1. HEV Motor General course information
Target group: Instructors, Technicians
Target of the course: To get the general knowledge and diagnosis method for hybrid motors in TF
Mandatory pre-courses: Electricity, Electronic
To understand the system features and diagnosis for Kia Hybrid motor.
To know the objectives and operating principle of newly developed HSG motor.
Material:
Training vehicle (TF HEV)
Training Part (Motor)
GDS
Instructors guide
Trainees textbook / File
Practice sheets
(Practice preparation)
Workshop manuals
Certificates
Nameplates
(Paper for notes)
(Pens etc.)
Method:
Lecture
Practice
Task
Lead over:
HEV Motor
Learning
Objective
1. Understand the functions of the electric motor and HSG.
2. Understand the internal components of the electric motor and HSG.
3. Understand the inspection procedures for the electric motor and HSG.
The electric motor is the core technology of a hybrid vehicle. It operates when the vehicle starts to move and during low-speed driving to provide lower NVH during driving and to achieve fuel efficiency. The electric motor supplements the engine during acceleration to increase power output and to allow the engine to operate in fuel efficient mode. In addition, the electric motor takes on the role of an alternator during deceleration and braking to charge the high voltage battery. The Hybrid Starter Generator (HSG) starts the engine while the vehicle is in motion.
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.

2. Overview Overview Engine Clutch Wheel Motor Engine A/T Wheel HSG
With increasing interest in global environmental issues, today's automobiles require greater technology innovation to respond to environmental needs.
One of the key technologies under the spot light is the Hybrid Electric Vehicle. The HEV requires a highly efficient electric motor power system with high output that is small and lightweight.
In response to this demand, Kia Motor Company has developed an electric motor power system that achieves high output with high efficiency based on the Kia’s existing hybrid motor drive technology.
The Optima HEV is equipped with two electric motors. These two electric motors include a drive (traction) motor that is used as the primary power source and a HSG, which acts as the starter motor and alternator in a conventional engine.
To know the overall feature and concept of hybrid motor.
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Overview
Engine Clutch
Wheel
Motor
Engine
A/T
Wheel
HSG
Battery
HSG
Theta Ⅱ
Hybrid Engine
Hybrid
6 Speed A/T
Drive Motor

3. Slide page only Specifications Specifications Item Drive Motor HSG
To know the general specification of hybrid motor.
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Specifications
Item
Drive Motor
HSG
Number of Mag. Polarity/Core
16 / 24 Slots
6 / 36 Slots
Output
Spec.
Max
(5s)
(5s)
Continuous
(40min)
(40min)
Max RPM
6300rpm
15750rpm
Max Torque
Max Output
95% ↑
Category
Core (Stator)
Split Core/0.35t/Sheet Type
Unibody Core/0.35t/Sheet Type
Permanent Magnet
High Energy Rare-earth Type
Position Sensor
Resolver
High Voltage Connector
100A Connector Type
40A Connector Type
Sensor Connector
8P Integrated Type (position and temperature sensors)
10P Integrated Type (position and temperature sensors)
Slide page only

4. (concentrated winding)
Composition of Drive Motor
The Interior Permanent Magnet (IPM) type motor for the drive motor is composed of a stator and a rotor. The stator is a concentrated-winding type with a resolver (position sensor), a connector type high voltage terminal and a motor cover. The rotor is composed of an IPM rotor core that maintains its magnetism even at high temperature, and a bearing that ensures smooth rotation of the core and the shaft.
To understand the composition of hybrid motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Composition of Drive Motor
Drive Motor Ass’y
Stator Ass’y
Rotator
Stator
· matching engine/transaxle
· motor cooling function (oil cooling type)
· power cable connection
· terminal
Resolver
Transaxle
Engine
ROTOR Ass’y
generate/deliver power
PM (16 polarities)
high voltage terminal
(connector type)
stator
(concentrated winding)
resolver (position sensor)
- detects magnet position
rotor core
(16 polarities, IPM)
PM (ND series)

