The HV battery is constructed in such a way that it can be disassembled in order to replace individual cells and sensors. In this way, the HV battery is diagnosed and repaired in an action and practice-oriented manner. Particular focus is placed on system-critical situations that can occur in the event of a malfunction in the hybrid and electric vehicle. In particular, faults are dealt with that occur on the vehicle but cannot be worked through independently during training. This includes not only the HV system and its control and protective devices, but also critical faults in the energy storage system itself. Diagnostics can be started practically using the integrated diagnostic tester. The diagnosis can be further deepened with the integrated and workshop-standard HV measuring equipment. This includes not only measurable faults in the HV safety systems, but also faults in the temperature sensors and battery cells, the practical replacement of which can be carried out. In this way, a qualification level for working in energy storage systems is also achieved.

Outstanding functions of the training system

• Precharge and main relays with self-diagnosis function and provided with fault circuits.

• 16 battery modules, individually replaceable, digitally coded, provided with fault circuits.

• 8 battery temperature sensors, replaceable and provided with fault circuits.

• Pilot line with diagnostic function and provided with fault circuits

• Hall-effect current sensor for contactless measurement of charging and discharging processes

• Real battery cell balancing with live data transmission to the diagnostic tester

• Visualised display of the selected driving profile

• Bidirectional energy flow display between drive and HV battery

• CCS type 2 fast charging socket for DC and AC charging

• Energy flow visualisation from charging ports to HV battery

• Digitally networked CAN bus battery management system with measurement interface

• CAN bus test sockets (3-fold, for signal tracking in the event of a fault)

• 50 fault switching options in the HV system and in the HV battery

Scope of supply:

• CarTrain CO3221-6S “Diagnostics and maintenance of a high-voltage battery”

• Interactive course on CD-ROM with LabSoft browser, course software and additional virtual instruments

• Integrated diagnostic software

• Lead set 

  • 4 × 2 mm safety measuring lead (yellow, 30 cm)

  • 4 × 4 mm safety measuring cable (red, 100 cm)

  • 4 × 4 mm safety measuring cable (black, 100 cm)

  • 1 × 4 mm safety connecting plug (red)

  • 1 × 4 mm safety connecting plug (brown)

Digital measuring instruments:

• Digitally networked measurement capacity

• 4-channel oscilloscope

• Voltmeter

• Ammeter

• Double voltage meter

• Power meter

Training contents:

• Understand customer complaints, carry out operational testing and determine diagnostics approach

• Read out fault memory

• Evaluate work safety

• Check effectiveness of electrical safety measures on the high-voltage system

• Replace high-voltage components

• Become familiar with location of components in the motor vehicle

• Determine faults and their causes with the aid of circuit diagrams and function plans

• Draft an inspection protocol and document results

• Understand measures taken to avoid hazards caused by voltage isolation faults

• Learn about data communication between control units

• Recognise repair needs and carry out repair options

• Determine diagnostics and repair options based on a customer’s job order

• Determine system operating states with the aid of the diagnostics systems, compare these to information in databases and evaluate results

• Measuring and testing systems

  • Determine the desired data

  • Select measurement procedure and measuring instruments

  • Document the measurement results

• Determine the measurement results, compare these to the desired data and evaluate

• Measure, check and evaluate signals at components and systems

• Measure, test and evaluate electrical connections

• Test high-voltage systems with diagnostics equipment, in particular perform measurements on isolation, equipotential bonding and voltage drops

• Analyze and evaluate messages in data bus systems

• Learn how battery cells are designed and function in the HV battery

• Learn how temperature sensors are designed and function in the HV battery

• Design and function of HV charging systems

• Advantages and disadvantages of individual HV charging systems

• Options to practically measure power consumption for different driving profiles

• Measuring voltage characteristics in HV batteries for different charging and discharging cycles

• How sensors and actuators interact

• IPO principle

• Open-loop control processes in the motor vehicle

• Closed-loop control processes in the motor vehicle

• Differences between open- and closed-loop processes

Components of the training-panel system:

• Mains power switch

• Emergency-stop safety switch

• Ignition switch

• Control unit BMS 1

• Control unit BMS 2

• Central control unit for BMS1 and BMS2

• Pre-charging and main relay with self-diagnostic function

• 16 battery modules, interchangeable, digitally encoded, including fault simulation circuits

• Active battery cooling

• 8 battery-temperature sensors, interchangeable

• Pilot line with diagnostics function

• Hall-effect current sensor for non-contact measurement of the charging and discharging processes

• Real battery cell balancing

• Selectable driving profile

  • Incline

  • Level

  • Coasting

  • Gradients with recuperation

  • Electrical braking with recuperation

• Visualised display of selected driving profile

• Low-voltage service disconnect

• High-voltage service disconnect

• HV protection for emergency services

• Combination instruments with

  • Power meter – power display

  • Speed indicator

  • Battery charge indicator

  • HV-ready and EPC warning light

  • Charging station control light

  • Warning light for power limitation

• Rotating drive gear

• Bidirectional power flow indicator between drive gear and HV battery

• Type 1 charging plug for AC charging

• CCS-type 2 rapid charging plug for DC and AC charging

• Charge buttons for controlling charge initiation

• Power flow visualisation from the charging plug to the HV battery

• 2-mm and 4-mm safety measurement sockets

• Removable complete battery cover

• Contact protection guards for battery cell terminals

• Digitally networked CAN-bus battery management system with measurement interface

• Test sockets for temperature sensors

• Test sockets for CAN-bus

• Test sockets for HV

• Test socket battery module 1

• Test socket battery module 2

• Test socket 12V

• Terminals for measuring equipotential bonding

• Terminal designations according to DIN 72552

• 46 fault simulation options

• USB connection socket

Supply voltage:

• 100-240 V AC 50-60 Hz

Operating voltage:

• 13.5V and 67V DC

Dimensions:

• 1010×320×805 (WxDxH)