Lesson 1Battery pack layout and locations: underfloor, rear cargo, engine bay—service access, thermal management, and crash protection considerationsThis section looks at where hybrid and PHEV battery packs are positioned in the vehicle, how layout impacts serviceability, cooling, noise-vibration-harshness, and crash safety, and what technicians need to inspect before removing or reinstalling 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 2Thermal management for high-voltage batteries: liquid vs air cooling, coolant circuits, sensors, and implications for electric range and longevityThis section compares air and liquid cooling methods for HV batteries, examines coolant circuits, pumps, valves, and sensors, and describes how temperature control affects power limits, usable energy, range, and long-term battery lifespan.
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 3Nominal pack voltages: common ranges for mild hybrids, full hybrids, plug-in hybrids, and BEVs and how pack topology affects voltageThis section reviews typical pack voltage ranges for mild, full, and plug-in hybrids, as well as BEVs, and explains how series cell count, module setup, and switching devices determine nominal 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 cabling, connectors, service plugs, and interlocks: colour coding, insulation, shielding, and common damage modesThis section details high-voltage cables, connectors, and interlocks, including orange colour coding, insulation systems, shielding for electromagnetic interference, 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)This section introduces high-voltage auxiliary 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 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 influences performance, degradation, and safetyThis section surveys major chemistries used in hybrids and PHEVs, including Li-ion variants such as NMC and LFP, plus NiMH, and explains how each chemistry impacts energy density, power capability, cycle life, cost, and safety behaviour.
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)This section explains how cells are grouped into modules and packs using series and parallel connections, how current and voltage scale, and how the BMS monitors modules, balances cells, and protects the 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 thresholdsThis section defines state of charge, state of health, and state of power, describes typical estimation algorithms and sensor inputs, and shows how manufacturers set diagnostic thresholds that 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
