Lesson 1Battery Pack Arrangement and Positions: Underfloor, Boot Area, Engine Compartment—Service Access, Heat Management, and Crash Safety ChecksThis part looks at where hybrid and PHEV battery packs are fitted in the vehicle, how their position affects ease of service, cooling, noise levels, and safety in accidents, and what mechanics should inspect before taking out or putting back a pack.
Underfloor pack designs and body integrationBoot area pack fitting and space compromisesEngine compartment packs and heat dangersService entry points, lifting and removal routesCrash safety areas and impact protectionLesson 2Heat Management for High-Voltage Batteries: Liquid vs Air Cooling, Coolant Paths, Sensors, and Effects on Electric Range and Battery LifeThis part compares air and liquid cooling methods for HV batteries, looks at coolant paths, pumps, valves, and sensors, and shows how keeping temperature right affects power output, available energy, travel distance, and how long the battery lasts.
Air-cooled pack setups and air flow routesLiquid-cooled plates, covers, and coolersCoolant pumps, valves, and heat exchangersTemperature, flow, and pressure sensorsCold weather pre-heating and warmersHeat limits, power reduction, and wear effectsLesson 3Standard Pack Voltages: Usual Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and Full EVs and How Pack Setup Affects VoltageThis part reviews common voltage levels for mild, full, and plug-in hybrids, plus full EVs, and explains how number of cells in series, module setup, and switching parts set the standard voltage and safety limits.
Voltage ranges for mild hybrid setupsFull hybrid and PHEV voltage levelsEV pack voltages and divisionsSeries cell numbers and module pilingContactors, pre-charge, and HV bus designVoltage class, safety gear, and service limitsLesson 4High-Voltage Cables, Connectors, Service Plugs, and Safety Locks: Colour Codes, Insulation, Shielding, and Common Damage TypesThis part details high-voltage cables, connectors, and safety locks, including orange colour coding, insulation types, shielding against interference, lockout features, and how to spot, test, and record common damages or failures safely.
Orange HV cable standards and labelsInsulation kinds, gap and space limitsShielding, earthing, and interference controlService plugs, cut-offs, and lockout stepsSafety lock chains, continuity tests, and errorsCommon wear, rust, and spark damagesLesson 5High-Voltage Support Systems: DC-DC Converters, Onboard Charger, Charging Port, 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 between battery, 12V system, and drive parts.
DC-DC converter jobs and setupsOnboard charger stages and power factorsCharging port types and signal basicsInverter working and pulse control fundamentalsMotor types in hybrids and PHEVsEarthing, separation, and leak testsLesson 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 kinds like NMC and LFP, plus NiMH, and explains how each type impacts energy storage, power output, cycle durability, cost, and safety features.
Main Li-ion cell parts and reactionsNMC type features for hybrids and PHEVsLFP type features and safety benefitsNiMH type and old hybrid systemsType effects on energy and power densityType-based safety and stress responsesLesson 7Battery Module and Cell Setup: Series/Parallel Links, Module Monitoring, and Role of Battery Management System (BMS)This part explains how cells are joined into modules and packs with series and parallel links, how current and voltage increase, and how the BMS watches modules, balances cells, and guards the pack from harmful conditions.
Series chains and pack voltage increaseParallel groups and current strengthModule building, bus bars, and fusesSensor wires and module watch chipsCell balancing methods: simple and advancedBMS guard limits and error responsesLesson 8Battery Status Measures: Charge Level (SoC), Health Level (SoH), Power Level (SoP), and Common Measurement Ways and Alert PointsThis part defines charge level, health level, and power level, describes usual calculation methods and sensor data, and shows how makers set alert points that start warnings, power cuts, or service needs.
Charge level ideas and calculationsHealth level signs and capacity lossPower level and changing limitsVoltage, current, and temperature dataFilter methods and model watchersAlert points and error code plans