5. HSG Configuration HSG Configuration HSG Ass’y Stator Ass’y
Like the drive motor, the HSG is also composed of an Interior Permanent Magnet (IPM) type motor with a stator and a rotor. The stator includes a resolver (position sensor), a connector type high voltage terminal and a motor cover. The rotor includes an IPM rotor core that maintains its magnetism even at high temperature. It also includes a bearing that ensures smooth rotation of the core, shaft and a pulley that can be connected to the engine with a belt.
To understand the composition of HSG motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
HSG Configuration
HSG Ass’y
Stator Ass’y
· Emergency power generation
· HSG cooling
· Power cable terminal
Resolver
Stator
Rotor Ass’y
· Engine start
· PM
· Rotating magnetic field
PM (ND series)
Housing
bearing
pulley
bearing
rotor

6. Motor Operating Principle
The drive motor installed in the Optima HEV is an IPM type small-sized/high-efficiency general industrial motor. It is an optimized PMSM (Permanent Magnet Synchronous Motor) for automobile usage that allows high-torque driving and a wide range of speed adjustments.
The PMSM type drive motor is embedded with IPM to provide high-output and high-torque. Its application has rapidly increased in a wide range of industries. In addition to electric automobiles, it is also utilized in household appliances including washing machines and air conditioners.
To understand the operating principle of drive motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Motor Operating Principle 0˚ N S
Magnetic Torque
Reluctance Torque
Permanent Magnet
※PMSM : Permanent Magnet Synchronous Motor

7. Motor Operating Principle
The operating principal of the electric motor is based on the torque generated by the interaction of the electric magnet in the stator and the interior magnet embedded in the rotor.
When the inverter (MCU, motor controller) 3-phase alternating current flows in the winding coil on the stator coil, a rotating magnetic field is formed. This generates rotating torque through electromagnetic induction from the interaction among the magnets embedded in the rotor. This power rotates the motor. The speed of the rotating magnetic field applied on the stator and the actual rotator speed are synchronized. Therefore, this motor is also known as the synchronous motor.
To understand the operating principle of drive motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Motor Operating Principle
Inverter
(MCU)
3 Phase Current
Inverter
HSG
Motor Drive

8. Role of the Drive Motor Role of the Drive Motor Electric Motor
The drive motor generates power when the vehicle starts to move. In EV mode the vehicle drives only on motor power during low-speed and cruising. When the vehicle is in HEV mode, the motor supports engine output.
In addition, the motor features conversion of energy created during deceleration or braking into electric energy. It uses the converted energy to charge the battery.
To understand the role and function of drive motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Role of the Drive Motor
Electric Motor
Power Source for HEV
Starting and low-speed/cruising: motor power only
Acceleration: supplement engine power
Deceleration and braking: store electric energy
Elec. Mode: electric motor only
Hybrid Mode: engine + motor
Regenerative Brake mode: stores electric energy

9. Engine + Electric motor
Role of HSG
The HSG is connected to the engine with a belt. It starts the engine and it also functions as an alternator. When HEV mode is engaged, which uses both the engine and motor power, the HSG starts the engine while the vehicle is in motion. At this time, the engine clutch is activated to connect the engine power and the motor power. The HSG instantly raises the engine RPM to equal motor speed. The HSG also controls power to ensure there is no vibration when the engine clutch is activated to link the two power sources. In addition, when the engine is turned off, the vibration load generated by the engine is placed on the HSG to minimize engine vibration caused by sudden reduction of the engine RPM and therefore achieves soft landing. When the SOC of the high voltage battery is low, the engine is started and the HSG takes on the role of an alternator. It uses the engine rotation energy to charge the high voltage battery. It also supplies 12V power to the electrical systems in the vehicle via LDC.
To understand the role and function of HSG motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Role of HSG
Engine Start Control: Starts the engine when HEV mode is engaged.
Engine Speed Control: Raises the engine RPM to equal the motor speed when the engine clutch is activated.
Soft Landing Control: Minimizes engine vibration when the engine is turned off.
Alternator: Starts the engine when the SOC is low and charges the high voltage battery.
② Instantly raise speed to equal motor speed
Engine + Electric motor
① Minimize engine vibration when turning OFF the engine
① Start the engine and recharge the high voltage battery when the SOC is low
① motor speed
High Speed
Accelerating
③ engage when both speeds are equal
Engine Start Control
Engine Speed Control
Soft Landing Control
Alternator Control

