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Upon completion of the course, students will be able to:
1. Demonstrate knowledge of introductory principles, motor and generator basics, and battery basics.
2. Perform routine hybrid vehicle repairs and maintenance using manufacturer specifications.
3. Demonstrate safety procedures and describe their critical importance.
4. Describe and demonstrate knowledge of system specific repairs and maintenance.
5. Use test equipment appropriately to diagnose hybrid system-related problems.
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A. Introductory Principles
1. Hybrid and electric vehicle vocabulary
2. Hybrid and electric vehicles in production
3. Types of hybrid systems
a. Series
b. Parallel
c. Series/parallel
d. Mild and assist hybrids
e. Plug-in hybrids
4. Electrical theory basics and safety implications
B. Motor and Generator Basics
1. Basic motor operations
a. Series
b. Parallel
2. Generators
3. Motor generators
4. Controllers
C. Battery Basics
1. Lead-Acid (Pb-A)
2. AGM (Absorbed Gas Mat) Battery (12 volt system)
3. High-Voltage (HV) System Batteries
a. NiMH (Nickel Metal Hydride)
b. Lithium-Ion (Li-Ion) and other new battery technologies
c. Importance of HV state-of-charge
D. Hybrid System Components and Operation
1. System components
a. Internal combustion engine (ICE) and motor generator (MG)
b. Battery pack
c. Rectifiers, inverters, converters
d. Cables, switches
2. Battery charging
3. Regenerative braking
4. Driving
E. Safety
1. Personal safety
2. Electrical safety gloves
3. Tools and equipment
a. Mega-ohm meter
b. Scanners (eg, Toyota Technical Information System (TIS))
c. Using appropriate fluids
4. Safety procedures (shop)
a. Depowering HV system
b. Importance of ensuring auto in shutdown mode
c. Repowering HV System
5. Safety procedures (test driving)
F. Honda and/or GM (Mild Hybrid) Systems
1. Routine maintenance (unique to this type of hybrid system)
a. System-specific fluids
b. Other system-specific requirements (e.g., brakes)
2. Diagnostics (for Hybrid-system related problems)
a. Types and use of test equipment
b. Reading data codes
c. Assuring proper use of fluids
G. Toyota and/or Nissan and/or Ford (Full Hybrid) Systems
1. Routine maintenance (unique to this type of hybrid system)
a. System-specific fluids
b. Other system-specific requirements (e.g., brakes)
2. Diagnostics (for Hybrid-system related problems)
a. Types and use of test equipment
b. Reading data codes
c. Assuring proper use of fluids
H. Plug-in Hybrids
1. Battery pack
2. Installation
3. Interface to car
4. Charger
5. Troubleshooting
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1. Conduct routine diagnostics and maintenance on a college vehicle (or vehicles)
2. Written paper analyzing one of the current (Toyota, Honda, Nissan or GM) Hybrid auto
systems (3-5 pages)
3. Orally summarize findings of group diagnostic results and present to class
4. Evaluations of on-line resources
5. Textbook and hand-out reading assignments (approximately 10-25 pages per week)
6. Chapter quizzes (5-7), midterm exam and final exam
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Hybrid, Electric & Fuel Cell Vehicles. Erjavec, Jack & Jeff Arias. Delmar Cengage Learning, 2006.
Rosebro, Jack. Basic Hybrid Powertrains. Perfect Sky, 2008.
Instructor prepared materials