Lesson 1Battery pack arrangement and positions: underfloor, back cargo, engine compartment—service access, heat management, and crash protection considerationsDis section go look at where hybrid and PHEV battery packs dey place in di vehicle, how arrangement affect serviceability, cooling, noise, and crash safety, and wetin technicians must check before removing or reinstalling a pack.
Underfloor pack designs and structural fittingBack cargo pack placement and space trade-offsEngine compartment 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 circuits, sensors, and implications for electric range and longevityDis section go compare air and liquid cooling strategies for HV batteries, review coolant circuits, pumps, valves, and sensors, and explain how temperature control influence power limits, usable energy, range, and long-term battery life.
Air-cooled pack arrangements 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 topology affect voltageDis section go review typical pack voltage ranges for mild, full, and plug-in hybrids, as well as BEVs, and explain how series cell count, module configuration, and switching devices determine normal voltage and 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 cabling, connectors, service plugs, and interlocks: color coding, insulation, shielding, and common damage modesDis section go detail high-voltage cables, connectors, and interlocks, including orange color coding, insulation systems, shielding for EMI, lockout features, and how to identify, test, and 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, and power electronics basics (inverter, motor)Dis section go introduce high-voltage auxiliary hardware, including DC-DC converters, onboard chargers, charge inlets, inverters, and motor drives, and explain power flow paths between di battery, 12 V system, and 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 used in modern hybrids/PHEVs (Li-ion, NMC, LFP, NiMH) and how chemistry influence performance, degradation, and safetyDis section go survey major chemistries used in hybrids and PHEVs, including Li-ion variants such as NMC and LFP, plus NiMH, and explain how each chemistry affect energy density, power capability, cycle life, cost, and safety behavior.
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 architecture: series/parallel arrangements, module monitoring, and role of the battery management system (BMS)Dis section go explain how cells dey grouped into modules and packs using series and parallel connections, how current and voltage scale, and how di BMS monitor modules, balance cells, and protect di pack from damaging 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), and their typical measurement methods and diagnostic thresholdsDis section go define state of charge, state of health, and state of power, describe typical estimation algorithms and sensor inputs, and show how OEMs set diagnostic thresholds wey trigger warnings, derating, 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
