instructor’s guide - infobase · 2013. 4. 25. · pcm or power control module, which regulates...

Copyright © 2012 Films Media Group® • www.shopware-usa.com • 1-800-322-8755

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Powertrain Technology and Service: Hybrid Powertrain Technology

IntroductionWith all major car manufacturers now producing hybrid gas-electric vehicles, it is critically important that automotive students understand the design and function of hybrid technology and the differences between various hybrid systems. This video helps develop that understanding through the use of dynamic 3-D animation and detailed live-action visuals. A helpful summary opens the program, explaining the basics of hybrid vehicle technology and its dual use of piston engine and electric traction motor. In-depth topics include the battery stack and its contents of high-efficiency lithium-ion modules; the dynamotor with its brushless armature and multi-coil stator assembly; the PCM or power control module, which regulates current flow to the battery and dynamotor; and the cable system which connects those components. Additional video sections focus on all-electric drive mode, regenerative braking, and other unique aspects of HV operation, as well as the various configurations of hybrid drive trains.

Learning Objectives After viewing this video, the student will be able to:

• Explainthemajorpartsofanelectricdrivetrain.

• SummarizewhichhybridassembliesoperateonDVvoltageversusACvoltage.

• ListtypesACandDCvoltagelevelsformodernhybridandfullelectricvehicles. • Explaintheconstructionofadynamotor(alternator/motor)thatservesasahigh-voltage traction motor for propulsion and AC generator or huge alternator for HV battery recharging. • SummarizehowanHVPCMpullsdirectcurrentoutoftheHV-batteryandconvertsitinto three-phase alternating current at even higher voltage.

Instructor’s Guide

Hybrid Powertrain Technology Instructor’s Guide


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• Describehowamodernhybridcanoperateinfullelectricmode,gas-electricmode,and regenerative braking mode.

• Comparethevarioustypesofhybridpowertrains:series,parallel,series/parallel,singledyna- motor, dual dynamotor, engine-mounted dynamotor, transmission-mounted dynamotor.

To the InstructorThisvideoisdesignedtobeavaluablesupplementtoyourcurriculum.Sinceyoungpeoplearehighly acclimated to television or video, it is a natural way to help present important aspects of your subject matter.

Feel free to print the contents of this user guide for classroom distribution. You can then hand out theprintedquizzesandotherinformationtoyourstudentsasdesired.

Mosteducatorsagreethatitisbesttouseasmanyinstructionalmethodsaspossible.Utilizequalitytextbooks, workbooks, videos, lectures, demonstrations, overheads, and other methods to present the technical information. This will hold your students’ interest and help them to understand the large amount of information required to succeed in today’s complex world of auto repair.

Thisvideoisorganizedintomajorsectionsortopics.Eachsectioncoversonemajorsegmentof the subject. Graphic breaks are given between each section so that you can stop the video for class discussions, demonstrations, or Q & As.

This allows you to either watch just a portion of the program each day or to present the complete video, depending on your curriculum requirements.

The video is designed to simplify the complex. Concise wording and carefully selected graphics are used to provide maximum learning in minimum time.

Computer animation is used to explain difficult-to-comprehend principles or techniques. These im-ages show how parts work, how they fit together, or how they vary in design. Use your own judgment to evaluate the definitions, short answer questions, and discussion topics. Most instructors use these as open-book activities.

Educational StandardsThisprogramcontentcorrelateswiththepresentASE(NATEF)autorepairstandardsbutgoes beyondthemtohelpthestudentrepairconventionalandhigh-voltagehybridvehicles.New information on hybrid and full electric, high-voltage drivelines has been included in this series of videos. For more information on educational standards for this series, please visit http://ffh.films.com/id/25198.



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ASEASE,orAutomotiveServiceExcellence,isanonprofitnationalinstitutethatworkstoimprovethequality of vehicle repair and service by testing and certifying automotive professionals. Today, more than350,000professionalsholdASEcertifications,andworkineverypartoftheautomotiveserviceindustry.OurvideoproducersworkcloselywithASEtocommunicatethetypesofsubjectsthatmust be included in our content.

The information in this video and the entire Powertrain Technology and Service series will help you passthefollowingASECertificationTests:

A2–Auto:AutomaticTransmissions/Transaxles 25A3–Auto:ManualDriveTrainandAxles 20

FormoreinformationonASECertification,pleasevisitwww.ase.com

NATEFTheinformationinthisvideocorrelateswithNATEFstandardsforautorepair.NATEFwas foundedasanindependent,nonprofitorganizationwithasinglemission:toevaluatetechniciantraining programs against standards developed by the automotive industry and recommend qualifyingprogramsforNATEFaccreditation.

