CarTrain "Hybrid and Electric Vehicles - ASE L3 Trainer"

Prepare your students for the ASE L3 test "Light Duty Hybrid/Electric Vehicle Specialist”. All topics related to the New ASE L3 test are now covered by our newest Hybrid/Electric vehicle trainer. We offer a blending of comprehensive curriculum with practical tasks to make sure your students have the competencies and system understanding needed to succeed in this emerging, highly technical market. Allow your students to build confidence by knowing they can safely work on a state of the art real world system performing the procedures needed to work on hybrid/electric vehicles.

One of the key topics involved in modern automotive technology is the move towards electric drive power or electromobility. This is viewed as the innovation of the modern age and the drive system of the future, so developments continue to proceed at rapid rate. One key aspect of these developments involves the education and training of specialists and mechanics, who always need to have their fingers on the pulse of the latest technology to keep pace with ever-changing challenges. Lucas-Nuelle training systems represent an essential link between education and industry. Particularly in the sphere of hybrid and electrical vehicles the company's training system plays an exceptional role, since it embodies the perfect synergy between authentic practice, high safety requirements and targeted theory, all in conjunction will real diagnostic exercises.

Trainees work directly on a real high-voltage system, which has nevertheless been adapted with special safety features so that it can be used without any prior qualifications. This means that the training system gives rise to an absolutely safe working environment, enabling work to proceed with confidence. All the training content is in line with ASE L3 and frequently even exceeds those requirements. Trainees can become familiar with all the key theoretical background by means of an interactive e-learning course. The subjects can be organized into topic areas, including drive configurations, components of high-voltage systems, disconnection/isolation of HV systems, safe working with such systems, electrical fundamentals, charging of high-voltage batteries and diagnostics. Each of the theoretical sections is accompanied by practical exercises and tests of knowledge, which also help to advance vital diagnostic skills, skills which are further boosted by the built-in diagnostic system and the scrupulously selected fault scenarios. This is the only training system which gives students the opportunity to develop various diagnostic strategies, even involving measurements on an actual HV system, yet nonetheless under the most stringent safety conditions.

 

Special features of the training system:

• High-speed CAN as communication bus integrated into the HV system control.
  • Communication between HV charging system, HV battery and inverter.
  • Voltage values read out as CAN messages.
• 12V battery integrated into the disconnection and isolation process
  • Incl. fast-action battery terminal for tool-free disconnection of the negative pole
• Real fault codes for all diagnostics cases
• Extended interlock (service maintenance plug, HV measurement point)
• Real service maintenance plug
• Complete preload sequence for booting up HV system
• Active discharge - function for rapid shut-down of the HV system
• Reworked user interface with new "Virtual Cockpit"
  • With power meter
  • READY display
• Extended tester functionality incl. tester-guided disconnection and isolation
• Display of the actual values in the tester:
  • Voltage of the link circuit, traction battery
  • Illustration of the switch-on process (preload phase)
  • Status polling of HV relay
  • Status polling of interlock
  • Voltage of PP contact
  • Status polling of charging process
• Upgrade of fault simulation (e.g. adjusted response to insulation faults)
• New LabSoft course with lots of new content
• New front panel design

 

Includes:

