TruckTrain "Hybrid and Electric Heavy Duty Vehicle"

The electrification of the powertrain is not only implemented in the field of passenger cars, but is also suitable for the field of commercial vehicles. Both a truck and an agricultural machine can be used as hybrid or even electric versions. This circumstance has now also been taken into account in the training regulations, which have taken up the topic of hybrid and electric vehicles in connection with commercial vehicles. In order to be able to optimally prepare the trainees for this challenge in the field of commercial vehicles, the renowned HV training system for passenger cars from Lucas-Nülle has been modified and adapted to the new topic accordingly. The special learning concept of the training system, which combines theoretical and practical content in a target group-oriented manner, enables flexible on-site implementation that is taking regional, operational and industry-specific features into account. 

The following topics are covered by the training system:

• Operation of vehicles and systems and protective measures 
• Analysis of high-voltage systems / preparation for country specific qualification
• Activation of a high voltage system according to manufacturer's specifications
• Perform diagnosis of faults and malfunctions in high-voltage systems and their components
• Carry out and document potential equalization and insulation resistance measurements on the vehicle
• Put the high-voltage system back into operation according to the manufacturer's instructions

The following knowledge is conveyed by the training system:

• Apply safety rules to avoid dangers from electric current
• Identify risks to health and safety at work and take measures to prevent them
• Apply occupational safety and accident prevention regulations
• Plan and define work steps and processes according to functional, organizational, technical and economic criteria as well as manufacturer's specifications
• Prepare the workplace in consideration of the work order
• Apply test methods and test equipment according to requirements
• Presenting and presenting the results of work

Includes:

• "TruckTrain Hybrid and all-electric vehicles" training course
• USB-ethernet network adapter
• 5 Overlay masks for various drive systems
• Operating instructions
• Interactive training course on data media

Integrated brand-independent drive concepts:

• Serial hybrid drive with plug-in capability
• Parallel hybrid drive with plug-in capability
• Serial-parallel hybrid with plug-in capability
• All-electric vehicles
• Fuel-cell vehicles

Set-up of the training system

• On the front there are two motor-generator units and two transmission systems which transfer drive power to the two wheels on the rear axle.
• Different overlay masks are used to depict the various types of drive and vehicle. In addition to the graphic representation of the relevant block circuit diagrams, direct measurements covering individual electrical components and the flows of energy between them can be made with the aid of the diagrams themselves.
• A capacitive colour touch panel, 10.4 inch, offers a view of the instrument cluster for the vehicle in question.
• The touch panel can also be used to invoke the built-in engine tester.
• Also on the colour touch panel, force and energy dynamics can be shown as animations which are based on the original vehicles themselves.
• A potentiometer can be used to reset the speed of the vehicle as required.
• Another potentiometer enables the energy available from the HV battery to be adjusted between 0% and 100%.
• The driving profile is changed between uphill, level and downhill road conditions using a switch.
• The vehicle is started using a 3-stage ignition switch.
• A service maintenance plug (incl. interlock contact) is located on the front panel in order to de-energise the high-voltage system.
• Measurement sockets to enable verification that the system is de-energised (voltage free) are located behind a lockable cover (incl. interlock contact).
• There are also externally accessible 4-mm measuring sockets directly connected to the resolver. Sine and cosine voltages from the resolver can thus be measured directly.
• 4-mm measuring sockets are also accessible for equipotential bonding.
• Other 4-mm safety measuring sockets are provided in order to measure shielding of the wiring.
• There are also externally accessible 4-mm measuring sockets directly connected to the inverter.
• Measuring sockets for motor/generator 1 and 2 are provided in the form of 4-mm measuring sockets.
• A fully functional type 2 charge terminal for connection to a charging station conforming to IEC 61851-1 is also installed.
• A lockable fault simulation switch box makes it possible to emulate an extensive variety of fault scenarios. 
• HV system implemented as an IT network.
• Two-voltage on-board power supply system
• Charge enabling switch
• Charge system based on DIN IEC 61581-1
• 24V Board network

Integrated WiFi measurement interface:

• Connection via USB port or via wireless WLAN
• 4-channel oscilloscope with trigger, cursor and freeze function
  • Four floating voltage inputs for voltages up to 500 V AC/DC
• Voltmeter
• Ammeter
• Student specific saving of measurement results inside the E-learning course
  • Saving per copy & paste - function 
     

Practical training contents:

• Servicing work
  • Correct selection and testing of suitable instruments and testing equipment
  • How to use service information
  • Carrying out service work on HV systems
  • Checking charging device
  • Charging of high-voltage battery
     
• Repair work
  • Measurement at potential equalisation conductors
  • Disconnection and isolation of a HV system
    • Manual disconnection and isolation
    • Tester-guided disconnection and isolation
    • Securing against reactivation
    • Verification of isolated status (absence of voltage)
  • Putting a HV system into initial operation
  • Measurement of insulation resistance
  • Measurement of the shielding
  • Measuring the temperature (traction battery, E-machine)
     
• Diagnostics work
  • Fault localization on a HV system
    • Fault finding on electric motor
    • Fault finding on the inverter
    • Fault finding on the connection lines
  • Measurement of the equipotential bonding
  • How to use the diagnostic device 
  • Read-out and deletion of fault memory
  • Measurement on the CAN bus

Course contents:

An interactive course is supplied, which contains the following topics:

• Criteria for putting the test equipment into operation
• Selection and checking of the test equipment
• Drive concepts
• Health and safety while working
• Electrical hazards
• Safety regulations
• HV battery
• Working with high-voltage vehicles
• Safety concepts for high-voltage vehicles
• Hybrid driving
• Pure electric driving
• Generator operation
• Boosting
• Regenerative braking
• Asynchronous machines
• Synchronous machines
• Inverters
• Regenerative braking and energy recovery
• Operating principle for resolvers
• Operating principle for interlock contacts
• High speed - CAN bus
• Measurement of the CP signal of type 2 charge connection during active charging process
• How to handle damaged HV vehicles
  • Safer handling by rescue services
  • Disconnection and isolation options for rescue services
  • Special hazards 
  • Rescue scheme for rescue services

Dimensions and power supply

• Voltage supply AC 230 V, 50-60 Hz/3 A
• Dimensions: 1000 x 800 x 220 mm (WxHxD)
• Weight: 72 kg approx.