[0:00] This is a 2021 Toyota Sienna. [0:03] It's a minivan. [0:05] The best kind of three row vehicle out there, [0:07] according to everyone who can get over themselves. [0:11] For this model year, [0:12] Toyota did something very daring. [0:14] They dropped the V6 engine and made every single one of these [0:18] a hybrid electric vehicle. [0:21] In doing so, [0:22] Toyota ruffled more than a few feathers, but they also released a minivan [0:26] which could go more than 50% farther [0:29] on every gallon of gasoline it burns than its competition. [0:33] This thing has gotten a shockingly consistent [0:36] 34 miles per gallon over its life, city or highway. [0:40] And it's a minivan. [0:42] My first car, a Honda Civic, could barely squeeze [0:45] that out on the highway and got far worse fuel economy in the city. [0:49] And that thing was a small two door coupe. [0:52] This is a three row minivan. [0:54] It's even all wheel drive. [0:56] The thing’s quite impressive. [0:58] By now, most people know that hybrid cars get better fuel economy than their non-electrified counterparts [1:04] through the use of a battery pack which stores electrical energy and electric motors [1:09] which use that energy to assist the engine. [1:12] But to explain this video's title, [1:15] something which I think is less well understood, is that those batteries and motors [1:20] actually have relatively little to do with how hybrid cars attain their amazing fuel economy numbers. [1:28] See, this vehicle is not one of those newfangled plug-in hybrids. [1:33] It's a conventional hybrid like the original Toyota Prius. [1:37] And that means all of the energy available to its drivetrain [1:41] comes from the gasoline in its fuel tank. [1:44] There is no way to charge its batteries except driving it. [1:48] And that means all of the energy the hybrid system uses to make the car go? [1:53] It ultimately came from the gasoline and the engine. [1:57] So why does it even have those electric motors and batteries? [2:02] Well, because without them, driving this thing would suuuuccccck. [2:05] To explain, we need to back up a bit. [2:09] I wasn't intending on making this video yet. [2:12] I'm in the middle of a series on engine management technology, and so far [2:16] I've only covered the catalytic converter [2:18] and a mechanical overview of the internal combustion engine. [2:22] So skipping ahead to hybrid drivetrains sure is skipping a lot. [2:27] But you see, my spidey senses keep picking up on frankly wild misunderstandings [2:33] about hybrid cars and how they work, and also why they work the way they do. [2:39] Now that suddenly people care about fuel economy again, [2:42] I figured it would be worth providing some actual information [2:46] and not just a collection of hot takes. [2:49] For example, if you've been under the impression [2:52] that a car like this has two separate drivetrains, [2:54] an electric one and a gasoline one that have been Frankensteined together into a wildly complex contraption, [3:01] that's simply not true. [3:04] What Toyota's hybrid system does is replace [3:07] the traditional transmission with a new device, which is in fact much, [3:11] much simpler than even the six speed manual gearbox you'll find in this Nissan cube. [3:19] Let me say that again. [3:20] This thing's drivetrain is simpler than a conventional manual transmission, and in fact, [3:26] it isn't even really a transmission at all. [3:30] But I'll get back to that. [3:31] The reason hybrid drivetrains were developed is that, frankly, [3:36] the internal combustion engine is just not very good at what it's supposed to do. [3:42] Yes, these are very interesting devices which tickle the ‘tisms and make lots of very satisfying noises. [3:48] But when you boil them down to their core job, [3:52] turning the chemical energy in a fuel into mechanical energy to move a car, [3:58] they're quite terrible. [4:00] You are lucky to capture just one quarter of the energy contained in gasoline using an engine, [4:06] and the rest will just be wasted as heat. [4:09] That's why your car's got such a big radiator, [4:12] and why cooling system problems can quickly destroy an engine. [4:16] But what I'd like to explain today [4:18] is that part of the reason engines are like that is due to a compromise. [4:24] You see, engines produce wildly different amounts of power [4:27] depending on how fast they're going. [4:30] Each combustion event which occurs in the cylinders can only produce so much power. [4:35] So when you need to produce more engine power, [4:38] you need those events to happen more frequently [4:40] which means you need the engine to speed up. [4:43] For example, this MR-18DE found in the Nissan Cube can only produce its rated 122 horsepower [4:51] when the crankshaft is spinning at about 5,200 RPM: [4:55] not that far from engine redline. [4:58] At any slower engine speed, [5:00] it cannot produce full power, and in fact, [5:03] when running at normal cruising speeds, [5:06] this thing can barely put out 50 horsepower. [5:09] That is why your car has a transmission. [5:12] We need to be able to vary the ratio between how quickly the engine crankshaft is spinning [5:17] and how quickly the wheels are spinning in order to make practical use of an engine given its operating characteristics. [5:23] When accelerating, we want to allow the engine to rev up fast [5:27] so it can produce more power to get the car moving, [5:30] which is why we have low gear ratios. [5:33] But as the car speeds up, the wheels will start spinning too fast for the engine to keep up and that would limit how fast the car can go. [5:42] But with a transmission, we can change the gear ratio as we accelerate [5:47] which will slow the engine back down while keeping the wheels moving as quickly as they were before. [5:53] It's the exact same principle as the different gears on a bicycle. [5:57] But we don't just want those gears to unlock the engine's power. [6:01] In general, internal combustion engines are more fuel efficient [6:04] when they are running at lower speeds. [6:07] There are many reasons for this which aren't worth picking apart too much, [6:11] but remember that an engine is full of metal parts sliding against each other very quickly. [6:17] While the lubrication system will do its best to reduce friction, [6:20] there's still lots of it working to slow the engine down and generate heat as it runs. [6:26] And the faster the engine spins, the more friction there is. [6:30] There are also plenty of pumping losses which get worse as engine speed increases. [6:35] But again, it's not worth dwelling on this. [6:38] What's important is that ideally, [6:40] we want an engine which can spin quickly when we need it to produce lots of power to accelerate, [6:46] but which operates very efficiently at lower speeds for fuel efficient cruising. [6:53] But here's the problem: [6:55] Life is cruel, and we can't have that. [6:58] The best we can manage is a pretty major compromise named Otto. [7:03] When discussing the four stroke engine cycle, [7:06] we are in fact