Day 5 Practical and Written Final SAE Exams for SAE Int l Advanced HEV Diagnostics CoC
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1 One of the fastest growing automotive sectors is the field of vehicles using electric propulsion systems. These technologies are providing significant opportunities and challenges to automotive instructors and technicians. The topics covered in this course are designed to prepare them to take and pass the Society of Automotive Engineers (SAE) International Advanced HEV Diagnostics Exam. Upon successful completion SAE awards their Certificate of Competency. The participants must complete the first 4-days of coursework with on-line assessments prior to taking the hands on practical assessment and final written exam on Day 5. Upon successful completion of the course, practical/hands-on assessment, and written final exam the participant would be awarded (from the SAE International) an SAE International Advanced HEV Diagnostics Certificate of Competency (CoC - Credential). Hybrid & Electric Vehicles comprise a significantly different powertrain operation than traditional automotive vehicle. High voltage safety systems, Atkinson-cycle engines, electric motor-generator units (MGU), and battery pack (energy management) systems are some of the major building blocks in understanding HEV systems operation and associated diagnostic systems. This Hybrid & Electric Vehicle Level 1 course is designed to provide the participant with extensive classroom and hands-on activities covering the necessary building blocks to ensure a comprehensive understanding of these HEV systems and associated components. This combination of classroom and hands-on course (with Day 5 dedicated to the hands-on practical assessment and FINAL written SAE Exam) will cover the fundamentals through advanced Hybrid & Electric vehicle concepts on topics such as, electrical personal safety, high voltage vehicle safety systems and controls, permanent magnet and ac induction MGU construction and operation, how torque is blended using the engine and electric propulsion system, HEV systems design and operation, battery pack systems design, operation including its control systems and battery module types. Basic and enhanced diagnostic considerations and failure mode conditions for each system will also be covered for all of the topics within the course. Also included will be the discussion and use of oscilloscopes, current probes, differential scope probes, electric machine test equipment, and specific scan tool PIDs to be used to support hands-on exercises for understanding and applying analysis and diagnostics Days 1 4 o There will be an on-line assessment/quiz supporting all topics covered each day Completion/results are applied toward requirements and preparation to successfully complete Final SAE EXAM for CoC on Day 5 Day 5 Practical and Written Final SAE Exams for SAE Int l Advanced HEV Diagnostics CoC o o Practical/hands-on diagnostic & safety competency test/assessment administered and proctored by an AR&D certified instructor Final (on-line) Written Exam proctored by an AR&D certified instructor Auromotive Research and Design. All Rights Reserved. Page 1
2 Course Content includes: The three main types of hybrid electric vehicles (Series, Parallel, and Series-Parallel) o Identify the common hybrid powertrain subsystems o Series, parallel, and series/parallel power flow Advantages of the various hybrid vehicle configurations o Operating characteristics of series, parallel, and series/parallel hybrids Efficiency differences between traditional gasoline and hybrid electric vehicle propulsion systems o Operating efficiency of a traditional automotive gasoline propulsion system o Operating efficiency of an automotive electric propulsion system o How the hybrid electric vehicle system uses the engine and electric propulsion systems to achieve maximum efficiency during operation The effects of various circuit failures in both series and parallel circuits o Classifying a circuit as being series, parallel, and series/parallel o Ohm s Law Watt s law o How an electric motor can produce more power without increasing the conductor size o Principles of electromagnetism to electric drive systems o The relationship between electricity and magnetism o Self and mutual inductance o How air gap distances effect magnetic fields Choosing the correct personal protective equipment (PPE) to safely work on a high voltage system o Appropriate clothing to be worn when servicing HV systems o Correct classification of high voltage gloves that must be worn when servicing HV systems o Inspection/testing requirements for HV gloves o Importance of wearing appropriate safety glasses when servicing high voltage systems Auromotive Research and Design. All Rights Reserved. Page 2
3 Correct equipment to test a high voltage circuit o The level of voltage protection provided by Class 0 gloves Why a differential input/probe is required on an oscilloscope when testing an HV circuit o How various levels of electrical current affect the human body Testing the insulation of a high voltage circuit or component o Voltage levels associated with Low, Intermediate, and High o How to use an insulation tester on an HV circuit o Identifying a high voltage cable or wire by its color Differentiating the HV system ground from Earth ground o Current paths to and from the hybrid drive system battery o Current paths that involve earth ground The purpose of an isolation-fault detection system Local interlock system with a serial interlock system o What is a local interlock system o What is a serial interlock system Differences between an active and a passive bus discharge circuit o The purpose of an HV bus discharge circuit o The operation of an active bus discharge circuit o The operation of a passive bus discharge circuit Testing HV bus discharge circuit for proper operation o The various types of HV service disconnects o Minimum CAT/Voltage rating a multi-meter must meet to be used safely on EV/HEV o The one hand rule for working on electrical circuits Vehicle Isolation Fault Diagnostic Systems o dc isolation fault diagnostic systems o ac isolation fault diagnostic systems o Why it is necessary to have both dc and ac isolation fault diagnostic systems How the vehicle system can identify an isolation fault using serial data tool PIDs and Diagnostic Trouble Codes (DTC) o The appropriate serial data (scan) tool to use on the vehicle being tested o Serial data tool PIDs that relate to isolation fault detection Auromotive Research and Design. All Rights Reserved. Page 3