Video Discussion TopicsHere are a few topics that might be used for a class discussion:

1. Discuss how you must gradually apply the brake pedal to get full benefit from regenerative braking. Mention how early hybrids had problems when customers would brake so carefully that the brake discs would rust and not provide normal braking in the first panic stop engaging the hydraulic brakes.

2. Discuss the various types of hybrids and their variations from manufacturer to manufacturer.

3. Open the hood on a hybrid vehicle and discuss what parts of the hybrid or electric drivetrain are visible. Also look at the battery pack and show students the battery disconnect while wearing insulatedrubberglovesandeyeprotection.Stressthedangeroftheindustrialpowerandvoltageavailable in a three-phase, alternating current pushed by hundreds of volts of pressure.

4. Compare the advantages and disadvantages of a full electric vehicle and a hybrid versus a gas or diesel-only powertrain.



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Technical Terms Write definitions for the following terms. Use your textbook or review the video if needed.

HV battery HV battery module HV battery voltage HV dynamotor HV generator motor dynamotor armature dynamotor stator HV insulating gloves FEV HGEV plug-in hybrid split hybrid series parallel hybrid series hybrid regenerative braking brake pedal sensor HV power cables inverter circuit converter circuit



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Short AnswerHave students briefly answer the following questions in their own words:

1. ExplaintheoperationofanHGEV,orhybridgas-electricvehicle.

2. When you press the brake pedal lightly on a hybrid vehicle, what is happening in the electric drivetrain and dynamotor circuit?

3. Describe several functions of an electric propulsion system.

4. Explainwhathappenswhenamodernhybridvehiclecomestoacompletestop.

5. Listthefunctionsofahybriddynamotor.

6. Define the term HV battery.

7. Definethetermdynamotorormotor/generatorandwhatitdoes.

8. ExplainhowahybridvehicleECM,orelectroniccontrolmodule,usestheelectricpowertrainwhen accelerating and braking moderately.

9. Where is the dynamotor located in a hybrid or full electric powertrain?

10.Why should you never pour water on a burning lithium-ion HV battery?



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Video QuizChoose the most correct answer after reading the statement:

1.HVisanabbreviationthatstandsforwhattwoterms? a. Hybrid voltage and high voltage b. High voltage and hybrid vehiclec.Hertzvoltageandhighvoltaged.Hertzvoltageandhybridvehicle

2.Whattwopowersourcesdohybridvehiclesuseforpropulsion? a.Engineandalternatorb.EngineandDCgeneratorc.Engineanddynamotord.EngineandDCalternator

3.AllhybriddrivelinesusealargeHVPCMandaseriesofthesetocontrolthegas/electricpower-train of the vehicle.

a.ECTsb.ETCsc.ECMsd.ETMs

4. What type of batteries can be found in today’s hybrid and full electric powertrains? a. lead acidb. lead ionc. lithium-calciumd. lithium-ion

5.Ahybridvehiclereducesfuelconsumptionandhydrocarbonexhaustemissionsby_______to______percent.

a.50to100b.25to50c.20to40d.15to20



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6.Thedynamotor____________consistsofasetofpermanentmagnetsmountedinsideaseg-mented steel or carbon fiber disc.

a. statorb. commutatorc. magnetic fieldd. armature

7. Hybrid gas-electric vehicles are now produced and sold by all major auto manufacturers. True or False?

8Somehybridsdonotuseaconventional12Vbattery,startingmotor,oralternator. True or False?

9.HVbatteryvoltagecanrangebetweenthesetwovoltageratings: a.12VDCto24VDC b.120VDCto240VDCc.150VDCto400VDCd.600VDCto1000VDC

10.ThispartconvertsHVbatteryvoltageintothree-phase,ACvoltage: a.HV-ECMb. HV-PCMc.dynamotor(motor/generator)d. HV diodes

11.Withthisengine/dynamotorconfiguration,thetractionmotoristheonlymethodusedtoapplytorquetothevehicle’sdrivetrain:

a. seriesb. parallelc. series paralleld. delta



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Video Quiz Answer Key

Other Titles in This Series:Hybrid Powertrain TechnologyWith all major car manufacturers now producing hybrid gas-electric vehicles, it is critically important that automotive students understand the design and function of hybrid technology and the differences between various hybrid systems. This video helps develop that understanding through the use of dynamic 3-D animation and detailed live-action visuals. A helpful summary opens the program, explaining the basics of hybrid vehicle technology and its dual use of piston en-gine and electric traction motor. In-depth topics include the battery stack and its contents of high-efficiency lithium-ion modules; the dynamotor with its brushless armature and multi-coil stator assembly; the PCM, or power control module, which regulates current flow to the battery and dynamotor; and the cable system which connects those components. Ad-ditional video sections focus on all-electric drive mode, regenerative braking, and other unique aspects of HV operation, aswellasthevariousconfigurationsofhybriddrivetrains.Aviewable/printableinstructor’sguideisavailableonline.AShopwareProduction.ApartoftheseriesPowertrain Technology and Service.(23minutes)