almost universally discussing the Otto cycle. [7:10] That's O - T - T - O, named for my man Nick over here. [7:14] Quick recap: [7:15] The reciprocating pistons work in conjunction with intake and exhaust valves. [7:19] During the intake stroke, the piston is descending and the intake valve is open, [7:22] resulting in an air fuel mixture being drawn into the cylinder. [7:25] When the piston is at the bottom, [7:27] the intake valve closes and the cylinder is then sealed. [7:30] The air fuel mixture will then be compressed as the piston travels up back towards the top, [7:34] and when it's near the top, the spark plug fires, [7:37] and the conflagration of hot expanding gases forces the piston back down into the engine block producing engine power, [7:43] after which the exhaust valve will open to allow the piston to push those spent gases out of the chamber as it comes back up, [7:50] so the process can repeat. [7:52] Cool. [7:53] And the Otto cycle does a decent job of making an engine powerful when it needs to be, [7:58] and also reasonably efficient when under moderate load. [8:02] This is why the Otto cycle engine is what gets put in cars. [8:06] It's a decent compromise between power and efficiency, [8:10] and meets the varying needs of an automobile reasonably well. [8:14] But then this guy named James Atkinson realized that since the power [8:19] the engine produces comes from the expansion of hot gases, [8:23] the Otto cycle wastes a bit of energy by constraining how much those gases can expand. [8:30] See, in the Otto cycle, [8:32] the length of the intake and compression strokes are identical to the power stroke. [8:37] Since the volume of gas after combustion is much greater than before ignition, [8:43] Atkinson saw this as a problem. [8:45] He figured at the end of the power stroke, when the piston is back at the bottom, [8:50] the newly expanded hot gases are still exerting pressure on the piston. [8:55] That could be captured, but in the Otto cycle, [8:58] the exhaust valve will open at that point, relieving the pressure inside the cylinder [9:03] and preventing us from harnessing that energy. [9:06] Atkinson got pretty hot and bothered by this, [9:08] so he designed... this contraption. [9:12] If this looks familiar, you've probably spent some time taking the green stairs. [9:17] Engines of the 19th century were all sorts of different from how we imagine them today. [9:21] And Atkinson used two opposing pistons in the same combustion cylinder, [9:26] which were being driven by an external crankshaft [9:29] and some totally normal linkages to make them move like that. [9:35] Yeah, this thing is quite strange and perhaps a little difficult to follow, [9:38] even with this lovely animation by Michael Frey. [9:42] But the key thing to notice is that the distance between the two pistons [9:45] varies dramatically throughout a full cycle. [9:49] This effectively enlarges the combustion chamber during the power stroke, [9:53] which in turn allows the expanding gases to do more work before they're tossed out of the cylinder. [9:59] Atkinson would later redesign his engine to be slightly less steampunk, [10:04] but still extremely weird. [10:06] We sure did love linkages back in the day, huh? [10:09] But in this design, you can see the point a little more clearly. [10:13] The piston hardly moves at all in the intake and compression strokes, [10:18] but it moves much farther during the power stroke, [10:21] allowing those hot gases to perform more work on the piston. [10:25] Now, back in 1887, [10:27] we didn't have the same valve technology we do now, [10:30] so this contraption made more sense in the past. [10:33] But today we can accomplish more or less the same thing [10:37] with a conventional Otto cycle engine design [10:40] simply through messing with the intake valve timing. [10:43] If we allow the intake valve to remain open through part of the compression stroke, [10:48] the ascending piston will force some of the air fuel mixture [10:52] out of the cylinder and back into the intake manifold before the cylinder is sealed for compression. [10:59] When done this way, it's known as a modified Atkinson cycle engine, [11:04] and that's what you'll find in any decent hybrid vehicle going back to the original Toyota Prius. [11:10] Leaving the intake valves open as the piston begins to ascend [11:14] means we can effectively shrink the size of the combustion chamber during the compression stroke [11:19] and enlarge it during the power stroke, attaining the same effect that Atkinson did [11:25] with all those wild linkages. [11:27] The result? [11:29] A modified Atkinson cycle engine can get over 40% of the chemical energy in gasoline converted to mechanical energy. [11:37] Toyota claims the 2.5l engine in this Toyota Sienna can hit 41% thermal efficiency. [11:44] I've also seen some spec sheets claim this engine tops out at 39.8%, [11:49] so it might not quite hit 40. [11:50] But either way, it's quite good. [11:54] For an engine: no matter what you do, [11:56] the internal combustion engine remains not that great at its job, [11:59] but the Atkinson cycle is a substantial efficiency improvement over a standard Otto cycle engine. [12:06] So if all it takes to make an engine significantly more fuel efficient is to tweak the intake valve timing, [12:14] well, you might wonder why we aren't putting modified Atkinson cycle engines into every car on the road. [12:21] Well, with the advent of variable valve timing, [12:24] we kind of are a little bit. [12:26] But when it comes to the engine itself, [12:29] you still have to make design compromises. [12:33] Remember, we're expecting this thing [12:35] to move the car from a stop and accelerate quickly. [12:38] Yet we also want it to run efficiently when at cruising speed. [12:42] And whenever you try to optimize for one of those two things, [12:47] you make the other one worse. [12:50] This is the crux of the problem. [12:52] The Atkinson cycle maximizes fuel efficiency at cruising speeds, [12:57] but it's pretty lousy at delivering large amounts of power when you need it. [13:02] And, well, that kind of lousy engine [13:06] is exactly what's sitting in this van’s engine compartment. [13:09] While this 2.5l four cylinder can produce 186 horsepower... [13:15] well, first of all, that's not a lot for a vehicle this large or an engine that large. [13:20] But also the engine delivers power in a way [13:24] which many people would find incredibly annoying. [13:27] So if all this minivan had was that engine, [13:30] it would be a very slow turd which nobody would enjoy driving. [13:35] It would be very fuel efficient! [13:38] In fact, with the right transmission [13:41] not far off from what this thing can manage, [13:43] but it would be an unacceptable driving experience for most people. [13:48] This engine is extremely compromised by being designed for fuel efficiency above all else. [13:56] However, the van doesn't just have that engine. [14:00] And that, dear viewer, is the point of hybrid cars. [14:05] See, here's the thing about cars. [14:07] They only