Lesson 1Battery Pack Design and Positions: Underfloor, Rear Storage, Engine Area—Access for Maintenance, Heat Control, and Crash SafetyThis part looks at where hybrid and PHEV battery packs are fitted in vehicles, how design impacts maintenance ease, cooling, noise levels, and safety in crashes, and what mechanics in Eritrea should inspect before removing or fitting 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 Control for High-Voltage Batteries: Liquid versus Air Cooling, Coolant Paths, Sensors, and Effects on Electric Range and DurabilityThis part compares air and liquid cooling methods for HV batteries, examines coolant paths, pumps, valves, and sensors, and shows how temperature management affects power output, energy use, range, and battery lifespan in hot Eritrean climates.
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 Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and BEVs and How Pack Structure Influences VoltageThis part reviews common voltage ranges for mild, full, and plug-in hybrids, plus BEVs, and explains how cell numbers in series, module setup, and switches set standard voltage and safety limits for Eritrean technicians.
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, Shielding, and Typical Damage TypesThis part details high-voltage cables, connectors, and safety locks, covering orange colour codes, insulation types, EMI shielding, lockout tools, and safe ways to spot, test, and record common damage or failures in Eritrean workshops.
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 Power Electronics Basics (Inverter, Motor)This part introduces high-voltage support parts, like DC-DC converters, onboard chargers, charge ports, inverters, and motor drives, and explains power flow from battery to 12V system and drive parts for reliable Eritrean service.
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 in Modern Hybrids/PHEVs (Li-ion, NMC, LFP, NiMH) and How Type Affects Performance, Wear, and SafetyThis part surveys main battery types in hybrids and PHEVs, including Li-ion types like NMC and LFP, plus NiMH, and explains how each impacts energy storage, power delivery, cycle life, cost, and safety in Eritrean use.
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/Parallel Links, Module Monitoring, and Role of Battery Management System (BMS)This part explains how cells form modules and packs with series and parallel links, how current and voltage adjust, and how BMS monitors modules, balances cells, and guards against harm in Eritrean vehicle maintenance.
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: State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Common Measurement and Diagnostic LevelsThis part defines charge level, health status, and power state, describes estimation methods and sensor data, and shows how makers set warning levels for alerts, power cuts, or service needs in Eritrean diagnostics.
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
