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Module III : Vehicle Systems and Safety Features

Module III : Vehicle Systems and Safety Features. Module III Objectives. Terminal Objective. Describe the operation of P/HEV and EV systems. . Enabling Objectives. Define terms related to P/HEV and EV systems. Compare and contrast P/HEV’s and EV’s. List major components of P/HEV systems.

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Module III : Vehicle Systems and Safety Features

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  1. Module III: Vehicle Systems and Safety Features

  2. Module III Objectives Terminal Objective Describe the operation of P/HEV and EV systems. Enabling Objectives • Define terms related to P/HEV and EV systems. • Compare and contrast P/HEV’s and EV’s. • List major components of P/HEV systems. • List major components of EV systems.

  3. Definitions HEV Hybrid Electric Vehicle A vehicle that has both an internal combustion engine (ICE) and electric motor(s). PHEV Plug-In Hybrid Electric Vehicle A vehicle that has both an ICE and electric motors, and can recharge its batteries to full charge from an external electric power source. EV Electric Vehicle A vehicle which uses only electric motor(s) for propulsion.

  4. Video Vehicle Types

  5. Hybrid Electric (HEV) • All hybrids use batteries and • electric motors to reduce demand • on the internal combustion • engine (ICE). • Allows better fuel economy. • ICE can shut down when not needed. • Full Hybrids can drive short distances on electric power only • (silent movement hazard). • For response purposes, treat • all hybrids the same. Toyota Prius Honda Civic Hybrid

  6. Plug-In Hybrid Electric (PHEV) A hybrid vehicle that allows the battery to be charged via an external power source. 2012 Ford Escape • Increases battery charge • Increases range • Reduces dependence • on the gasoline engine. 2012 Toyota Prius

  7. Electric Vehicle • Electric motors are the only means of propulsion. • Vehicle must be charged by an external power source. Nissan Leaf

  8. Extended Range Electric Vehicle • Electric motors provide the propulsion. • When battery is low, gasoline generator provides the electricity for the motor. • For emergency response, treat as a PHEV with… • a gasoline engine • high voltage battery • electric propulsion • possible external power. Chevrolet Volt

  9. HEV / PHEV / EV VEHICLE COMPONENTS

  10. Standard Components Internal Combustion Engine 12 Volt DC Battery 12 VDC battery can be located in various locations around vehicle. Less Common Locations: ·  Front wheel well ·  Under 2nd Row seats Common Locations: ·  Trunk / Cargo compartment ·  Under hood

  11. Video 12 VDC and High Voltage Batteries

  12. High Voltage Batteries Battery Types Lithium Ion NiMH Nickel Metal Hydride Various Materials

  13. High Voltage Batteries Nickel Metal Hydride (NiMH) Battery • Most common battery in existing hybrids. • Less common in newer vehicles. • Electrolyte is alkaline.

  14. High Voltage Batteries Lithium Ion (Li-Ion) Battery • Most common in electric vehicles. • Will be used more in future hybrids. • Many different chemical variations. • Different from Li-Ion batteries in home electronics.

  15. Video High Voltage Battery Construction

  16. High Voltage Batteries Small Cells in Series • High voltage batteries are made of many small, low-voltage cells. • Small cells wired in series to multiply voltage. • Ex: Four 1.5 VDC batteries in series equals • 6 VDC.

  17. High Voltage Batteries Location of Batteries in HEVs, PHEVs Generally located in rear of vehicle. Under 2nd row seating in most SUVs and trucks, in trunk/ cargo area in most sedans.

  18. High Voltage Batteries Location of Batteries in EVs • EV Batteries are larger and of higher • voltage than P/HEV batteries. • Usually located on the underside of • the vehicle.

  19. High Voltage Batteries Service Disconnects • Recommendations for • use and required • safety equipment vary • by manufacturer. • Consult appropriate • ERG before using • service disconnect. • Located on the • battery. • Cuts off the battery • from the high voltage • system. Service disconnect will be addressed later in course.

  20. Inverter/ Converter Located under hood • Found in vehicles using AC drive motors. • Converts DC from HV Battery to AC to run motor. • Converts AC from regenerative braking back to • DC tocharge HV Battery.