need large amounts of engine power to accelerate. [14:11] Sure, having 300 horses under the hood can make car go vroom real fast, but once you're up to speed, [14:17] you don't need any where near that much power. [14:21] This minivan only needs about 30 horsepower to maintain 70 miles an hour. [14:26] You can get that out of some lawnmowers. [14:29] So rather than give the car a huge V6 engine just to make highway on-ramps a little easier, [14:36] what if we gave it a little four banger optimized for amazing efficiency at cruising speeds, [14:41] and we used some electric motors to give the engine a boost when accelerating? [14:46] We can power those motors using some stored energy in a small battery pack, [14:50] and then, whenever we get a chance, we'll recharge what we took from the batteries [14:55] and we'll get them ready for the next time you need to pass someone or whatever. [14:59] That's really what hybrid drivetrains have always been about. [15:03] They’re an exercise in solving the edge case of rapid acceleration [15:08] without resorting to the brute force option of equipping a car with a bigger, thirstier engine. [15:14] The electric motors and battery pack in this thing [15:17] are only there to be an auxiliary source of energy [15:20] which can be borrowed from and replenished whenever it makes sense to do so. [15:25] Sometimes that will be for increasing total system power output. [15:29] While the engine in this minivan tops out at 186 horsepower, [15:33] its electric motors can add about 60 horsepower on top of that, [15:38] bringing the total to 245 horsepower whenever you floor it. [15:42] Incidentally, that's five horsepower more than the 3.5l V6 in a 2002 Honda Odyssey, [15:49] a minivan which could barely manage 20 miles per gallon. [15:53] But the drivetrain in this van will also borrow energy [15:56] from the battery pack during mild acceleration, if it makes sense. [16:00] For instance, if the throttle pedal is pushed down enough to request 80 horsepower, [16:05] but the car's computers know that the engine is more fuel efficient when limited to 60 horsepower or less... [16:12] well, then the car is just going to have the engine produce 60 horsepower [16:16] and fill in the remaining 20 using the electric motors and energy stored in the battery pack. [16:21] Now here's where I need to take a break and explain what I meant by the video title. [16:26] Obviously, “nobody” is hyperbole. [16:29] The engineers designing these things sure do get the point of hybrid cars! [16:34] But when the broader public discusses how hybrid cars attain their better fuel economy, [16:40] discussions tend to focus on the cool new stuff a hybrid drivetrain can unlock, [16:45] like regenerative braking or the ability to move the car without using the engine. [16:50] But what I'm trying to get across here [16:53] is that that's all just icing on the cake. [16:56] The actual cake batter is the engine. [16:59] Yes, hybrid cars need those electric motors [17:02] to make the engine not seem like the wheezy, compromised slow turd of a thing that it is, [17:08] but that engine is the only thing which consumes energy. [17:12] And that's why it's the special sauce. [17:15] Since James Atkinson died in 1914, [17:19] we could have had this special sauce in cars the whole time. [17:22] But the engine on its own is miserable. [17:26] And until we had perfected the electronics [17:29] and control systems necessary to develop hybrid drivetrains, [17:33] nobody was going to buy a car with an Atkinson cycle engine. [17:36] Not even a midwesterner. [17:38] But even though an Atkinson-cycle engine is much more fuel efficient than an Otto cycle engine, [17:45] it is still a reciprocating piston engine with many of the same problems. [17:49] This engine still has friction losses and pumping losses, [17:53] meaning it's only at its peak fuel efficiency under certain conditions. [17:58] So the other thing we can do with a hybrid drivetrain is keep the engine in those conditions [18:04] under many more circumstances than would be possible without some batteries and motors to fill in usability gaps. [18:12] And now here's the other thing I meant by the video title. [18:16] If you're not familiar with how Toyota's hybrid system works both mechanically and operationally, [18:23] you should probably hold off on writing that comment explaining how you think hybrid cars could be improved. [18:29] Because I promise you, Toyota is already doing that. [18:32] Okay, I've got a lot to unpack here. [18:35] First, I don't mean to sound like a shill for Toyota. [18:38] For one thing, they've really been dragging their feet on battery electric vehicles [18:42] and are still playing with hydrogen for some reason. [18:45] So, you know, there's that. [18:48] Also, their user interface software is... well, it could be better. [18:52] But when it comes to the engineering of hybrid drivetrains [18:57] they kind of nailed it. [18:59] There's a reason they are the standard bearer [19:01] and they've earned that distinction. [19:03] But before I explain the mechanical parts of their Hybrid Synergy Drive [19:08] and dispel some of the various misconceptions about hybrid cars that are out there, [19:13] let's first look at what the thing is actually doing as you drive it. [19:16] And with the help of this scan tool, [19:18] I can graph some parameters which will help us make sense of it. [19:22] We begin our journey at a gas station in Hammond, Indiana. [19:26] I've set the scan tool up to log vehicle speed in blue, engine RPM in red, [19:32] the accelerator pedal position in black, and the hybrid battery state of charge in green. [19:37] Not graphed, but shown below is the target engine power in Watts. [19:41] And for those who would like to convert that to horsepower, [19:44] divide that number by 746. [19:47] Before we get on the road, [19:49] I'm going to take the car through a car wash, and I want you to notice that the car does not need [19:54] the engine to be running in order to move. [19:56] Right now, it's simply using one of its two electric motors [19:59] to spin the front wheels and drag itself along. [20:03] When I started logging, the hybrid battery was at 52.5% state of charge, [20:08] and by the time I had parked it in the car wash, [20:10] it was down to 49%. [20:13] Now the car is on this whole time. [20:16] The reason the battery state of charge is slowly dropping [20:19] is because the car has a lot of electronics running, [20:21] including the HVAC system which has an electric air conditioning compressor. [20:27] That's one of the fun side benefits of having a hybrid drivetrain with a lot of stored electrical energy on board: [20:33] if you make all the accessories electric, [20:36] the car can be fully functional while the engine is shut down. [20:40] The car let the state of charge get down to just below 40%, [20:44] and then it decided to start the engine. [20:47] This happened just before the end of the car wash. [20:50] But I want you to notice as I pull out that it's not really working to charge the battery. [20:57] Instead