Hybrid and Electric Vehicle Systems
I.D. # C1504 Duration 3 Days

Hybrid Electric Vehicle (HEV), Plug-In Hybrid Electric Vehicle (PHEV), and Battery Electric Vehicle (BEV) technology model offerings and production volumes continue to accelerate with each model year. Advanced technology vehicle populations are significantly increasing throughout the world, making it vital for engineers, technicians, and educators to have a thorough understanding of these technologies and systems. This three-day practical and applications-based course will concentrate on architectures, operation, functions, and design considerations of the safety, power electronics, energy systems, and failure modes associated with HEV and BEV vehicles, providing an environment in which participants can acquire a solid systems and integration foundation for applying this content to vehicle/systems design. Practical systems and circuit analyses with calculations will be used throughout the course.
Learning Objectives
By completing this course, you will be able to:

  • Identify the different hybrid and electric vehicle (HEV) architectures
  • Follow a procedure for safe interaction with high voltage
  • Identify the components of HEV safety systems, controls, and diagnostics
  • Consider the architectural options for controls and diagnostics
  • Identify energy management components and functions
  • Identify electric motor components and functions



Who Should Attend
This course is designed for engineers, scientists, and technicians who are involved with the design, development, manufacturing, or service of electrified vehicles or subsystems.
Prerequisites

An engineering degree is highly recommended, but not required. This course does not cover basic electrical concepts and assumes that the attendee already understands such concepts (voltage, current, resistance, capacitance, inductance, impedance, phase angles, current-to-frequency ratios, semiconductors, and software control strategies). In order to best understand concepts discussed, all participants are encouraged to have driven an HEV prior to attending the course.


Seminar Content

DAY ONE



HEV/BEV Systems Operation Modes, Torque Production and Component Contributions


  • HEV
  • PHEV
  • BEV


High Voltage Safety ¿ Personal Protection Equipment

  • High Voltage Safety Gloves
  • High Voltage Systems
  • Using Meters, Oscilloscopes, Insulation Meters, and HiPot Equipment to Test High Voltage System Components


HEV/PHEV/BEV ¿ Vehicle Safety Systems, Controls and Diagnostics

  • Battery Pack Manual Disconnect Systems
  • High Voltage Interlock Circuits
  • High Voltage Bus Active and Passive Discharge Circuits
  • Isolation Fault Detection Circuits
  • CAN Parameter ID Structure for Safety Systems and Diagnostics



DAY TWO



Rechargeable Energy Management (Battery Pack) Systems, Controls and Diagnostics


  • Hardware Components
  • Overview of NiMH and Li-Ion Battery Technologies

    • NiMH and Lithium Battery Families
    • Module/cell sensing systems (voltage, temp, air, etc.)
    • Lithium Battery Pack Balancing Systems
    • Battery systems service considerations


  • Thermal Management Systems

    • Passive and Active Air Heating and Cooling Systems
    • Liquid Heating and Cooling Systems
    • Using Air Conditioning Low Pressure Gas System to Cool Battery Modules


  • Battery Pack/Module Testing

    • HEV/PHEV/BEV Power Testing
    • HEV/PHEV/BEV Energy (Capacity) Testing
    • Lab and Field Grade Equipment for Battery Testing
    • Automotive Field Experiences with NiMH and Lithium Battery Systems



DAY THREE


HEV/BEV ¿ Permanent Magnet (PM) and Induction Machine (IM) Electric Machine and
Power Inverter Technologies



  • PM and IM Technologies

    • Permanent Magnet Electric machine construction and operation
    • Induction Electric machine construction and operation
    • Rotor position and speed sensing: Resolvers
    • PM-IM failure modes
    • On/off-board electric machine testing ¿ insulation meter, electric signature, oscilloscope, and HiPot

  • Power Inverter Technology and Electric Machine Control

    • Power electronics devices: IGBTs and Gate Drives
    • Sensing circuits: Current Sensing and Using External Controller CAN Inputs/Outputs
    • Electric machine controls - torque and speed controls, wave shaping (sine wave, six-step), current regulation
    • Failure modes
    • Power Inverter Testing: Analyzing Waveforms using Oscilloscopes, Current Probes


  • dc-dc Converter Systems

    • Buck converter
    • Buck/Boost converter
    • Failure modes
    • Testing




Instructor(s): Mark Quarto
Dr. Mark Quarto is currently the Chief Technology Officer (CTO) for Quarto Technical Services where he is responsible for the design/development of diagnostic test equipment and software, technical education and training programs, and technology innovations focused on hybrid and electric vehicle propulsion and energy management systems. Dr. Quarto previously worked within the General Motors Company as an Engineer and Engineering Group Manager in Advanced Powertrain Technology Systems / Global Aftermarket Engineering where he was responsible for the management and development of control and diagnostics systems and service solutions for the Chevrolet Volt, Fuel Cell, Two-Mode Hybrid, Parallel Hybrid Truck (PHT), EV1 Electric Vehicle, S10 Electric Truck, and Alternative Fuel Systems Programs. He also served as the Service Training Development Manager and Resident Service School Instructor. Mark began his automotive career as a technician at both dealership and aftermarket facilities. In addition to his accomplishments and experiences while working at General Motors, Mark has served as a Chief Engineer, Senior Consultant, Author, and Subject Matter expert in Hybrid, Electric, and Fuel Cell Technologies. Dr. Quarto has a Bachelor¿s Degree in Electrical Engineering from LaSalle University specializing in Power Electronics; a Bachelor¿s Degree in Automotive Technology from Ferris State University; Master¿s Degree in Technical Education from Ferris State University specializing in electric and hybrid propulsion systems; and a Doctorate in Technical Education from Nova Southeastern University, specializing in designing and developing learning systems for hybrid/electric vehicles and high voltage energy and propulsion systems.


Fees: $1745 SAE Members*: $1396 - $1571
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary  according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
CEU 2