  21. Inverter/ Converter Located under hood Dangerous to penetrate cover with tools. • Capacitors inside unit can store voltage • for a period of time. • If damaged, capable of rapid energy • discharge that can cause severe injuries.

  22. DC/DC Converter DC-DC Converter (APM) for Chevrolet Volt • Takes the place of the alternator. • Converts DC from high voltage battery to 12 VDC • to run vehicle’s low voltage systems. • In some models the DC/DC converter is housed • in the inverter/converter module.

  23. Video High Voltage Battery Relay

  24. Color coded to SAE voltage levels EV/ HEV Cabling • Low Voltage: <30 Volts Often Red or Black • Intermediate: 30-60 Volts • Usually Yellow or Blue • High Voltage: >60 Volts • Orange

  25. Medium and high voltage should both be considered highly dangerous. Medium/High Voltage Cabling For the purposes of this program, treat blue cables the same as high voltage orange.

  26. High Voltage Cabling Location • Between the HV • battery, HV components, and the electric motor. • Typically routed along the underside of the vehicle and under hood.

  27. High Voltage Cabling Construction/Fault Protection If a cable is compromised or damaged, the system is designed to detect the damage and shut down. For safety, ALL high voltage cable should be considered energized during response operations.

  28. Electric Motors P/HEVs • Provide propulsion in some models. • Start and stop the ICE when not needed. • Recharge HV battery through regenerative braking and ICE. EVs • Provide propulsion and recharge HV battery through regenerative braking.

  29. Regenerative Braking A process used to capture energy from braking and help recharge the high voltage battery. • During braking, wheels turn the electric motor, making it act as a generator and produce electricity. • Electricity routed to HV battery to increase charge. Can damage HV system if towed in overhaul.

  30. Safety Systems P/HEVs and EVs have safety systems designed to automatically shut down the high voltage systems in the event of: • Crash Impact • Airbag Deployment • Cabling damage • Short Circuits Always treat HV systems as energized for maximum safety.

  31. Charging Ports • Used to connect a charging cord to the vehicle. • The charging components reside on the vehicle. • The charging unit is an interface between the power supply and the vehicle.

  32. Charging Stations

  33. Charging Stations Level I Level II DC Quick Charge 120 VAC 240 VAC 480 VDC 8-16 hours 3-8 hours 20-30 min.

  34. Level 1 Charging Station Level I • Utilizes 120VAC power. • Uses standard household • plug. • Slowest rate of the three • levels. • Can accompany vehicle • to charge it anywhere. 120 VAC 8-16 hours

  35. Level II Charging Station • Utilizes 240VAC power. • Can be a fixed • installation or portable • unit. • Faster than Level I • systems. Typically 3-8 • hours depending on • the size of the battery. Level II 240 VAC 3-8 hours

  36. J1772 Plug and Receptacle • SAE standardized for Level • I and II charging. • Multi-pin charging/ • communication link between • charger and vehicle. • Conducts current. • Relays charge status. • Shuts down charging • when battery “full.” • Prevents vehicle from • moving when pluggedin.

  37. DC Quick Charge Station • Currently provides 480VDC • directly to the battery. • New standards being • developed, so this may • change. • Fastest charging system. • Due to wiring requirements, • availability, and expense, will • likely be in commercial sites • only. DC Quick Charge 480 VDC 20-30 min.

  38. Activity 3.1 P/HEV, EV Components You will be shown a series of slides, each with a picture of a component of a P/HEV or EV. You will be given a few moments to discuss and decide on the name of the component and its function. Be prepared to share your answer with the class.

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  40. Component High Voltage Battery Function The electrical storage system that provides power for vehicle systems.

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  42. Component High Voltage Cabling Function Wiring used to carry electric current from the high voltage battery to the electrical motor.

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  44. Component Inverter / Converter Function Devices which convert DC from the high voltage battery to AC to drive the motor. May also house DC-DC converter to step down high voltage DC to 12VDC to run standard vehicle systems.

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  46. Component Charging Ports Function Electrical connections on a vehicle for connecting the high voltage battery to a charging source.

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  48. Component Manual Service Disconnect Function Cuts off the battery from the high voltage system. Refer to Manufacturer ERG before use!

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  50. Component J1772 Connector Function Multi-pin communication link between charger and vehicle.

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