4 Difference between an Otto-cycle and an Atkinson-cycle engine o The operating characteristics of an Atkinson-cycle engine o How variable valve timing cam be used to simulate the Atkinson-cycle design o How an Atkinson-cycle engine utilizes energy efficiently from the fuel it burns Benefits of supplementing an Atkinson-cycle engine with an electric drive system o The torque, rpm, and efficiency characteristics of an Atkinson-cycle engine o The torque, rpm, and efficiency characteristics of an electric motor o How the hybrid system uses the Atkinson-cycle engine and the electric propulsion system to optimize efficiency and fuel economy The methods of controlling electric machine torque and speed o The effect a change in current has on motor torque o The effect a change in frequency has on motor speed o Regenerative braking Comparing a PMBDC Machine to an AC Induction Machine o The two types of electric machines commonly used in automotive applications o The common core components found in all electric machines o The basic operation of a PMBDC Machine o The basic operation of an AC Induction Machine Comparing the operation of an AC Induction machine to a transformer o How mutual induction is utilized in an AC induction machine o How the interaction between the stator and the rotor causes the rotor to rotate Comparison of a PMBDC rotor and an AC Induction Machine rotor o Describe the construction of a Permanent Magnet rotor o Describe the construction of an AC Induction Machine rotor Comparison of a distributed wound stator and a concentrated wound stator o The basic construction of a stator o The two basic configurations of stators o The characteristics of a distributed wound stator o The characteristics of a concentrated wound stator Difference between a synchronous and an asynchronous motor o Lead/lag as it relates to a PMBDC machine o Slip (positive, zero, negative) as it relates to an AC induction machine o Field weakening as it applies to PMBDC machines Auromotive Research and Design. All Rights Reserved. Page 4
5 o The relationship between the speed of the rotor rotation and the speed of the stator rotation Electric Machine Failure Modes o The common failure modes of distributed and concentrated winding stators o The difference in how open and shorted winding failures effect distributed and concentrated winding stators o The common failure modes of permanent magnet and induction machine rotors and how their operation is effected o The symptom of electric machine rotor bearing failure Testing an electric machine using an AT33EV o Motor test connection points o How to properly connect the AT33EV to the motor o How to perform a static motor test o How to perform a dynamic motor test Interpreting the results of an electric motor test report o Potential failure modes of electric machines o The limitations of testing an electric machine using a milliohm meter and/or an insulation tester o The various sections of an AT33EV motor test report The layout of a typical high voltage battery pack o The main components of a typical high voltage battery pack o The typical location of the high voltage system fuse o The high voltage contactors o The operation of the terminal-voltage sensing circuits Comparing the various types of battery cell designs used in hybrid vehicles o Prismatic cells o Cylindrical cells o Cell venting Comparing active and passive battery cooling systems o Typical passive battery cooling system o Typical active battery cooling system o The purpose of battery temperature sensor(s) The operation of the battery-pack contactor system o The purpose of the pre-charge contactor o The operation of the battery-pack contactor system Auromotive Research and Design. All Rights Reserved. Page 5
6 Comparing energy density to power density o Energy density o Power density o The importance of energy density in a hybrid vehicle battery o The importance of power density in a hybrid vehicle battery Chemical and physical characteristics of a Nickel-metal hydride battery o The materials that make up the positive electrode o The materials that make up the negative electrode o The electrolyte mixture contained in nickel-metal hydride cells o The charge and discharge process within a nickel-metal hydride cell o Gas recombination in a battery o Charge and discharge curves (characteristics) of nickel-metal hydride cells o Nickel-metal hydride cell self-discharge characteristics The ability of an onboard system to test a high voltage battery o Battery data available in scan tool PIDs o The importance of testing a battery for energy, power, and balance o Comparing the differences between vehicle on-board battery tests with function tests and PIDs vs. using off-board commercial battery testing equipment and tests o The process of testing a battery for energy and power Auromotive Research and Design. All Rights Reserved. Page 6
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