Electric Vehicle Technician CBT

Electric Vehicle CBT

The Electric Vehicle (EV) Technician CBT is intended to meet the demand for people who are skilled in diagnosing, servicing and repairing EVs and commercial charging stations. The EV CBT provides both theoretical and laboratory instruction through a combination of multimedia learning resources and simulation software to allow for the testing, validation, and understanding of electrical and electronic circuits that are found in a typical EV. The CBT is designed primarily for automotive service technicians who have a strong background in internal combustion engine (ICE) powered vehicles, but who lack the knowledge and skills in power electronics and data communication systems to safely perform service-related work on EVs and Hybrid Electric Vehicles (HEVs). In addition, the CBT is intended for electricians who will be installing, servicing and maintaining residential and commercial EV charging stations. The EVT CBT will also be highly beneficial to anyone who is interested in a career servicing, repairing, designing or selling EVs.

EVT

The multimedia program presents fourteen modules of interactive curriculum using text, video, 2D and 3D animations, photos, audio clips and interactive lab simulations. The Electric Vehicle CBT presents an in-depth, interactive coverage of the fundamentals of electric vehicles, built within an innovative state-of-the-art computer-based training and simulation environment. The module material is delivered using video, audio, text, 2D and 3D animations, photos, and many simulation-based laboratory exercises using CircuitLogix Pro and 3DLab. Click on the link below for a demonstration of the lab simulation software used in the Electric Vehicle CBT.

The following links provide you with detailed descriptions of the modules contained in the Electric Vehicle Technician CBT.

  1. Introduction to EVs
  2. Basic Electricity
  3. Direct Current Circuits
  4. Alternating Current Circuits
  5. Power Electronics
  6. Batteries & Fuel Cells
  7. Battery Charging Systems
  8. DC Motors & Controls
  9. AC Motors & Controls
  10. Powertrains
  11. Sensors & Actuators
  12. Communication & Control
  13. Safety, Maintenance & Repairs
  14. Autonomous Vehicles

Module 1 - INTRODUCTION TO EVs
This module is designed to introduce the student to the fundamental concepts of electric vehicles (EVs) and describe some basic applications. This module covers the differences between BEVs, HEVs and FCEVs and describes the advantages of electric motors over internal combustion engines. The basic types of EV frames are discussed as well as the purpose of the reduction gearbox.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Differentiate between a BEV, HEV, and FCEV.
  • List the three main types of HEVs.
  • Calculate the MPGe of an electric vehicle.
  • Describe two EV accessories with the highest range impact.
  • Name three EV regulatory agencies.
  • Differentiate between series hybrid and parallel hybrid.
  • Define the term instant torque.
  • Name four advantages of electric motors over ICEs.
  • Describe the main difference between an ECU and VCU.
  • List three types of EV frames.
  • Explain the purpose of a reduction gearbox.

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Module 2 - BASIC ELECTRICITY
This module introduces students to the fundamentals of current, voltage and resistance and Ohm's law. In addition, the module introduces essential concepts such as the relationship between temperature and resistance, electron velocity, and the direction of current flow. The module also covers the difference between work and energy and explains the methodology of calculating power consumption.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Apply the principle of electric charge.
  • Express Coulomb's Law.
  • Define electric current.
  • Explain electron flow and conventional flow.
  • Describe electric potential and voltage.
  • List the five main types of voltage sources.
  • Differentiate between a voltage and current source.
  • Define resistance.
  • Explain the difference between capacitance and inductance.
  • Use Ohm's law to find voltage, current or resistance.
  • Describe relationship between temperature and resistance.
  • Differentiate between work and energy.
  • Determine efficiency of an electrical device.
  • Calculate power consumption in kilowatt-hours.

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Module 3 - DIRECT CURRENT CIRCUITS
This module is designed to cover the fundamentals of series, parallel, and series-parallel circuits. A discussion of positive ground and negative ground is presented, as well as the effects of connecting voltage sources in parallel. The theoretical and practical aspects of basic circuit calculations using Kirchhoff's voltage and current laws are also presented in this module using a combination of video, animation, and laboratory projects using CircuitLogix simulation software.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Describe how voltages are distributed in a series circuit.
  • Define Kirchhoff's Voltage Law and Current Law.
  • Determine the polarity of emfs and voltage drops.
  • Calculate internal resistance.
  • Use the voltage divider and current divider rule.
  • Describe the effect of connecting voltages sources in parallel.
  • Define positive ground and negative ground.
  • Determine the total resistance in a series-parallel circuit.
  • Calculate voltage drops and power.
  • Explain the purpose of loaded voltage dividers.
  • Describe the basic principles of DMMs and probes.
  • Troubleshoot DC circuits.

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Module 4 - ALTERNATING CURRENT CIRCUITS
This module introduces the fundamentals of alternating voltages and currents. In addition to sine waves, the module also covers non-sinusoidal waveforms and harmonic frequencies. The phase relationships between alternating current and voltage are also described. The principles of transformers and transformer polarity are presented as well as the effects of inductive and capacitive reactance on AC circuits.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Identify sine waves.
  • Explain the instantaneous value of a sine wave.
  • Define impedance.
  • Determine the average and RMS values of a sine wave.
  • Describe the phase relationships between alternating current and voltage.
  • Explain the basic operating principle of transformers.
  • List the standard markings used to identify transformer polarity.
  • Differentiate between a sinusoidal and non-sinusoidal wave.
  • Name three types of non-sinusoidal waves.
  • Define harmonics.
  • Explain the effects of inductive and capacitive reactance on AC circuits.
  • Discuss power in AC circuits.