it simply maintaining its state of charge around 39%. [21:03] I will explain why it's not charging the battery in due time. [21:07] But now that I'm actually moving, [21:08] I want you to notice that the engine speed is entirely decoupled from the vehicle speed. [21:14] This cars engine can be used as an electrical generator, [21:17] to push the car forward with the front wheels, [21:20] or indeed both at the same time, which is actually the only way the engine can push the car forward. [21:26] But more on that later. [21:28] As I accelerate to this traffic light, [21:31] you'll see the engine speed up to produce more power to accelerate. [21:35] But then the light was turning red and I had to let off the gas so the engine revved right back down. [21:40] And notice that here the battery state of charge went up rapidly, [21:45] but only as vehicle speed was decreasing. [21:49] That's because the car was using regenerative braking to charge the battery pack. [21:55] Again, I'll explain that more later. [21:57] But now the light turning red was a problem for me [22:00] because I need to take that entrance ramp up there and I'm in the wrong lane. [22:05] So I had to practically floor it to get around this truck next to me, [22:08] and I felt very bad about that maneuver. [22:10] But look at the data we got out of it! [22:13] Here we see the hybrid battery state of charge quickly drop back below 40% [22:18] as the car used some of its stored energy to assist the engine during this sudden need for power. [22:24] But as soon as I let off the accelerator, [22:27] the state of charge stopped dropping. [22:30] I was nowhere near highway speeds yet and still had to do quite a lot more accelerating. [22:34] But now I don't need to exceed what the engine can do by itself. [22:38] So the car simply lets the engine do all the work. [22:42] In fact, the hybrid battery state of charge is increasing slightly, [22:47] indicating that the engine is producing more power [22:49] than is actually required to move the car right now, and it's [22:53] using that excess power to charge the battery back up. [22:56] Now here's something which is very important. [23:00] It is unusual that this is happening [23:03] and the car doesn't ever want to do this if it can be avoided. [23:07] It's only using the engine to charge the battery pack right now [23:11] because the battery fell below 45% state of charge from the car sitting in the car wash parked for a good five minutes. [23:19] 45% is as low as the car ever wants the battery to be when it's being driven, [23:25] because if it's lower than that, the car [23:28] can't sustain the power boost function of its electric motors for very long at all. [23:33] When getting around that truck, we saw it lose three percentage points in just six seconds [23:39] and I wasn't even flooring it. [23:41] So now that the car is in drive and in motion, [23:45] it wants to quickly get the battery back to its target minimum charge to prevent an apparent loss of available power to the driver. [23:54] But, and this is something I really want to make sure everyone out there understands, [23:59] in all other circumstances, [24:01] the car goes out of its way to avoid charging the battery pack using the engine, and for a very good reason. [24:10] If you'll permit me, one of the things I'd like to unpack [24:13] is what I have found to be a very common, but I would argue [24:17] misplaced fixation on the concept of the diesel-electric locomotive [24:21] and how that technology could potentially be deployed in hybrid cars like this. [24:26] I'm not going to get too deep into this, because what follows will hopefully explain why [24:30] I believe the fixation is very misplaced. [24:33] But one of my goals with this video is to help more people realize [24:37] that it is not good to convert one source of energy to another unless you actually need to do that. [24:45] Now, I know this might sound odd [24:47] to the many people out there who know that a diesel-electric locomotive does just that: [24:52] They use a generator to convert the mechanical output from their diesel engine into electricity, [24:57] which will then power electric motors to move the train. [25:01] But what I've never seen discussed [25:04] is that efficiency is not the point of that process. [25:08] And in fact, trains would be more fuel efficient if they weren't doing that. [25:13] See, no electric generator is 100% efficient. [25:17] And likewise, no electric motor is 100% efficient. [25:22] By converting the mechanical energy from the diesel engine to electricity and then back to mechanical energy, [25:28] a two-step conversion process is happening [25:32] in which a significant percentage of the power output from the engine gets wasted in conversion losses. [25:39] Those losses mean that more diesel fuel gets burned than if that two-step conversion process wasn't happening. [25:46] But that's the thing. [25:48] Locomotives need to get tons of material moving from a dead stop by themselves. [25:55] That requires a gargantuan amount of torque, [25:59] an amount which a piston engine is not capable of producing on its own. [26:03] But it can do it in a roundabout way if you... do precisely what a diesel electric locomotive does. [26:10] Locomotives actually need to do that two-step conversion in order to perform their function. [26:17] But it is not the most fuel efficient way to move a vehicle using an engine. [26:23] Now, what I think is a pretty major source of confusion here [26:27] is that many people know trains are very fuel efficient, [26:31] but that's nothing to do with the drivetrain. [26:34] Trains are inherently fuel efficient [26:37] because they have steel wheels running on steel rails [26:40] and a middle finger to the concept of aerodynamics. [26:44] They're so energy efficient, by virtue of being trains, [26:48] that the conversion losses of the diesel-electric drivetrain [26:51] essentially don't matter to that use case. [26:54] In short, what I want to stress [26:56] is just because it's a good idea for a train [26:59] does not mean it's a good idea for a car [27:02] where aerodynamics do matter a lot, [27:04] and it has rubber tires running on a road surface. [27:08] And if you're thinking, “Well, fine, [27:10] but trains don't have that battery pack to store energy. [27:13] So what if the engine could stay in its most efficient [27:17] operating profile no matter what, [27:18] and whenever it's producing more power than is needed to move the car, [27:22] we'll just shuffle that power over to the battery pack to use later?” [27:26] Well, that sounds like a good idea, [27:28] but charging a battery is another kind of energy conversion, [27:32] which is also inherently lossy and thus should also be avoided. [27:37] That is why the car doesn't charge the battery with its engine [27:41] unless the battery is too low. [27:43] When the car is parked as it was in the car wash, [27:46] it does use the battery pack like a buffer to power its accessories, [27:50] and will run the engine for a few minutes at a time [27:53] to charge it back up when it gets low. [27:55] In fact, here's exactly what that looks like: [27:57] with the vehicle stationary, once the battery pack dips below 40%, [28:01] the engine switches on and charges the battery up to about 48%, [28:05] a process which takes three minutes. [28:07] And then it will shut the engine back off and use the energy it just stored until it's too low again. [28:13] But that's just a fancy kind of idling this drivetrain can do [28:18] thanks to its fully electric suite of accessories. [28:21] Otherwise, when the vehicle is being driven, [28:24] the battery pack is charged almost exclusively with regenerative braking. [28:30] For those who may not know what regenerative braking is, [28:33] well, the electric motor which can propel the car forward via the front wheels does that [28:38] when we put electric current through its stator windings, [28:40] which in turn generate a rotating magnetic field which spins the motor. [28:46] But if the motor is spinning because of something else, it creates [28:51] a rotating magnetic field, which we can draw power from using those same stator windings. [28:56] That was a long winded way to say “electric motors are also electric generators,” [29:01] and when using the motor as a generator, [29:04] it will actually slow down the rotational speed of whatever it's attached to. [29:09] In this case, the wheels of the car. [29:11] In other words, it functions like a brake when generating electricity. [29:16] And that's what regenerative braking is. [29:19] It's a way to capture energy from the vehicle slowing down and charge the battery pack. [29:23] And since you need brakes anyway, this is a free source of energy. [29:29] And when the energy is free, conversion losses don't matter. [29:33] And so as I drive on the open road where I'm not using the brakes much at all, [29:38] the battery pack is just sitting there at about 45% state of charge. [29:43] The car doesn't want to dip into that energy because there's no point! [29:47] It all came from the engine anyway. [29:50] There are only two reasons for this car to use that stored energy: [29:56] One, the driver has floored it and wants all 245 horsepower this system can offer. [30:01] Or two, the current load on the system causes the engine to go so far outside of its efficiency band [30:09] that it would save fuel to borrow from the battery pack and replenish what was borrowed when the engine is no longer under such a heavy load. [30:17] But, because of conversion losses, [30:20] that second scenario is much rarer than people think it is. [30:24] The engine has to get way outside of its efficiency band [30:28] for borrowing energy from the battery pack to make any sense, [30:31] and that's why the car is not really using the energy in there at all [30:35] when it's cruising on the highway, or even during mild acceleration. [30:39] If the engine is able to do it by itself efficiently, [30:43] that is always the best course of action. [30:46] Around town is a completely different story though. [30:50] When you're on the highway, a car is constantly working [30:53] to push itself forward, but off the highway, [30:56] you're going to keep switching back and forth between accelerating and braking. [31:00] In a traditional car, friction brakes reduce vehicle speed simply by converting energy into heat. [31:06] That works great for stopping the car, but that's all it does. [31:11] The battery pack in this car is able to absorb [31:14] what would be wasted as heat through regenerative braking, [31:18] and since that process doesn't use the engine at all, [31:22] whatever energy it can absorb from the vehicle slowing down is free. [31:27] So when regen breaking gets the battery pack above 45%, then the car will use that energy to... [31:35] help the engine. [31:37] This is what I keep getting back to, [31:39] and what I'd really like to hammer home today. [31:41] If you've been imagining hybrid cars [31:44] to use their battery packs something like a bank account [31:47] which gets paid into when there's excess energy and borrowed from when there's excess power demand, [31:53] this is only kinda sorta of true. [31:56] The gasoline in this thing's fuel tank and that engine remain the only source of input power this system has. [32:04] So the engine is always going to be the primary propulsion device. [32:09] And that's why this minivan almost always starts the engine just after you begin moving. [32:15] You have to treat it very gently if you don't want the engine to start [32:19] because there just isn't that much energy or power to be had from its small battery pack sitting underneath the front seats. [32:27] That battery is not really there to push the car forward when it's got a full charge. [32:32] It's just there to augment this engine’s output so the engine itself can stay entirely [32:38] within its most efficient operating range in as many circumstances as possible. [32:42] In that way, this thing is like the diesel-electric drivetrain [32:46] many people imagine hybrid cars should emulate. [32:49] And that's why I said “Toyota's already done that.” [32:53] But the most efficient way for an engine to run is for it to not. [32:57] So when the car has an opportunity to shut the engine off, [33:00] it almost always takes it. [33:03] For example, pretty much whenever you let off the accelerator, the engine shuts off. [33:08] You're no longer commanding forward power, [33:11] so there's no point burning any gasoline. [33:14] If the car has enough free energy stored in its battery pack from regen braking [33:19] and you're commanding only light throttle, [33:21] then it might decide to keep the engine off for a good while. [33:26] But once your accelerator request exceeds the power output of the battery pack, [33:31] the car has to start the engine to keep up. [33:33] So it does. [33:35] Still, if there's free energy left in the battery pack, [33:39] the car will sometimes kind of flip the script and use the engine [33:43] to augment the limited power from the electric side of its drivetrain. [33:48] Here you can see the battery state of charge dropping [33:51] even though the engine is running. [33:53] It's doing that because it's got some free energy to use up, [33:56] so it might as well do that and take some load off the engine, [34:00] which has the side bonus of keeping the engine in a really energy efficient operating condition [34:05] even though the vehicle is accelerating and climbing a hill. [34:09] If you'd like to see in data and hear from a microphone what the powertrain of this vehicle [34:14] does under a wide variety of circumstances, [34:17] you can check out this Sights and Sounds video I've released on my second channel. [34:21] I put an audio recorder in the engine compartment of this thing on my way to Hammond, [34:26] and being able to hear the engine and motors so clearly revealed some interesting things [34:31] about how the system makes decisions and how it works in general. [34:35] But to wrap this video up, [34:37] now it's time to talk about the mechanical