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Here's a look inside the inverter assembly of the 2nd Generation Ford Hybrid System and how it works!

The inverter assembly is the heart of the hybrid system. It interfaces the various control modules, such as the power train, engine, battery and other CANBUS computers. It is responsible for taking the high voltage (270VDC) from the battery in the trunk and converting it to alternating 3 phase current to drive the 2 electric motors inside the e-CVT transmission. It is very similar to Toyota's Hybrid Snergy drive, which you can find more details on here:



The inverter works by taking DC, using a capacitor and inductor to ramp up the voltage using a boost circuit. The power is controlled with a motor control board and a transistor controller. The transistors or IGBT's are then switched on and off rapidly to form a waveform, and phased 120* apart to form 3-phase AC current, which can easily control the two motors inside the transmission and propel the vehicle.

Under deceleration, regenerative braking is used to capture kinetic energy, pass it through diodes and a capacitor to rectify the current, changing it back to direct current which can charge the high voltage battery.

The battery pack houses the DC to DC converter instead of the inverter like in Toyota systems. It will convert the power from 270 VDC to 14V DC to charge the auxillary battery to run the electronics throughout the vehicle.

The vehicle torn down in this video is a 2014 Ford Fusion Hybrid with 290,000km on it which suffered internal transmission bearing failure. More on the engine teardown for this car can be found here:



Stay tuned for the hybrid transmission teardown and the AC compressor teardown for this vehicle.

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