• "CarTrain Hybrid and all-electric vehicles" training course
• USB-ethernet network adapter
• Type 1 charging cable
• 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 color 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 color 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.
• The system is equipped with batteries connected in series, in order to clarify the principle behind series connection of the traction battery.
• A service maintenance plug (incl. interlock contact) is located on the front panel to de-energize the HV system.
• Measurement sockets to enable verification that the system is de-energized (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 screening of the wiring.
• There are also externally accessible 4-mm measuring sockets directly connected to the inverter.
• Measuring sockets for motor/generator 1 are provided in the form of 4-mm measuring sockets.
• Measuring sockets for motor/generator 2 are provided in the form of 4-mm measuring sockets.
• A fully functional type 2 charge terminal for connection to a charging station is also installed.
• Measuring sockets for demonstrating safety communication between the charging station and the vehicle via an interlock contact are also available in the form of 4-mm safety measuring sockets.
• To aid faster understanding, the right-hand side of the front panel features a graphic representation of each drive configuration implemented in the system.
• An emergency stop switch is also located on the front panel.
• The system as a whole can be connected to a PC with the help of a USB cable. A built-in measuring instrument allows all measurements on the system to be recorded and sent to the computer via the USB link.
• A lockable fault simulation switch box makes it possible to emulate an extensive variety of fault scenarios.
• Measurements of insulation resistance can also be made using an instrument which is included in the system.
• HV system implemented as an IT network
• Two-voltage on-board power supply system
• Charge enabling switch
• Preparation for inductive charging

 

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
• Function generator output
• Resolver reference signal
• Variable voltages and waveforms via function generator
• Variable signals via frequency generator
• Variable voltages via three-phase supply
• Variable voltage and phase-shift via extended three-phase supply

 

Performing the following measurements:

• Charging processes of the traction battery
• Discharging processes of the traction battery
• Voltage measurements on the traction battery
• Verifying voltage isolation
• DC link circuit voltage
• Insulation resistance measurement
• 3-phase measurement on motor/generator 1 (power and recuperation)
• 3-phase measurements on motor/generator 2 (power and recuperation)
• Sine and cosine voltages from resolver
• Measurement of equipotential bonding
• Shielding measurement
• CP contact in charging system
• Analysis voltage in charging system
• Charge voltage in plug-in system
• The maximum voltage amplitude is approx. 425 V AC and approx. 320V DC
• Charge system

 

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 equalization 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 on a CD-ROM. The course is incorporated into the LabSoft training platform which also allows access to measuring instruments. In addition to imparting training content via text, images and animations, it also allows for monitoring of student progress and fault-finding experiments in the form of workshop job orders. Training contents are SCORM-compatible (HTML) and can be imported into training platforms of your own, such as Moodle.

• Smart grids
• Criteria for putting the test equipment into operation
• Selection and checking of the test equipment
• Drive concepts
• Drive configurations
• Drive variants
• Operating modes
• Health and safety while working
• Electrical hazards
• Passage of electricity through the human body
• Hazards due to AC
• Safety regulations
• HV battery
• Batteries made of nickel-metal hydrides
• Lithium-ion batteries
• Cooling of battery systems
• Meaning of "high voltage (HV)"
• Electricity "fueling" stations
• Working with high-voltage vehicles
• On-board power networks in high-voltage vehicles
• Intrinsically safe HV vehicles
• Safety concepts for high-voltage vehicles
• Vehicle-internal safety concepts
• Switch-on current and current limiting
• Serial hybrid drive with plug-in capability
• Parallel hybrid drive with plug-in capability
• Serial-parallel hybrid with plug-in capability
• Axle-split parallel hybrid
• Power-split hybrid drive
• Other drive configurations
• Hybrid driving
• Pure electric driving
• Generator operation
• Boosting
• Regenerative braking
• Electric drive systems for hybrid vehicles
• Electric vehicles
• Hydrogen-fueled electric vehicles
• Design of electrical machines
• Asynchronous machines
• Synchronous machines
• Control units for hybrid drives
• Rectifiers
• Inverters
• Regenerative braking and energy recovery
• Fault finding in traction motor circuits
• Fault finding in inverter circuits
• Fault finding in screening circuits
• Fault finding in equipotential bonding circuits
• Fault finding in battery circuits
• Operating principle for resolvers
• Operating principle for interlock contacts
• High speed - CAN bus
• Measurement of the CP signal of type2 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 120 V, 50-60 Hz
• Removeable connection cable with earthing pin plug
• Dimensions: 1000 x 800 x 220 mm, 39.4" x 31.5" x 8.7" (WxHxD)
• Weight: 72 kg / 160 lbs approx.