details of Toyota's hybrid system, [34:41] because what I've talked about so far might very well make it sound fragile and dauntingly complex, [34:48] when in fact the system is so mechanically simple [34:52] it almost hurts to think about. [34:54] So, here's the wildest thing about how Toyota designed their hybrid system: [35:00] The engine in this vehicle is not actually connected to the front wheels. [35:05] And yet, the engine in this vehicle [35:08] is permanently coupled to the front wheels. [35:13] To explain that apparent contradiction, let's put the Cube up on the lift [35:17] and let its engine spin the front wheels while it's off the ground. [35:21] With the engine running and the car in gear, [35:23] both front tires are turning at equal speed. [35:26] But because the car has to navigate turns where one wheel will be rotating faster than the other, [35:32] the power coming from the engine and transmission is delivered through what's called a differential. [35:38] It's not important to know the mechanical details of that, [35:41] but the differential is designed to split the power output of the engine between the two wheels, [35:47] while also allowing them to spin independently. [35:50] And the ordinary differential has a bit of a quirk: [35:54] I can easily stop one of the two wheels with my hands, [35:58] and now that I've done that, the other wheel has sped up. [36:03] Note that the engine didn't get any faster, [36:06] it's still just idling. But by preventing one wheel from moving, [36:10] the other wheel is now spinning twice as fast. [36:14] But it gets even weirder. [36:16] If I start to rotate the wheel I'm holding backwards, [36:19] the free spinning wheel on the other side spins even faster! [36:22] And if I then start pushing the wheel forward again but faster than the engine wants to spin it, [36:28] the wheel on the other side starts to slow down. [36:31] In fact, if I can spin the tire fast enough, [36:34] I can get the other tire to come to a complete stop. [36:38] What's this got to do with the Sienna? [36:41] Well, believe it or not, [36:43] this phenomenon is at the heart of Toyota's hybrid system. [36:46] But rather than use the engine to spin a pair of wheels through a differential, [36:51] the engine spins the rotors of two electric motors. [36:56] I'm only going to give you a very surface-level explanation of this, but look. [37:00] That's it. [37:02] Watch this video from the Weber Auto YouTube channel if you want the full explanation. [37:06] But those parts on the table are the whole thing. [37:09] That is Toyota's Hybrid Synergy Drive. [37:13] It's just two electric motors and a planetary gearset. [37:17] That's it. [37:18] The only parts not shown are the stators and wiring which actually drive the electric motors [37:24] and the case which holds all this stuff together. [37:27] Oh, and also in reality, [37:28] this would all be covered in oil for lubrication and cooling. [37:32] But when it comes to the spinny bits which connect the engine and motors to the wheels of the car, [37:37] there are literally just three: [37:40] the parts of a planetary gearset. [37:43] The crankshaft of the engine spends the planet carrier of the planetary gear set, [37:48] a small electric motor generator unit known as MG1 spins the sun gear of that gearset, [37:55] and a larger electric motor, MG2, spins the ring gear of that gearset, [38:01] which is itself coupled to the wheels of the car through a conventional differential. [38:06] Okay, [38:06] it's time to get out the whiteboard because I need something to point at [38:10] as I explain the details of how this works. [38:12] This drawing is not at all accurate [38:15] when it comes to how these three parts are arranged and fit together, [38:18] but that's kind of the whole problem with describing Toyota's system. [38:23] What each part by itself does is very simple, [38:26] and how they're coupled together is also very simple. [38:29] But the choreography of the dance they're performing to make the car go [38:34] is not. [38:35] Here is my best (and revised) attempt [38:37] at painting the complete picture for you. [38:40] So here's the engine. [38:42] Here's MG1 and here's MG2. [38:45] What connects this all together is that planetary gearset which acts to split the output power [38:51] from the engine between the rotors of MG1 and MG2. [38:55] What I think is the most confusing thing [38:58] to wrap your head around here is that all three of these devices [39:02] can move under their own power. [39:05] MG1 and MG2 are both electrical generators, [39:08] but they are also both electric motors. [39:11] The engine burns fuel to spin and the motors use electricity to spin, [39:15] but the car is in direct control of all three of these things [39:20] and can spin them at whatever speed it desires. [39:23] Now for a moment, I want you to forget that these are motors, [39:28] because you can think of this arrangement [39:30] as equivalent to a diesel electric drivetrain. [39:33] But rather than connect an engine to a single electrical generator, [39:36] it's been connected to two of them at the same time [39:40] through that planetary gearset. [39:42] We refer to that gearset generically [39:44] as a power splitdevice, because that's what it does. [39:48] And it operates exactly like the differential in a typical car. [39:52] That is why I used the Cube as a demo. [39:55] And just as I can make one of the Cube’s [39:57] tires speed up just by stopping the other one, [40:00] a Toyota Hybrid can make one of its two generators speed up [40:04] just by slowing the other one down. [40:07] Now, that might seem trivial, [40:09] but what I haven't drawn into this diagram yet [40:11] is that one of those generators, MG2, [40:14] is also coupled to the wheels of the car. [40:18] So this one is not actually free to spin at whatever speed it wants to. [40:23] Its rotational speed depends on how fast [40:27] the wheels and thus the car are going. [40:29] And in fact when the car is stopped, this can't spin at all. [40:34] But that doesn't mean the engine can't spin. [40:38] MG1 is always free to rotate. [40:40] So if MG2 cannot, what will happen [40:43] is that all of the engine's rotational output [40:46] gets sent to MG1 and this will spin really fast. [40:50] It's just like me holding this tire stationary. [40:53] The engine output is all going to the other tire or in a Toyota hybrid, [40:59] if the wheels are stopped and MG2 cannot spin, [41:03] then all of the engine output will go to MG1. [41:06] But of course, MG1 isn't a tire, it's an electrical generator. [41:11] And MG2 isn't just an electrical generator, [41:15] it is also a motor. [41:18] So whenever a Toyota hybrid wants to move forward, [41:22] it will simply use the engine to spin the rotor of MG1 really fast, [41:27] which will generate electricity. And then it will shuttle that electricity [41:31] over to MG2 in order to make it spin. [41:35] Since MG2 is connected to the front [41:38] wheels, that's going to push the car forward [41:40] or indeed backwards. [41:43] Reverse gear