tachometer will go to zero The engine automatically restarts when: Brake pedal is released Accelerator is pressed Tow/Haul mode is selected Gear selector is moved out of Park Door opens while in Park
6 Auto Start/Stop Feature The engine will remain running when the vehicle is at a complete stop, or will restart automatically when: Climate control system is in front defrost mode Outside temperatures are above 95 F and the climate control system is in the Auto mode Shift lever is in Neutral, Reverse, Second or First Tow/Haul mode is selected 4WD-Lo is selected Hood is open The 42-volt lead-acid battery pack charge is low A load greater than 1 kw is connected to the 120-volt auxiliary power outlets
7 Auxiliary Power Outlets APO 120-V AC, 2400 Watt Ground-fault and overload protection 2 outlets in truck bed, 2 outlets under back seat Activated with switch on instrument panel 2 operation modes Normal: Vehicle moving Continuous: Vehicle stationary
8 2004 Parallel Hybrid Truck (PHT) Accessory Power Outlets
9 Accessory Power Outlets (APO) Normal Mode: Activate by starting the engine and pressing the APO button Disable by pressing the APO button, or turn off the ignition Continuous Mode: Activate by starting the engine and place the transmission in Park. Press and hold the APO button for two seconds until the light begins to flash turn the ignition to LOCK while the light is flashing. When the APO button stops flashing and remains on, the system is ready. Disable by pressing the APO button, or turn the ignition to ACCY or ON
10 Vehicle & Component Overview
11 2004 Parallel Hybrid Truck (PHT) Starter Generator Control Module (SGCM)
Starter Generator Control Module 12 Controls starter generator 42-V DC 3-phase AC Generates 14-V power 42-V DC 14-V DC Generates 120-V power 42-V DC 120-V AC Electronics submerged in phase change liquid for cooling
SGCM Location 13
SGCM Cooling System 14 Pump Heat Exchanger Coolant Reservoir Fan and Radiator Assembly
15 2004 Parallel Hybrid Truck (PHT) Starter Generator Integration
16 2004 Parallel Hybrid Truck (PHT) Starter Generator Integration 5.3-L V-8 Engine Assy. Production Case SG Stator Assy. Compact Torque Converter SG Rotor Assy. Unique Flexplate Unique Bellhousing Stator Cooling Line
Electric Machine Stator Assembly 3 Phase Cable Pass Through Location 17 Removable Cover Rear View Front View
18 2004 Parallel Hybrid Truck (PHT) Engine and Transmission Modifications Transmission Auxiliary Oil Pump Modified Engine Accessory Drive
19 2004 Parallel Hybrid Truck (PHT) Hybrid Control Module
Hybrid Control Module (HCM) 20 Controls hybrid functions Auto Start/Stop events Controls energy into/out of 14-Volt and 42-Volt batteries Auxiliary Power Outlet (APO) mode Power maintain relay Hood ajar Diagnostics for HCM component
21 2004 Parallel Hybrid Truck (PHT) Electro-Hydraulic Power Steering Pump
22 Electro-Hydraulic Power Assist (EHPA) Controls power steering assist Controls power brake assist Powered by 42V system Provides power steering and brake assist while the engine is off Diagnostics for EHPS system
23 EHPS In Vehicle
24 2004 Parallel Hybrid Truck (PHT) Energy Storage Box
42-V Energy Storage Box (ESB) 25 Three 14-V Valve-Regulated Lead Acid (VRLA) batteries Air Circulation Fan Manual and automatic battery cut off switches 400-A fuse Energy Storage Control Module (ESCM)
Energy Storage Control Module (ESCM) 26 Manages State of Charge (SOC) Communicates battery pack status Controls battery cut off switch Controls Energy Storage Box (ESB) fan Diagnostics for ESB components
ESB Location 27
2004 Parallel Hybrid Truck (PHT) ESB Interior 28
29 42-Volt System Isolation 42-V battery charged through 12-V terminals Service disconnect Battery cutoff switch Activated when Airbags are deployed Can be activated via Tech 2
Powertrain Control Module (PCM) 30 Performs base vehicle engine & transmission functions Stores ESCM, EHPS, HCM, & SGCM fault codes Translate service data between Class 2 & GMLAN buses
Driver Information Center Messages 42V SWITCH OFF Service Disconnect, BCO, or ESB Fuse is open BATTERY NOT CHARGING 12V or 42V battery is not charging 120V READY Entrance into APO Continuous Mode 120V DISABLED APO disabled due to over temperature condition ENGINE AUTOSTART MODE Auto-Stop is active while in Park SERVICE 42V BATTERIES SERVICE STEER SYSTEM SERVICE BRAKE SYSTEM HOOD AJAR 31
Electric Powertrain Subsystem Overview 32 Electric Machine (3Ø AC Induction) Starter Generator Control Module (Underhood) AC <=> DC Inverter DC => AC Inverter EHPS 42 VDC 120 VAC (On Engine) Energy Storage Box 14V Battery 14V Battery 120 VAC (Pickup Bed) DC <=> DC Converter ESCM 14V Battery (Between Engine & Transmission & Outside of Torque Converter Downsized 14V Battery (Engine Compartment) (Under Rear Seat) 14V Vehicle Electrical Systems
HVAC Sensors & Switches Wheel Speed Sensors HVAC 2004 Parallel Hybrid Truck (PHT) Electrical Mechanization Horn Key Information APO Switch & LED TBC HCM Aux. Coolant Pump Aux. Transmission Pump Hood Ajar Power Maintain Relay EHPS Brake Apply Sensors Steering Wheel Sensor 33 ABS Class 2 Bus CAN Bus ESCM PCM IPC UART Bus SGCM THROTTLE BY WIRE TACM Electric Machine Transmission 42 V Battery Pack
PHT Drive Profile 34 Surge Smoothing (TCC Lock-up) Coastdown Regen & Downshift Assist 4.0 Auto-Start Auto-Stop Fuel Rate (g/s) Vehicle Speed (mph/10) 3.0 2.0 1.0 0.0 Vehicle Speed PHT Fuel Rate 326 346 366 386 406 426 Time (s)
Acronyms Parallel Hybrid Truck 35 ABS Antilock Brake System APO Auxiliary Power Outlets DFCO Decel Fuel Cut-Off EHPA Electro-Hydraulic Power Assist ESB Energy Storage Box ESCM Energy Storage Control Module HCM Hybrid Control Module HVAC Heating Ventilation Air Conditioning IPC Instrument Panel Cluster PCM Powertrain Control Module PHT Parallel Hybrid Truck S/G Starter Generator SGCM Starter Generator Control Module TACM Throttle Actuator Control Module TBC Truck Body Computer TCC Torque Converter Clutch