Lesson 1Battery Pack Design and Positions: Under the Floor, Back Storage, Engine Area—Access for Repairs, Heat Control, and Crash Safety ChecksThis part looks at where hybrid and PHEV battery packs are fitted in vehicles, how their position impacts repairs, cooling, noise levels, and safety in crashes, and what mechanics in Botswana should inspect before taking out or putting back a pack.
Underfloor pack designs and structural integrationRear cargo pack placement and space trade-offsEngine bay packs and heat exposure risksService access points, lifting and removal pathsCrash protection zones and intrusion mitigationLesson 2Heat Management for High-Voltage Batteries: Liquid Against Air Cooling, Coolant Paths, Sensors, and Effects on Electric Distance and Battery LifeThis part compares air and liquid cooling methods for high-voltage batteries, looks at coolant paths, pumps, valves, and sensors, and shows how keeping the right temperature affects power output, energy use, driving range, and how long the battery lasts in hot Botswanan weather.
Air-cooled pack layouts and airflow pathsLiquid-cooled plates, jackets, and chillersCoolant pumps, valves, and heat exchangersTemperature, flow, and pressure sensorsCold-weather preconditioning and heatersThermal limits, derating, and aging impactLesson 3Standard Pack Voltages: Usual Levels for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and Pure EVs and How Pack Setup Influences VoltageThis part reviews common voltage levels for mild, full, and plug-in hybrids, plus pure electric vehicles, and explains how the number of cells in series, module setup, and switching parts set the standard voltage and safety limits for Botswanan roads.
Voltage ranges for mild hybrid systemsFull hybrid and PHEV voltage rangesBEV pack voltages and segmentingSeries cell counts and module stackingContactors, precharge, and HV bus designVoltage class, PPE, and service limitsLesson 4High-Voltage Cables, Connectors, Service Plugs, and Safety Locks: Colour Codes, Insulation, Protection, and Typical Damage TypesThis part details high-voltage cables, connectors, and safety locks, covering orange colour coding, insulation types, protection against electrical noise, lockout systems, and safe ways to spot, test, and record common damage or failures in Botswana's dusty environments.
Orange HV cable standards and markingsInsulation types, creepage and clearance limitsShielding, grounding, and EMI control methodsService plugs, disconnects, and lockout stepsInterlock loops, continuity checks, and faultsTypical abrasion, corrosion, and arc damageLesson 5High-Voltage Support Systems: DC-DC Converters, Onboard Chargers, EVSE Ports, and Basics of Power Electronics (Inverter, Motor)This part introduces high-voltage support parts, like DC-DC converters, onboard chargers, charging ports, inverters, and motor drives, and explains how power moves between the battery, 12V system, and drive parts for reliable use in Botswana.
DC-DC converter roles and topologiesOnboard charger stages and power factorsEVSE inlet types and communication basicsInverter operation and PWM fundamentalsMotor types used in hybrids and PHEVsGrounding, isolation, and leakage checksLesson 6Battery Types Used in Modern Hybrids and PHEVs (Lithium-Ion, NMC, LFP, NiMH) and How Type Affects Performance, Wear, and SafetyThis part surveys main battery types in hybrids and PHEVs, including lithium-ion kinds like NMC and LFP, plus NiMH, and explains how each type impacts energy storage, power delivery, cycle durability, cost, and safety in Botswanan heat.
Key Li-ion cell components and reactionsNMC chemistry traits for hybrids and PHEVsLFP chemistry traits and safety advantagesNiMH chemistry and legacy hybrid systemsChemistry effects on energy and power densityChemistry-driven safety and abuse responseLesson 7Battery Module and Cell Setup: Series and Parallel Links, Module Monitoring, and the Job of the Battery Management System (BMS)This part explains how cells form modules and packs with series and parallel connections, how current and voltage adjust, and how the BMS watches modules, balances cells, and guards the pack from harm in varying Botswanan conditions.
Series strings and pack voltage scalingParallel groups and current capabilityModule construction, busbars, and fusingSensing harnesses and module monitoring ICsCell balancing strategies: passive and activeBMS protection limits and fault responsesLesson 8Battery Status Measures: Charge Level (SoC), Health Level (SoH), Power Level (SoP), and Common Ways to Measure and Set Diagnostic LimitsThis part defines charge level, health level, and power level, describes usual calculation methods and sensor data, and shows how makers set warning limits that lead to alerts, power cuts, or repair needs for Botswanan technicians.
State of charge concepts and estimationState of health indicators and capacity lossState of power and dynamic limitsVoltage, current, and temperature inputsKalman filters and model-based observersDiagnostic thresholds and DTC strategies