is accomplished simply [41:45] by spinning the rotor of MG2 backwards. [41:49] But, when the car is moving forward... [41:52] well, you may notice that what I've just described [41:55] here is a diesel electric locomotive. [41:58] And earlier I went on a tirade about why that is a silly way [42:01] to move a car because of conversion losses. [42:04] Well, that is the brilliant thing about the powersplit device. [42:09] If the engine is running at a fixed speed [42:12] and one of these two motors slows down, then the powersplit device [42:18] will mechanically force the other one to speed up. [42:23] Now, to explain why this is important, well, [42:25] remember how regenerative braking works? [42:28] When we use a motor as a generator, [42:30] It creates an opposing mechanical force on the thing which is spinning it. [42:34] And that force acts to slow the spinning thing down. [42:38] During regenerative braking, the slowing rotor of MG2 [42:43] slows down the wheels of the car, acting like a brake. [42:46] But the same thing happens as MG1 generates electricity using the engine. [42:52] As the stator windings surrounding MG1's rotor harness power [42:57] from the rotating magnetic field the engine is producing by spinning this rotor, [43:03] an opposing torque is generated which will try to slow the rotor down. [43:08] But because of the powersplit device coupling all of this together, [43:13] even if the engine is running at a constant speed, MG1 slowing down causes MG2, [43:21] and thus the wheels of the car to speed up. [43:26] The fact that the relative rotational speed of the engine and wheels can be altered on the fly [43:31] simply by speeding up or slowing down the speed of MG1 is what makes this system functionally equivalent [43:38] to a continuously variable transmission. [43:40] And that's why Toyota calls it an eCVT. [43:45] Personally, I don't think they're doing themselves any favors using that term, [43:49] since most people who know the term CVT associate it with horrible things which are mechanically fragile [43:56] when this is anything but. [43:58] The powersplit device has no gears to change, or clutch packs to wear out, or weird [44:04] belt chain things to move between two cones. [44:08] It's as mechanically simple as you could possibly imagine, [44:11] and all of its parts are permanently coupled together. [44:14] Yet it does all the stuff we've been talking about. [44:17] And what's really remarkable to me about this system [44:20] is that it all fits into a package which doesn't even look [44:23] that different from a traditional transmission. [44:26] That's why nothing under the hood of this car [44:28] looks all that out of the ordinary, except for the fact that the gearbox [44:31] has some beefy wires coming out of it. [44:34] Now, in reality, [44:35] and this is another thing which makes holding all this together in your head pretty difficult, [44:39] We don't actually need the rotational speeds to change [44:43] in order to transmit power from the engine to the wheels. [44:47] What matters is the opposing torque [44:49] MG1 is putting on the engine crankshaft, [44:52] and that torque can be constant while the speeds are constant, too. [44:58] Remember, it's really easy to stop this spinning tire [45:01] because an ordinary open differential will send all the engine power [45:06] over to whichever tire has the least traction. [45:09] It's kind of a bummer, really, [45:11] and that's why limited slip differentials are a thing. [45:13] But luckily for us, a similar thing happens with the planetary gearset. [45:18] So if MG1 is producing an opposing torque on the engine, [45:23] rather than actually slow the engine down, that torque just gets shuttled over into MG2. [45:29] And thus the act of using MG1 as a generator [45:33] actually causes the engine to push directly on the wheels of the car. [45:38] This is why the Toyota hybrid system, in my opinion, [45:42] can't neatly be classified as either a series hybrid or a parallel hybrid. [45:47] It's actually somewhere in the middle. [45:50] While there is a mechanical connection between the engine crankshaft and the wheels, [45:55] the engine can't actually push the wheels forward [45:58] unless the hybrid system is doing something to slow down MG1. [46:03] Otherwise, it's equivalent to a car with one tire off the ground. [46:07] All the engine will do in that case is spin that tire really fast [46:11] and the car won't actually move. [46:14] Now, this means there are some conversion losses happening in Toyota's system, but [46:20] how much and exactly where they're occurring is way above my pay grade. [46:26] My mental model suggests the car doesn't have to do very much work [46:30] to cause the engine to mechanically contribute, so the losses are minimal, [46:34] but I have no real basis for that [46:36] other than the stellar real world fuel economy most Toyota hybrids have historically attained. [46:42] Now, that was the first time I've even mentioned the terms [46:45] series hybrid and parallel hybrid in this video. [46:49] And that's because to the end user, the difference doesn't really matter. [46:53] But at the same time, the difference is kind of the heart of the point [46:58] I'm trying to make in this video. [47:01] Toyota's hybrid system is a parallel hybrid system, [47:04] because the engine can mechanically contribute to the movement of the car, [47:08] and I hope by now you understand why this is a good thing. [47:12] Series hybrids are different. [47:15] Series hybrids have an engine which can only power [47:18] an electrical generator, and the electricity which is generated [47:21] that way will be used to charge a battery [47:23] or power electric motors to move the car. [47:27] But unless you have a very good reason to design a system that way, [47:32] this is not a good idea. [47:35] Diesel electric locomotives have a very good reason [47:38] to decouple the engine from the motors: for torque. [47:41] And in theory, a future extended-range electric vehicle [47:45] might benefit from separating the engine and generator [47:48] from the rest of the car. [47:50] But I promise, [47:51] such a future vehicle is not going to benefit from that from a fuel efficiency standpoint. [47:57] There could very well be a good packaging reason to design the vehicle that way. [48:01] But if you're insisting on using the engine primarily as a generator [48:05] for any other reason, I would argue you're making a mistake. [48:11] And we have a perfect example of such a mistake with my previous car, [48:15] a Gen1 Chevy Volt. [48:18] For reasons which are unclear but probably rhyme with General Motors, [48:22] that car was designed explicitly to operate as a series hybrid in most driving conditions. [48:29] Well, after its battery charge had been depleted. [48:31] The whole point of the Chevy Volt was to be [48:33] an electric car first with a small electric range, [48:37] but which also had a gas powered range extender [48:40] to give it unlimited range for road trips. [48:43] But once you had run out of charge and it started