Item:43859Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62290-507-2

Automatic Transmission TechnologyDriving a car with an automatic transmission may be relatively simple, but the machinery isn’t! Technicians-in-training need a clear and thorough visual guide. This video provides an in-depth technological grounding that will enable students to troubleshoot and repair systems which make up today’s automatic transmissions. Topics include transmis-sion case construction; transmission hydraulics; electronic components, in particular the onboard computer or electronic controlmodule(ECM)andhowitsendssignalstosolenoidsinthetransmissionvalvebody;thetorqueconverterandits constituent parts; the holding devices that engage the different gearsets, including friction discs, bands, and one-way clutches; and the planetary gearsets, including sun, planet, carrier, and ring gears, as well as the parking pawl used to lock the transmission output shaft. A detailed section on various kinds of hybrid automatic transmission is also presented. A viewable/printableinstructor’sguideisavailableonline.AShopwareProduction.ApartoftheseriesPowertrain Technol-ogy and Service.(25minutes) Item:43860Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62290-508-9

Manual Transmission TechnologyFor enjoyable open-road driving many people prefer a stick shift. In much the same way, there’s nothing quite like the satisfaction of providing first-rate service and maintenance on a manual transmission. This video illustrates the engineer-ing and operating principles of helical gear manual transmissions with help from high-energy graphics, animation, and live-actionfootage.Studentswilllearnaboutthepurposeandconstructionofhousings,gaskets,seals,thrustwashers,bearings,synchronizers,drivegears,shiftmechanisms,andothercomponents.Withanoverviewofgearratiosandan illustration of power flow through the transmission gears, the program also compares the construction of different manual transmission and transaxle designs. In particular, the video explores automated manual transmission technology, whichusescomputercontrolandelectricsolenoidsorservomotorstoactuatelargehelicalgearsets.Aviewable/printable

l. b 2.c 3. c

4. d 5.d 6. d

7. True 8.True 9.c

10.b 11.a



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instructor’sguideisavailableonline.AShopwareProduction.ApartoftheseriesPowertrain Technology and Service. (21minutes)

Item:43861Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62290-509-6 Clutch Operation and ServiceDemonstrating a wide range of standard shop techniques as well as a few handy tricks of the trade, this video introduces viewerstotheoperationandserviceoftypicalautomotiveandlighttruck–typeclutches.Beginningwithanoverviewofthe theory and construction of clutches, the program then shows how to inspect, diagnose, remove, and replace clutch components efficiently. The inspection chapter focuses on observing pedal free play, checking free height, and listening for abnormal bearing-related noises during a test-drive. Instruction on clutch removal highlights removal of the U-bolts securing the shaft to the rear differential yoke, sliding the slip joint out of the rear of the transmission, using an exten-sion or transmission jack, removing the rear crossmember bolts, unbolting the shifter, removing the clutch housing, and more. Inspecting the flywheel and the clutch pilot bearing and replacing the pilot are covered. A complete section on clutchinstallationisalsoincluded.Aviewable/printableinstructor’sguideisavailableonline.AShopwareProduction. A part of the series Powertrain Technology and Service.(21minutes) Item:43862Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62290-510-2

CV Axle TechnologyAlmost all new cars come equipped with constant-velocity, or CV, drive axles, and CV joints are needed in front-wheel-drivevehiclestoavoiddrivelinevibration.Likewise,carswithfront-wheeldriveorindependentrearsuspensionuseCVaxleshaftsformaximumflexibility.Sincemillionsoftoday’scarsnowutilizethistechnology,understandingthemakeupand function of CV axles is crucial to mastering this high-demand area of auto repair work. Viewers of this program will learn about basic CV components, including inner-stub, outer-stub, and interconnecting shafts as well as the various types of CV joints and joint boots. An in-depth section on joint inspection depicts both road testing and shop analysis. Anotherchapterdemonstratesaxleremoval,fromlooseningtheaxlenuttotakingoffthesteeringtie-rod(andpossiblytheinner-stub-shaftsnapringsorcirclips),whilestep-by-stepsectionsonCVjointserviceandaxleinstallationarealsofeatured.Aviewable/printableinstructor’sguideisavailableonline.AShopwareProduction.Apartoftheseries Powertrain Technology and Service.(23minutes) Item:43863Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62290-511-9

