Hybrid System Overview
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
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
Starter Generator Control Module 7-kW AC induction
machine surrounding down-sized (258-mm) torque converter 120-V Electrical outlets No conventional starter or alternator
120-V
Electrical outlets
+ 10% Composite fuel economy (+ 15% MPG City)
Quiet start
Product Concept:
Electrohydraulic Power Steering Pump
42-V “Advanced” Lead Acid Battery Pack
Delete from engine: •Conventional starter
•Alternator
•P/S pump
Modify transmission: •Coast braking capability
•Auxiliary trans. oil pump
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
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
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
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
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
Starter Generator Control Module (SGCM)
Starter Generator Control Module
•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
SGCM Cooling System
Fan and Radiator Assembly Pump
Heat Exchanger Coolant Reservoir
Starter Generator Integration
Production Case
Stator Cooling Line SG Stator Assy.
Compact
Torque Converter
Unique Flexplate SG Rotor Assy.
Unique Bellhousing 5.3-L V-8 Engine Assy.
Rear View Front View
3 Phase Cable Pass Through Location
Modified Engine Accessory Drive
Hybrid Control Module
Hybrid Control Module (HCM)
• 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
Electro-Hydraulic Power Steering Pump
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
Energy Storage Box
42-V Energy Storage Box (ESB)
– 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)
• Manages State of Charge (SOC)
• Communicates battery pack status
• Controls battery cut off switch
• Controls Energy Storage Box (ESB) fan
• Diagnostics for ESB components
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)
• 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
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
•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
Starter Generator Control Module
(Underhood)
AC <=>DC Inverter
Energy Storage Box
(Under Rear Seat) ESCM
EHPS (On Engine)
DC <=>DC
Converter
Downsized
14V Battery 14V Vehicle Electrical Systems
(Engine Compartment) DC => AC
Inverter 120 VAC
120 VAC
(Pickup Bed)
Electric Machine (3Ø AC Induction)
(Between Engine & Transmission & Outside
of Torque Converter
14V Battery 42 VDC 14V Battery 14V Battery
IPC ABS TBC HVAC PCM HCM EHPS SGCM
42 V Battery Pack
E lect ri c M ach in e ESCM Transmission TACM THROTTLE BY WIRE
Wheel Speed Sensors
HVAC Sensors & Switches
Brake Apply Sensors Steering Wheel Sensor Aux. Coolant Pump
Aux. Transmission Pump Hood Ajar
Power Maintain Relay
Class 2 Bus
CAN Bus
UART Bus Key Information
Time (s)
Vehicle Speed
PHT Fuel Rate
Fuel Rate (g/s) Vehicle Speed (mph/10) 0.0 1.0 2.0 3.0 4.0
326 346 366 386 406 426
Surge Smoothing (TCC Lock-up)
Auto-Stop
Auto-Start
Coastdown Regen & Downshift Assist
• 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
