Disassembling the 5th-Generation Prius Power Control Unit and Comparing It with the 4th Generation

The internal structure of the power control unit (inverter) removed from a 5th-generation Toyota Prius ZVW60 is disassembled and examined section by section, with comparisons to the 4th-generation design. The breakdown covers the exterior, control circuit board, power stage, and 12V DC/DC converter, showing which components and layouts changed between generations.

■ Exterior and Structure Overview
- External terminals, wiring harness fuse rating, and coolant inlet/outlet paths
- Overall internal layout: control board, inverter module, inductor, DC/DC converter
- Difference in coolant channel placement compared with the 4th generation

■ Control Circuit Board
- Microcontroller and custom IC configuration on the board
- Gate driver circuit, floating power supply, and insulation distance on the PCB
- Change from contact sockets to soldered power card leads

■ Power Stage and Generational Differences
- Power cards, laminated bus bar, inductor, film capacitor, and water-cooled heat sink
- Power card count and bidirectional converter configuration vs. the 4th generation
- Motor output figures of the 4th and 5th generation models

■ 12V DC/DC Converter
- Single-board structure with surface-mounted power semiconductors
- Circuit configuration, busbar thickness, and secondary-side rectification

This content is suited to viewers interested in hybrid and EV power electronics, engineers, and automotive technicians. Watching it provides an understanding of how a hybrid power control unit is laid out internally and which design changes were introduced in the latest generation.