Lesson 1Battery Pack Arrangement and Places: Under the Floor, Back Cargo, Engine Area—Service Reach, Heat Handling, and Crash Safety ThoughtsThis part looks at where hybrid and PHEV battery packs are put in the vehicle, how the setup affects easy fixing, cooling, noise, and crash safety, and what mechanics must check 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 Handling for High-Voltage Batteries: Liquid vs Air Cooling, Coolant Paths, Sensors, and Effects on Electric Range and Long LifeThis part compares air and liquid cooling ways for HV batteries, looks at coolant paths, pumps, valves, and sensors, and explains how keeping temperature right affects power limits, usable energy, range, and battery life over time.
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 3Normal Pack Voltages: Common Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and BEVs and How Pack Setup Affects VoltageThis part reviews usual pack voltage ranges for mild, full, and plug-in hybrids, as well as BEVs, and explains how number of cells in series, module setup, and switching parts set the normal voltage and safety limits.
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 Locks: Color Marks, Insulation, Shielding, and Common Damage WaysThis part details high-voltage cables, connectors, and locks, including orange color marks, insulation systems, shielding for noise, lockout features, and how to find, test, and record common damage or failure ways 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 Extra Systems: DC-DC Converters, Onboard Charger, EVSE Inlet, and Power Electronics Basics (Inverter, Motor)This part introduces high-voltage extra hardware, including DC-DC converters, onboard chargers, charge inlets, inverters, and motor drives, and explains power flow paths between the battery, 12 V system, and drive parts.
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/PHEVs (Li-ion, NMC, LFP, NiMH) and How Type Affects Performance, Wear, and SafetyThis part surveys main battery types used in hybrids and PHEVs, including Li-ion kinds like NMC and LFP, plus NiMH, and explains how each type affects energy amount, power ability, cycle life, cost, and safety ways.
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 Arrangements, Module Watching, and Role of the Battery Management System (BMS)This part explains how cells are grouped into modules and packs using series and parallel links, how current and voltage grow, and how the BMS watches modules, balances cells, and protects the pack from bad 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 Signs: State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Their Usual Measurement Ways and Check LimitsThis part defines state of charge, state of health, and state of power, describes usual guess methods and sensor inputs, and shows how makers set check limits that start warnings, power cuts, or fix 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