10. Temperature Sensor’s Role
The motor temperature has the greatest effect on the motor output. When the motor overheats, it’s IPM and stator coil may deform or their performance may be affected. To prevent this, a temperature sensor is embedded in the motor to control the motor torque according to its temperature.
To understand the role of temperature sensor in the motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Temperature Sensor’s Role
Drive Motor
HSG
PIN NO
PIN ASSIGN 1
REZ + 2
REZ S1 3
REZ S2 4
TEMP 5
SHIELD 6
REZ ㅡ 7
REZ S3 8
REZ S4 9
TEMP GND 10
PIN NO
PIN ASSIGN 1
REZ + 2
REZ S1 3
REZ S2 4
TEMP 5
REZ ㅡ 6
REZ S3 7
REZ S4 8
TEMP GND
Temp Sensor
온도 센서
Temp.
sensor
Pin 4-8
126.8 ㏀±5%
@20℃
Temp.sensor
Pin 4~9
143~71 ㏀

11. Position sensor (Resolver) Position sensor (Resolver)
Resolver’s (Position Sensor) Role
The accurate position of the rotor and the stator must be known at all times to ensure maximum output control of the motor. The resolver is mounted to allow the MCU to control the motor at its maximum torque with the accurate position and speed information about the rotor. The resolver is mounted on the housing plate, as shown in the above figure. It is configured with the motor rotor connected to the resolver rotor, and the housing is connected to the resolver stator. Like the CMP sensor on the engine, it detects the position of the rotor and the stator in the motor.
To understand the role of position sensor in the motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Resolver’s (Position Sensor) Role
Drive Motor
HSG
Position sensor (Resolver)
Position sensor (Resolver)
PIN NO
PIN ASSIGN 1
REZ + 2
REZ S1 3
REZ S2 4
TEMP 5
REZ ㅡ 6
REZ S3 7
REZ S4 8
TEMP GND
PIN NO
PIN ASSIGN 1
REZ + 2
REZ S1 3
REZ S2 4
TEMP 5
SHIELD 6
REZ ㅡ 7
REZ S3 8
REZ S4 9
TEMP GND 10
Position
Sensor
(resolver)
Pin 1-5
11.7 Ω±10%
@20~30℃
Pin 2-6
32 Ω±10%
Pin 3-7
27 Ω±10%
Position
Sensor
(resolver)
Pin 1~6
14.2~17.4 Ω
@20~30℃
Pin 2~7
26.1~32 Ω
Pin 3~8

12. Resolver’s (Position Sensor) Waveform
The accurate position of the rotor and the stator must be known at all times to ensure maximum output control of the motor. The resolver is mounted to allow the MCU to control the motor at its maximum torque with the accurate position and speed information about the rotor. The resolver is mounted on the housing plate, as shown in the above figure. It is configured with the motor rotor connected to the resolver rotor, and the housing is connected to the resolver stator. Like the CMP sensor on the engine, it detects the position of the rotor and the stator in the motor.
To understand the meaning of position sensor waveform
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Resolver’s (Position Sensor) Waveform
↓ HSG ON
↑ IG ON

13. Motor Cooling ATF Oil Cooling Type Motor Cooling
The cooling system for the drive motor is installed together with the automatic transaxle and it uses the ATF oil for cooling.
The ATF oil fills the lower section of the motor up to the oil level. The cooling system is structured so that the motor is cooled via oil inflow from the oil cooler that circulates the outer area of the motor and then out into the transaxle.
To understand the motor cooling system
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Motor Cooling
ATF Oil Cooling Type
ATF is filled in the lower section of the motor up to the oil level

