Lesson 1Battery Pack Arrangement and Places: Under the Floor, Back Storage, Engine Area—Ways to Reach for Service, Heat Handling, and Protection from CrashesThis part looks at where battery packs in hybrid and PHEV vehicles are put, how the arrangement affects easy fixing, cooling, noise from shaking, and safety in accidents, and what mechanics need to look at 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 Against Air Cooling, Coolant Paths, Sensors, and Effects on Electric Travel Distance and Lasting TimeThis part compares air and liquid ways to cool HV batteries, looks at coolant paths, pumps, valves, and sensors, and shows how keeping temperature right affects power limits, energy you can use, travel distance, and how long the battery lasts.
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 3Usual Pack Voltages: Common Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and BEVs and How Pack Setup Affects VoltageThis part reviews usual voltage ranges for mild, full, and plug-in hybrids, plus BEVs, and explains how number of cells in series, module setup, and switching tools set the usual 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: Colour Marks, Insulation, Shielding, and Common Ways They Get DamagedThis part details high-voltage cables, connectors, and locks, including orange colour marks, insulation setups, 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 Extra Systems: DC-DC Converters, Onboard Charger, EVSE Inlet, and Power Electronics Basics (Inverter, Motor)This part introduces high-voltage extra tools, including DC-DC converters, onboard chargers, charge inlets, inverters, and motor drives, and explains power flow paths between the battery, 12 V system, and parts that move the vehicle.
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 Chemicals Used in Modern Hybrids/PHEVs (Li-ion, NMC, LFP, NiMH) and How Chemistry Affects Work, Wearing Out, and SafetyThis part looks at main chemicals used in hybrids and PHEVs, including Li-ion types like NMC and LFP, plus NiMH, and explains how each affects energy amount, power strength, 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 guards 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 Measures: State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Their Usual Ways to Measure and Warning LevelsThis part defines state of charge, state of health, and state of power, describes usual ways to guess and sensor inputs, and shows how makers set warning levels that start alerts, 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
