Lesson 1Battery Pack Design and Positions: Underfloor, Rear Cargo, Engine Bay—Service Access, Heat Management, and Crash Safety FactorsThis part looks at where hybrid and PHEV battery packs are fitted in vehicles, how their placement impacts maintenance ease, cooling, noise levels, and safety in crashes, and what mechanics need to 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 vs Air Cooling, Coolant Paths, Sensors, and Effects on Electric Range and DurabilityThis part compares air and liquid cooling methods for HV batteries, looks at coolant paths, pumps, valves, and sensors, and shows how keeping temperatures right affects power output, available energy, driving range, and battery lifespan 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 3Standard Pack Voltages: Usual Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and BEVs and How Pack Setup Affects VoltageThis part reviews common voltage ranges for mild, full, and plug-in hybrids, plus BEVs, and explains how the number of cells in series, module setup, and switching parts set the standard 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 Wiring, Connectors, Service Plugs, and Safety Locks: Colour Coding, Insulation, Shielding, and Typical Damage TypesThis part details high-voltage cables, connectors, and safety locks, covering orange colour coding, insulation types, shielding against electrical noise, lockout features, and how to spot, test, and record common damage or failures 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 Support Systems: DC-DC Converters, Onboard Charger, EVSE Connection, 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 how power moves 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 in hybrids and PHEVs, including Li-ion types like NMC and LFP, plus NiMH, and explains how each type impacts energy storage, power delivery, cycle life, cost, and safety features.
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 the Battery Management System (BMS)This part explains how cells are arranged into modules and packs with series and parallel links, how current and voltage adjust, and how the BMS watches modules, balances cells, and guards the pack against harmful 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: State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Common Measurement Methods and Alert LevelsThis part defines state of charge, state of health, and state of power, describes usual calculation methods and sensor data, and shows how manufacturers set alert levels that trigger warnings, power cuts, or service needs.
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