14. HSG is cooled via water cooling of EWP System
HSG Cooling
To protect the HSG, a separate water cooling EWP system is used to cool the HSG. For more detail information on this, refer to the section of MCU in this manual.
To understand the HSG motor cooling system
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
HSG Cooling
Cooling System Configuration
HPCU R A D I T O
Reservoir
Tank
EWP
▶Elec. W/Pump
HSG is cooled via water cooling of EWP System

15. Precautions when replacing motor
During repairs, check the following conditions before removing or installing the motor.
Switch off the high voltage supply before conducting any maintenance work. The motor and inverter in the HEV are operated at high voltage.
Before you switch off the high voltage, turn the ignition key to OFF and wait 1 minute for discharge.
Make sure that the voltage of U, V, W terminal is 0V to check for discharge.
Always comply with all safety precautions and wear high voltage protection gloves before you start any high voltage related maintenance.
※ Precautions when changing motor
The magnetism of an IPM in a hybrid motor is about 7-10 times stronger than the conventional ferrite magnet we normally use (magnets used in speakers or in small motors). When the IPM is removed, it may affect your mobile phone, credit cards, or other magnetic devices. Therefore, when conducting motor maintenance, make sure you remove mobile phone and credit cards from your possession before you start the task.
To understand the general precautions of motor replacement
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Precautions when replacing motor
Drive Motor
HSG
When the IPM is removed, it may affect your mobile phone, credit cards, or other magnetic devices. Therefore, when conducting motor maintenance, make sure you remove mobile phone and credit cards from your possession before you start the task

16. Inspecting Drive Motor
Conduct the above inspections to troubleshoot any potential problems that may occur after replacing the drive motor.
To understand how to inspect the drive motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Inspecting Drive Motor
PIN NO
PIN ASSIGN 1
REZ + 2
REZ S1 3
REZ S2 4
TEMP 5
REZ ㅡ 6
REZ S3 7
REZ S4 8
TEMP GND
Test item
Test part
spec
note
Resistance
Power
(Line-Line)
U-V
Average±5% mΩ
@10Arms
@20~30℃
V-W
W-U
Temp.
sensor
Pin 4-8
126.8 ㏀±5%
@20℃
Position
Sensor
(resolver)
Pin 1-5
11.7 Ω±10%
Pin 2-6
32 Ω±10%
Pin 3-7
27 Ω±10%
Insulation
Cover
(ground)
U, V, W
10 ㏁↑
@DC500V, 1min
5 mA↓
@AC1500V, 1min
Resolver
Temp. sensor W V U

17. Inspecting HSG Inspecting HSG ② Sensor connector Test item Test part
Conduct the above inspections to troubleshoot any potential problems that may occur after replacing the HSG.
To understand how to inspect the HSG motor
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Inspecting HSG
② Sensor connector 1 2 W 1 V
Test item
Test part
spec
note
Resistance
Power
(Line-Line)
U-V
95~106 mΩ
@10Arms
@20~30℃
V-W
W-U
Temp.
sensor
Pin 4~9
143~71 ㏀
U-V-W
1 ㏁↑
Position
Sensor
(resolver)
Pin 1~6
14.2~17.4 Ω
Pin 2~7
26.1~32 Ω
Pin 3~8
Insulation
Housing
/Cover
(ground)
10 ㏁↑
@DC500V,1min
5 mA↓
@AC1500V,1min
Resolver
Temp.sensor U
① High Voltage
connector 2
PIN NO
PIN ASSIGN 1
REZ + 2
REZ S1 3
REZ S2 4
TEMP 5
SHIELD 6
REZ ㅡ 7
REZ S3 8
REZ S4 9
TEMP GND 10

18. Resolver Calibration Resolver Calibration
To detect the precise position of the resolver, the hardware deviance between the rotor and the stator that occurs during fabrication and/or the assembly process of the motor requires calibration. This calibration task is required each time the motor or inverter (MCU) is replaced or removed and remounted. This calibration is performed with the self-diagnostic tool.
To understand how to calibrate resolver after service the motor.
Material:
Trainees textbook
Training Parts (Motor)
Method:
Lecture
Lead over:
Resolver Calibration
Conduct Calibration after replacing;
- Drive Motor
- HSG
- MCU