up its engine, [48:47] you discovered that the car wouldn't [48:49] keep the engine running when you were cruising at moderate speeds. [48:53] Instead, it would run the engine in spurts [48:56] where it was producing way more power than the car [48:59] actually needed to drive, say, 40 miles an hour, [49:02] and then it would send the excess power [49:05] into the battery pack to use later. [49:07] So after a while it would shut off the engine and use up that energy. [49:11] But because there were four steps of energy conversion going on there: [49:16] engine to electricity, excess electricity to charge the battery, [49:19] discharging the battery to get electricity out of it, [49:22] and then using that electricity to spin an electric motor, [49:25] It got surprisingly mediocre fuel economy. [49:29] The Gen 1 Volt, on premium gas to boot, [49:32] could only manage 35 miles per gallon city 40 highway. [49:37] So that car, which was a lot smaller than a minivan, [49:42] got basically the same fuel economy as this minivan. [49:45] Worse, from a dollars perspective, if you actually used premium fuel. [49:51] That's pretty terrible! [49:52] But given how that car was designed to operate, that's to be expected. [49:57] Even with the flexibility of electric motors and fancy electronics, series hybrids are just less efficient than parallel hybrids. [50:06] If you can use the engine to push the wheels of the car, [50:09] you should be doing that to avoid conversion losses. [50:13] Nissan, for some reason, is supposedly about to release a new series hybrid drivetrain with the Nissan Rogue, [50:20] and I don't really understand why they're doing that, but [50:22] we'll see what kind of fuel economy they can get out of it. [50:26] My guess is, like the Volt, it's going to be decent, [50:29] but far from exceptional. [50:32] By the way, it's very possible there's a patent reason that GM chose to build the Volt the way they did. [50:38] Their Voltec drive system was actually remarkably similar [50:42] in many ways to Toyota's hybrid system. [50:45] It, too, fit two electric motor generator units into a package [50:48] which replaced the conventional transmission, and in a layout [50:52] which was really similar to what's in this minivan. [50:56] They could very well have gotten into legal trouble had they made the design any more similar. [51:00] And Ford ended up licensing Toyota's hybrid technology [51:04] because Ford also ended up making a very similar design. [51:08] In fact, the hybrid Ford Maverick is basically a Prius, but truck shaped. [51:13] By now, most of the original Toyota patents will have expired, so [51:17] I don't know how much this matters in 2026, but I wanted to mention it. [51:22] I'm about to wrap up, [51:23] but in case any of you out there need another reason to see this as a really cool way to do things [51:29] well, remember how this van is all wheel drive? [51:32] Toyota made that happen in a really fascinating way, [51:35] which is only possible because this is a hybrid electric vehicle. [51:39] They just slapped a third electric motor on the rear axle. [51:43] This thing's not very powerful. [51:44] It's only about 40 horsepower. [51:46] But that's plenty to get the car unstuck [51:48] or to give it some extra traction in wet, slippery conditions. [51:52] And because this thing normally just tootles along without doing anything, [51:56] there's virtually no efficiency penalty to having it. [52:00] The EPA rating between the front wheel drive [52:02] and all wheel drive versions of this car varies by exactly [52:06] one mile per gallon, so doing it this way is pretty clever. [52:11] And Toyota’s hybrid drivetrain design has another pretty huge trick up its sleeve: [52:16] It can be tweaked to make a car a plug-in hybrid trivially. [52:22] This van's main electric motor, MG2, can actually produce 180 horsepower. [52:28] The reason the hybrid system can only provide [52:31] about 60 horsepower of boost power to the engine [52:34] is a limitation of the battery pack it's been equipped with. [52:37] If it had a larger battery pack capable of delivering more power, [52:41] this thing could operate in all-electric mode with pretty decent power on tap. [52:46] And that's why many of Toyota's plug-in hybrids really are just their standard hybrids. [52:52] But with a larger battery pack [52:54] which can be recharged using off board power. [52:58] However, something I want you to know is that plug in hybrids [53:01] only make sense for those that can reliably charge them at home [53:05] or at work with cheap electricity, [53:08] because when plug in hybrids switch to gasoline power, [53:12] they have a pretty significant fuel economy penalty [53:15] compared to their non plug in counterparts. [53:18] This is mostly due to the fact that they're carrying more weight around with them, [53:21] since they have a much larger and heavier battery pack, [53:25] though changes to the drivetrain design to prioritize engine-less operation can also make fuel economy worse. [53:31] So if you're not able to charge your car every day, [53:35] either at home or at work with cheap electricity, [53:39] don't consider a plug in hybrid. [53:41] There's no point having those extra batteries unless you can actually use them. [53:46] Personally though, as I'm sure many of you already know, [53:49] I'm over the internal combustion engine. [53:52] Since I can charge my car at home, [53:54] I’d much rather that car just have more batteries [53:58] and not have such things as a catalytic converter [54:01] or a transmission, or a fuel tank, fuel pump, fuel injectors, or fuel. [54:06] But while we are still figuring out how to undertake [54:09] the monumental task of getting wires from buildings to parking lots, [54:15] well, charging a car will be less convenient [54:18] than refueling for many people. [54:20] So if you're going to have a car with an engine, [54:23] why not make the smarter choice and get one with an engine [54:25] designed to burn as little fuel as possible? [54:29] Gas costs money, you know, and sometimes it gets very expensive very quickly. [54:34] Making choices which lower your ongoing costs, I think, should always be in fashion [54:40] because your future self is worth treating, too. [54:45] ♫ losslessly smooth jazz ♫ [54:49] whoop [54:50] And because this thing normally just tootles along without doing anything, [54:53] There's virtually no penalty to having it. The miles per gallon - [54:57] Oh, I'm looking at my face. [54:59] That's silly. [55:00] There are still, woo. hoo. hoo! [55:04] And I backed the teleprompter up too much. [55:07] Farts. [55:08] Farts. Farts! [55:10] ...replenished whenever it makes sense to do so from an efficiency perspective. [55:15] Why did you add that line? [55:16] I should have written that differently and I just figured out how. [55:20] That. [55:21] Why'd you stop? [55:23] You weren't supposed to stop, you turd. [55:25] this line could use a revision. [55:26] I'm doing it on the fly. [55:27] This may be a mistake. [55:29] with a larger battery pack capable of.