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Predictive Maintenance Course

This 2-day course teaches students how to analyze the state of health of high voltage components in hybrid electric vehicles, including motors, generators, batteries, inverters, and converters. Students will learn how to perform tests on these components and analyze the results to determine their condition and predict potential failures. The course uses multiple hybrid vehicles and specialized testing equipment. At the end, students will be able to conduct key tests and analyses to determine the state of health of high voltage systems and components.

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amhosny2010
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249 views

Predictive Maintenance Course

This 2-day course teaches students how to analyze the state of health of high voltage components in hybrid electric vehicles, including motors, generators, batteries, inverters, and converters. Students will learn how to perform tests on these components and analyze the results to determine their condition and predict potential failures. The course uses multiple hybrid vehicles and specialized testing equipment. At the end, students will be able to conduct key tests and analyses to determine the state of health of high voltage systems and components.

Uploaded by

amhosny2010
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Predictive Maintenance Course State of Health (SOH)

Course Length: 2-days Predictive Maintenance Course Overview:


The Predictive Maintenance course is designed to instruct the student in how to determine High Voltage system component State-of-Health (SOH) for the purpose of analyzing and diagnosing or, tracking the performance of a hybrid electric vehicle (HEV) propulsion system. The SOH includes analysis of Electric Machines (motors/generators), Power Inverter system, Energy Storage (Battery Pack) system, and the dc-dc Converter. A Predictive Maintenance program at any educational institution or service facility permits a vehicle to be trended over time so that a statistical prediction can be implemented to provide an accurate analysis on the operational reliability and durability of an electric propulsion system. Components in the system can be tracked to analyze the commencement of a possible failure or end-oflife prediction before it becomes catastrophic. Predictive Maintenance can also be used strictly as an analysis (diagnostic) method to measure the current status of the electric propulsion system components without tracking component performance over time. Multiple lab vehicles will be used to perform all of the SOH tests on the high voltage systems and/or components. This course is an advanced step in HEV analysis, diagnostics, and repair. Some of the areas of where Predictive Maintenance analysis can be used in the college classroom and/or in the field of HEV repair:

SOH check before a prospective buyer purchases a hybrid/electric/fuel cell vehicle Customers with "out-of-warranty" vehicles that want to know of any impending or eminent repair
possibilities

Trend/track the SOH of customer HEV systems.......a service that dealers don't provide Ensure that any analysis and diagnosis of the HEV systems have empirical (statistical) analysis
that removes subjectivity from the analysis

Reduces or eliminates unnecessary part replacement of expensive components and the


associated labor costs

Conjoin with used car businesses to provide an analysis on a prospective trade-in or sale Offer customers a once-per-year "SOH Check-up" o Results are documented and graphed to visually show customer the vehicle high voltage
system health status Course Objectives: At the completion of this course attendees will be able to perform and/or complete the following analysis tasks: Perform High Voltage battery module charging Perform High Voltage battery discharging Analyze battery data to determine the battery pack SOH Perform Power Inverter waveform capture Analyze Power Inverter waveforms to determine SOH Perform Electric Machine (motors/generators) rotor and stator tests Analyze Electric Machine data to determine the SOH Perform a dc-dc Converter output test Analyze dc-dc Converter output data

Automotive Research and Design Email: [email protected] www.autoresearchanddesign.com

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Predictive Maintenance Course State of Health (SOH)

Tools and Equipment that will be used in this course: High Voltage Charger High Voltage Discharger Data Acquisition (DAQ) unit Laptop Computer (to analyze data from DAQ) Carbon Pile unit Digital Storage Oscilloscope Special Electric Machine test equipment Serial Data (scan) tool DVOM Insulation Tester Electrical Safety Gloves

Equipment needed at hosting facility to support Predictive Maintenance Training Course:

Current Probes .Fluke I310s or equivalent

o (qty = six) Carbon Pile (VAT 60) or equivalent o (qty = three) DVOM o (qty = five) Insulation Meter.Fluke 1587 or equivalent (or students could bring their own meter) o (qty = four)
Class 0 Electrical Gloves o Minimum 1 pair for each vehicle (3-6 pairs total) o Gloves must have (or maintain) current test certification Utility Carts approximately 36L x 26W x 40H with one shelf (or small benches on wheels) to hold charging and discharging equipment, laptop, and data acquisition equipment o Quantity = Two Each participant MUST bring their own scan tool There must be at least one (1) OEM scan tool At least one scan tool that is not a generic tool for this class!

Vehicles needed at hosting facility to support Predictive Maintenance Training Course:

Minimum of 5 Cars to include:


o o
Three ..Toyota Prius Two .. consisting of Honda Civic (and/or) GM Tahoe Yukon

Note: The AR&D Instructor will bring all other specialty equipments, tools, and supplies to support the training class.

Automotive Research and Design Email: [email protected] www.autoresearchanddesign.com

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