Differential TechnologyAs any automotive trainee soon learns, a car’s differential must provide torque to propel the vehicle, even when the



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wheels and axles are turning at different speeds. Various differential designs are used to accomplish this and other functions in rear-wheel-drive, front-wheel-drive, and all-wheel-drive vehicles. This video guides students through various differentialanddrivedesignsandsummarizeshoweachoneoperates.Viewersareshownthebasicworkingsofanen-closed drive shaft and of a solid rear-axle assembly, and how either solid or flexible drive axles link the differential to the drivewheels.Subsequentchaptersshedlightonringandpiniongears,opendifferentials(includingthesetof spidergearsmountedinsidethecarrier),limited-sliporpositractiondifferentials,Torsen-Gleasondifferentialsusingworm gears to produce a no-slip drive setup, and computer-controlled electric clutch differentials. Various all-wheel-drivedesignsarealsodiscussed.Aviewable/printableinstructor’sguideisavailableonline.AShopwareProduction. A part of the series Powertrain Technology and Service.(18minutes) Item:43864Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62290-512-6

Differential ServiceSincethedifferentialmusttransferenginepowertobothdriveaxles,itisexposedtohigh-stressloads.Afterprolongeddriveruse(orabuse),gears,bearings,shafts,andotherpartscanfail.Therefore,well-trainedtechniciansareneededtoservice the front and rear differentials found in today’s vehicles. This video shows how to diagnose common differential and drive axle problems and perform essential services and repair operations. An overview of differential disassembly showshowtoremovethedriveshaftandaxleandunboltthepiniongearassembly.Next,positractionserviceisillus-trated, including removal of the roll pins or bolts that secure the spider gear shaft as well as any clutch pack guide inserts. The video concludes with differential reassembly, from installing new friction discs to checking the ring and pinion gear teeth contact. Helpful 3-D animation and live-action visuals are featured throughout to reinforce vital concepts andtechniques.Aviewable/printableinstructor’sguideisavailableonline.AShopwareProduction.ApartoftheseriesPowertrain Technology and Service.(21minutes) Item:43865Copyrightdate:©2012

DVD(Chaptered)ISBN978-1-62290-513-3

Additional Video Programs from Shopware:Braking Systems ASE Certification SeriesWhen it comes to automotive professionalism and a concern for customer safety, nothing is more important than high-quality brake repair work. Use this three-part series to give auto-shop students and service trainees their best shot at acingtheASEA5test,alongwithreal-worldcapabilitiesindiagnosingandsolvingavarietyofbrakingsystemproblems.Episodesaredividedintoself-containedchapters,eachofwhichpinpointscertainareasofASE-relatedcompetence,andledbytwoauthoritative,ASE-certifiedinstructorswhomakeiteasytoidentifypartsandinternalizemaintenancelessons.Demonstrationsarecarriedoutinafullyequippedshoponarangeofvehicles,whileconcisequizzes,helpfulgraphics, and friendly coaxing on the need for professional integrity add extra shine to this vital teaching toolkit. CorrelatestoASEandNATEFstandards.Aviewable/printableinstructor’sguideincludingASE/NATEFtask correlationchecklistsisavailableonline.AShopwareProduction.3-partseries,22–33minuteseach. Item:44879Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62102-261-9

Engine Performance ASE Certification Series



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Fixing a car’s engine is like being a cardiologist—you’re working with the most vital part of the vehicle and every decision requires fine-tuned know-how. With this three-part series on engine performance and repair, technicians-in-trainingdeveloptheaptitudethey’llneedtosucceedontheASEA8testwhilebuildinghands-onskillsthatwillenablethem to diagnose and solve a range of engine problems. Videos are broken down into self-contained segments, each of whichfocusesonspecificareasofASE-relatedproficiency,andpresentedbytwohigh-energy,ASE-certifiedinstructorswho make parts identification and maintenance lessons easy to follow. Demonstrations are performed in a full-service shoponarangeofautomobiles,whileno-fluffgraphics,on-screenquizzes,andplentyofupbeatremindersabout professionalintegrityroundoutthismust-haveinstructionalresource.CorrelatestoASEandNATEFstandards. Aviewable/printableinstructor’sguideincludingASE/NATEFtaskcorrelationchecklistsisavailableonline. AShopwareProduction.3-partseries,25–35minuteseach. Item:44875Copyrightdate:©2012DVD(Chaptered)ISBN978-1-62102-257-2 Hybrid Auto Repair SeriesA new generation of automotive technicians is emerging, made up of men and women with solid training in hybrid technology. Give your students a chance to be part of this technological revolution. This three-part series provides a thorough grounding in hybrid technologies, focusing on building both system knowledge and safety awareness. In addi-tion to outlining the history and growth of electric, hydrogen, diesel, and other alternative propulsion systems, the series explores major hybrid components and details the safety challenges that these complex mechanisms present to techni-cians. Job seekers who are looking to set themselves apart from the average automotive trainee will find the ideal learning resourceinthisseries.Viewable/printableinstructor’sguidesareavailableonline.AShopwareProduction.3-partseries,15–18minuteseach. Item:35525Copyrightdate:©2007DVD(Chaptered)ISBN978-1-4213-5010-3

