Lesson 1Battery pack layout an' locations: underfloor, rear cargo, engine bay—service access, thermal management, an' crash protection considerationsDis section examine where hybrid an' PHEV battery packs place in di vehicle, how layout affect serviceability, coolin', NVH, an' crash safety, an' wha' technicians mus' check before removin' or reinstallin' 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 2Thermal management fi high-voltage batteries: liquid vs air coolin', coolant circuits, sensors, an' implications fi electric range an' longevityDis section compare air an' liquid coolin' strategies fi HV batteries, review coolant circuits, pumps, valves, an' sensors, an' explain how temperature control influence power limits, usable energy, range, an' long-term battery life.
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 3Nominal pack voltages: common ranges fi mild hybrids, full hybrids, plug-in hybrids, an' BEVs an' how pack topology affect voltageDis section review typical pack voltage ranges fi mild, full, an' plug-in hybrids, as well as BEVs, an' explain how series cell count, module configuration, an' switchin' devices determine nominal voltage an' safety boundaries.
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 cablin', connectors, service plugs, an' interlocks: colour codin', insulation, shieldin', an' common damage modesDis section detail high-voltage cables, connectors, an' interlocks, includin' orange colour codin', insulation systems, shieldin' fi EMI, lockout features, an' how to identify, test, an' document common damage or failure modes safely.
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 auxiliary systems: DC-DC converters, onboard charger, EVSE inlet, an' power electronics basics (inverter, motor)Dis section introduce high-voltage auxiliary hardware, includin' DC-DC converters, onboard chargers, charge inlets, inverters, an' motor drives, an' explain power flow paths between di battery, 12 V system, an' traction components.
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 chemistries use in modern hybrids/PHEVs (Li-ion, NMC, LFP, NiMH) an' how chemistry influence performance, degradation, an' safetyDis section survey major chemistries use in hybrids an' PHEVs, includin' Li-ion variants such as NMC an' LFP, plus NiMH, an' explain how each chemistry affect energy density, power capability, cycle life, cost, an' safety behaviour.
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 an' cell architecture: series/parallel arrangements, module monitorin', an' role of di battery management system (BMS)Dis section explain how cells group into modules an' packs usin' series an' parallel connections, how current an' voltage scale, an' how di BMS monitor modules, balance cells, an' protect di pack from damagin' 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 state metrics: state of charge (SoC), state of health (SoH), state of power (SoP), an' dem typical measurement methods an' diagnostic thresholdsDis section define state of charge, state of health, an' state of power, describe typical estimation algorithms an' sensor inputs, an' show how OEMs set diagnostic thresholds dat trigger warnings, deratin', or service actions.
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
