Lesson 1Battery Pack Design and Positions: Underfloor, Rear Boot, Engine Compartment—Service Access, Heat Management, and Crash Safety FactorsThis part looks at where hybrid and PHEV battery packs are fitted in the vehicle, how the design impacts ease of service, cooling, noise levels, and crash protection, and what mechanics need to inspect before taking out or putting back a pack.
Underfloor pack designs and body integrationRear boot pack fitting and space compromisesEngine compartment packs and heat risksService access spots, lifting and removal routesCrash protection areas and impact reductionLesson 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 temperature control affects power output, available energy, range, and battery lifespan over time.
Air-cooled pack designs and air flow routesLiquid-cooled plates, jackets, and coolersCoolant pumps, valves, and heat exchangersTemperature, flow, and pressure sensorsCold-weather pre-heating and heatersHeat limits, power reduction, and ageing effectsLesson 3Standard Pack Voltages: Usual Ranges for Mild Hybrids, Full Hybrids, Plug-In Hybrids, and BEVs and How Pack Setup Affects VoltageThis part reviews typical pack 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 setupsFull hybrid and PHEV voltage rangesBEV pack voltages and divisionsSeries cell numbers 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 Common Damage TypesThis part details high-voltage wires, connectors, and safety locks, including orange colour coding, insulation types, shielding against interference, lockout features, and how to spot, test, and record common damage or failures safely.
Orange HV wire standards and markingsInsulation types, creepage and clearance limitsShielding, grounding, and interference controlService plugs, disconnects, and lockout stepsSafety lock loops, continuity tests, and faultsTypical wear, rust, and arc damageLesson 5High-Voltage Support Systems: DC-DC Converters, Onboard Charger, EVSE Socket, and Power Electronics Basics (Inverter, Motor)This part introduces high-voltage support parts, including DC-DC converters, onboard chargers, charge sockets, inverters, and motor drives, and explains power flow between the battery, 12 V system, and drive parts.
DC-DC converter roles and designsOnboard charger stages and power factorsEVSE socket types and communication basicsInverter operation and PWM fundamentalsMotor types in hybrids and PHEVsGrounding, isolation, and leakage testsLesson 6Battery Types in Modern Hybrids/PHEVs (Li-ion, NMC, LFP, NiMH) and How Type Influences 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 affects energy storage, power output, cycle life, cost, and safety features.
Key Li-ion cell parts and reactionsNMC type traits for hybrids and PHEVsLFP type traits and safety benefitsNiMH type and older hybrid systemsType effects on energy and power densityType-driven safety and stress responseLesson 7Battery Module and Cell Setup: Series/Parallel Arrangements, Module Monitoring, and Role of the Battery Management System (BMS)This part explains how cells are grouped 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 strings and pack voltage scalingParallel groups and current capacityModule building, busbars, and fusingSensing wires and module monitoring chipsCell balancing methods: passive and activeBMS protection limits and fault responsesLesson 8Battery Status Measures: State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Usual Measurement Methods and Alert LevelsThis part defines state of charge, state of health, and state of power, describes common estimation methods and sensor data, and shows how manufacturers set alert levels that trigger warnings, power cuts, or service needs.
State of charge ideas and estimationState of health signs and capacity lossState of power and dynamic limitsVoltage, current, and temperature inputsKalman filters and model-based watchersAlert levels and fault code strategies