Hybrid Auto Repair Series IIWhether you’re training students, new hires, or long-time employees, hybrid auto technology is a crucial part of today’s automotive instruction. A natural follow-up to the Hybrid Auto Repair Series(item#35525),thisthree-partseriesguidesviewers through the systems that hybrid auto professionals must become familiar with and shows what it takes to main-tain shop safety and efficiency. Veteran automotive technicians share their hybrid knowledge and experience, explaining bestpracticesandspecificproceduresrelatingtoFord,Honda,andToyotamodels.Eachprogramemphasizestheneedfor patience and caution while lowering the fear factor often associated with a hybrid’s high-voltage components. A view-able/printableinstructor’sguideisavailableonline.CorrelatestoallNationalCTEOrganizationalStandards(includingtheprovisionsofthePerkinsAct).AShopwareProduction.3-partseries,21–23minuteseach. Item:38765Copyrightdate:©2008DVD(Chaptered)ISBN978-1-4213-9001-7

Chassis and Front EndMake sure your students have the best possible training in chassis and front-end parts and service. This nine-part series willsupportanyintensivecoursecoveringthefollowingsystemsandhowtheyareserviced:brakes,steering,suspension,and both conventional and front-wheel-drive wheel bearings. Wheel alignment theory and adjustment is also a program topic. Detailed yet easy-to-understand animation and graphics are found in each episode, accompanied by live-action videothattakesstudentsdirectlyinsideeachinspectionandserviceprocedure.CorrelatestoallNationalCTE



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OrganizationalStandards(includingtheprovisionsofthePerkinsAct).Viewable/printableinstructor’sguidesare availableonline.AShopwareProduction.9-partseries,17–27minuteseach. Item:24992Copyrightdate:©2008DVD(Chaptered)ISBN978-1-4213-9884-6

Automotive Computer SystemsAsanyautomotivetechnicianunderstands,theworldofcartechnologyisnowfullycomputerized.ThisseriesprovidesabasicworkingknowledgeofautomotivecomputersystemsandtheinsandoutsofOBD-IIdiagnostics.Studentswillabsorb lessons in computer system operation, trouble codes, scan tools, and repair procedures. Ford, GM, Chrysler, and other makes are discussed, while hybrid engine technology is also addressed. Videos can stand alone or as a series for bothbeginningautomotivestudentsandmoreadvancedclasses.CorrelatestoallNationalCTEOrganizational Standards(includingtheprovisionsofthePerkinsAct).Viewable/printableinstructor’sguidesareavailableonline. AShopwareProduction.4-partseries,14–30minuteseach. Item:24743Copyrightdate:©2008DVD(Chaptered)ISBN978-1-4213-8059-9

Auto Shop SafetyReinforcing concepts with helpful animation, this video provides crucial knowledge about accidents that can occur in automotive repair shops. The best ways to prevent them, and the smartest and safest steps to take when they happen, are explained. The video covers all major shop areas, including the stall, grease rack, front-end rack, tool room, and classroom.Runningengines,openfuellines,weldingtools,movingcars,carsonliftsorjacks,andothershophazardsare illustrated, with detailed information on avoiding fires, explosions, asphyxiation, chemical burns, electric shock, and impactinjuries.Hybridvehicletechnologyisalsoexplored.CorrelatestoallNationalCTEOrganizationalStandards(includingtheprovisionsofthePerkinsAct).Aviewable/printableinstructor’sguideisavailableonline.AShopwareProduction. Part 6 of the Safety and Technology Series.(21minutes) Item:24746Copyrightdate:©2008DVD(Chaptered)ISBN978-1-4213-9950-8



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instructor’s guide - infobase · 2013. 4. 25. · pcm or power control module, which regulates...

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