Course Offerings

This course will provide an in-depth study of the technology, maintenance, and repair of hybrid, plug-in, and all electric light duty passenger vehicles. Basic diagnostic, repair, and maintenance procedures of the unique systems associated with hybrid and electric vehicles will be discussed and practiced. Special tools and diagnostic equipment will be used during the laboratory exercises.

Course Objectives

Students will...
a. Utilize service information (electrical diagrams, diagnostic charts, specifications) to perform diagnosis and repair on hybrid and electric vehicles.
b. Apply electrical/electronic theory to the operation of the unique systems and components used in modern hybrid and all electric vehicles.
c. Demonstrate proficiency at charging plug-in and all electric vehicles.
d. Demonstrate proficiency using a digital multimeter and pass NC3 certification.
e. Assess hybrid and electric vehicle performance by using the proper diagnostic tools and proper interpretation of test data.
f. Utilize specialized diagnostic equipment to test and validate vehicle performance.
g. Utilize specialized repair tools and equipment when performing laboratory repair tasks.
h. Correctly perform all laboratory tasks assigned.
Students will also....
1. Observe special safety procedures related to different vehicles.
2. Locate relevant safety information.
3. Research system operation using technical information to determine how to safely handle and disable various electrical systems.
4. Use appropriate disconnect procedures to remove the charging cable from the vehicle and charging station
5. Use appropriate start up procedures and how to engage the vehicle for operation
6. Use appropriate shutdown procedures based on available vehicle data and service information.
7. Understand how to identify safe/unsafe charging stations/plugs

Outline of instruction

a. Hybrid Electric Vehicles
i. Define what a hybrid vehicle is
ii. Compare the differences between series, parallel and series-parallel hybrid configurations
iii. Analyze the basic operational differences between the different types of electric hybrid vehicles
iv. Identify the accessory components found in hybrid electric vehicles
b. Review of Electrical Theory
i. Explain the basic principles of electricity
ii. Examine the effects of various circuit failures in both series and parallel circuits
iii. Examine how the principles of electromagnetism effect electric drive systems
iv. Describe the relationship between electricity and magnetism
v. Explain how self and mutual inductance is used
c. Unique Hybrid Electrical Circuits
i. Describe the basic operation of electric motors and generators
ii. Identify the major parts of a DC motor and a three-phase AC motor
iii. Explain the differences between a motor and a generator (AC and DC)
iv. Analyze the operation of a controller in a motor/generator circuit
v. Examine the communication and multiplex systems used in most hybrid electric vehicles
vi. Explain the function and operation of an inverter
vii. Describe the operation and function of the idle stop mode
viii. Examine the operation and function of regenerative braking
ix. Describe the basic operation and function of the air conditioning system found in most hybrid electric vehicles
d. High Voltage Battery Packs
i. Explain the purpose of a high voltage battery pack
ii. Describe the construction, and operation of the various types of high voltage batteries
iii. Explain how hybrid batteries are recharged
iv. Examine the operation and construction of the high voltage battery cooling system
v. Identify the precautions that must be adhered to when working with or around high-voltage systems
vi. Identify diagnostic method to test high voltage batteries
vii. Identify methods to recondition various high voltage batteries
viii. Identify and demonstrate procedures for removing and replacing high voltage battery packs
ix. Identify and demonstrate diagnostic testing on the battery management system
x. Identify and demonstrate procedures diagnostic testing on high voltage systems cooling system
e. Hybrid Transaxles
i. Compare the differences between a conventional transmission and those used in most hybrid and electric vehicles
ii. Examine the basic operation of the transaxle used in its hybrid and electric vehicles
f. Maintenance and Service:
i. Examine the unique methods of servicing a hybrid and electric vehicle
ii. Identify the procedure for de-powering the high-voltage system
iii. Identify the preventative maintenance procedures unique to a hybrid and electric vehicle
iv. Describe the special diagnostic tools that must be used on a hybrid and electric vehicle
3. Course Lab Content
a. Identification and Operation
i. Identify unique hybrid and electric components and systems
ii. Explain the major systems function
b. Safety Procedures
i. Identify and locate safety shut-off switches
ii. Perform general safety procedures and follow safety guidelines
c. Routine Maintenance
i. Perform traditional services impacted by hybrid and electric vehicle design
ii. Perform various maintenance tasks required on hybrid and electric vehicles
d. Battery Maintenance
i. Perform battery diagnostics
ii. Diagnose a hybrid battery
iii. Perform diagnostic testing on the battery management system
iv. Perform diagnostic testing on the high voltage systems' cooling system
e. Troubleshooting
i. Demonstrate how to use special diagnostic tools
ii. Perform various diagnostic procedures
iii. Interpret and identify Diagnostic Trouble Codes (DTCs) associated with hybrid vehicles
iv. Perform diagnostic testing on a multiplex communication system

Why do we need electric, plug in and Hybrid vehicles?
A. Oil dependency
B. Vehicle emissions and air quality

2. Battery Electric Vehicles
A. History of electric vehicles
B. Location of and safety concerns for Traction battery vehicles
1. High voltage strings
2. Charging
3. Maintenance
4. Traction motors
5. Controllers and inverters

3. Hybrid Electric Vehicles
A. Location of and safety concerns for a hybrid vehicle
B. Drive train configurations
1. Series
2. Parallel
C. Electric motor control
D. ICE controls
E. Hybrid module principles

Contact Hours

40

CEUs

1

Industry Standard, State or National Certification

National Coalition of Certification Centers

CE or CU Articulation

No

Prerequisites

Successful completion of this course requires 90% attendance and satisfactory class participation (i.e. be able to demonstrate proficiency in all concepts taught). Students with irregular attendance, less than 90% attendance, or who are unable to demonstrate competency will receive a grade of NG (no grade)
Students must arrive on time on testing day. Students will not be allowed into the classroom after the test begins. No makeup testing dates will be offered
Lab exercises, when applicable, are due on the date assigned by the instructor. Late assignments may be accepted only at the instructor's discretion.

Text and Supplies Needed

Notebook
Pen
Safety glasses
Safety shoes
Gloves

Clinical Site/Special Facilities

Automotive Garage /Lab

Requirements for Successful Completion

90% attendance

Accreditation/Special Approval Requirements

N/A

Intended Audience

Students interested in becoming technicians in EV diagnostics maintenance and repair. This course is intended for experienced technicians with a basic knowledge of diagnostic procedures and equipment.

Specific Industry or Business Support Needs

Automotive Body Repair, Restoration, and Collision.

Wake County Need for Industry Positions

Interoperability Test Engineer, EV Charging ABB - Cary, NC Regular

Industry or Job Titles Related to training Outcomes for Employment

Related Courses

Course Contact Information

Justina Barreiro
919-819-0203
[email protected]