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Module 5 - POWER ELECTRONICS
This module will provide the student with an introduction to power semiconductor devices including power MOSFETS and IGBTs. The module is designed to demonstrate the purpose of rectifiers, inverters and converters and their application in EV powertrains. A discussion of filters is also covered along with a comparison of isolated and non-isolated converters. In addition, an introduction to troubleshooting power electronics devices and circuits is presented.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Define power electronics.
  • Explain the difference between a FET and a BJT.
  • List two main types of power transistors.
  • Differentiate between enhancement and depletion mode.
  • Describe the operation of an SCR.
  • Compare inverters and converters.
  • List three types of rectifiers.
  • Explain the difference between a coupling and bypass capacitor.
  • Describe the purpose of filters in power electronics circuits.
  • Compare isolated and non-isolated converters.
  • Name five types of converters.
  • Troubleshoot diodes, rectifiers, and transistors.

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Module 6 - BATTERIES & FUEL CELLS
This module provides an introduction to EV batteries and fuel cells and describes the three main types of batteries used in an EV.. The student will learn to calculate the internal resistance of a battery and explain the chemical composition of EV batteries and fuel cells. The module also covers the main components of a battery management system and describes standard protective measures and safety considerations for EV batteries.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Differentiate between calendar life, charge cycle, and cycle life.
  • Define the term "battery capacity".
  • Explain the difference between SoH and SoC.
  • Calculate the internal resistance of a battery.
  • List the three main types of batteries used in EVs.
  • Explain the purpose of a separator in a battery cell.
  • Name three types of cathode materials in a lithium-ion battery.
  • List five types of fuel cells.
  • Describe the main components in a battery management system.
  • Explain the difference between a relay and a contactor.
  • Differentiate between a CMC and BMC.
  • Name five protective measures for EV batteries.

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Module 7 - BATTERY CHARGING SYSTEMS
This module will focus on the various types of battery chargers in use, including Level 1, 2 and 3 EVSEs. It will also cover the five basic types of EV connectors and the principle of bidirectional charging. In addition, the student will learn how to calculate charging time and charging cost. Upon completion of this module, the student will also be able to describe the purpose of OCPP and the main considerations for commercial EVSE installations. EVSE test equipment will also be discussed as well as the steps required to safely charge an EV.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Differentiate between Level 1, Level 2 and Level 3 chargers.
  • Define acceptance rate.
  • Explain the purpose of power factor correction in an OBC.
  • Name the two main types of Level 3 chargers.
  • Describe the principle of bidirectional charging.
  • List the five basic types of EV connectors.
  • Calculate charging time and charging cost.
  • Define the term peak shaving.
  • Explain the purpose of Open Charge Point Protocol (OCPP).
  • Name five considerations for a commercial EVSE installation.
  • Describe the main features of EVSE test equipment.
  • Discuss the two main safety hazards associated with EVSEs.
  • List seven steps that ensure safe charging of an EV.

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Module 8 - DC MOTORS & CONTROLS
It is in this module that the student learns the principles of DC motors and the systems that are used to control their speed and direction. The main components of a DC motor are explained and the fundamentals of torque, counter emf and speed regulation are introduced. The applications of DC motors in EVs are presented and the most popular DC motors, including BLDCs are described. An introduction to pulse width modulation (PWM) and regenerative braking is included as well as the principles of four quadrant operation of a motor.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Name the main components of a DC motor.
  • Explain the purpose of commutation.
  • Differentiate between a stator and an armature.
  • Define torque and counter emf.
  • Calculate the torque of a DC motor.
  • Explain the operating principle of BLDC motors.
  • Name the two commutation methods in BLDCs.
  • Determine the % speed regulation of a DC motor.
  • Calculate the step angle of a stepper motor.
  • List five types of stepper motors.
  • Explain how PWM is applied to DC speed control.
  • Define the terms dynamic and regenerative braking.
  • Describe the four quadrant operation of a DC motor.

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Module 9 - AC MOTORS & CONTROLS
This module provides an introduction to the basic operation of AC motors and explains the difference between synchronous and asynchronous motors.. Starting torque and breakdown torque are described. In addition, the student will learn how to calculate synchronous speed and speed regulation of AC motors. The advantages of PMSMs over induction motors in EV applications are also presented. The main components in AC motor speed control are also discussed.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Explain the basic operating principles of induction motors.
  • Differentiate between synchronous and asynchronous motors.
  • Define starting torque and breakdown torque.
  • Describe how torque is developed in a 3-phase induction motor.
  • Calculate synchronous speed.
  • Name three types of synchronous motors.
  • Describe operation of a permanent magnet synchronous motor.
  • List three advantages of a PMSM over an induction motor.
  • Differentiate between flux density and power density.
  • Name the main components in AC motor speed control.
  • Explain the difference between scalar control & vector control.

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Module 10 - POWERTRAINS
This module will focus on EV powertrains and its components and systems. The student will learn the three types of differentials used in EVs and the main components in a motor controller. The difference between 4WD and AWD powertrains is also discussed as well as the reason for using field weakening in regenerative braking. This module also introduces the student to EDUs and the operating principles of mild hybrid and full hybrid powertrains.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Differentiate between powertrain, drivetrain and driveline.
  • Name the three main types of EV motors.
  • Define the term "power density".
  • Describe the operation of an EV transmission.
  • List the three types of differentials used in EVs.
  • Explain the difference between 4WD and AWD.
  • Name the main components in a motor controller.
  • Describe the purpose of FOC in EV applications.
  • Explain how field weakening is used for regenerative braking.
  • Name the three main components in an EDU.
  • Describe how unsprung weight affects in-wheel motors.
  • Differentiate between a mild hybrid and full hybrid.
  • List the three main classifications of HEV powertrains.

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Module 11 - SENSORS & ACTUATORS
This module introduces the student to the fundamentals of EV sensors and actuators. In addition to pressure and temperature sensors, the operating principles of ultrasonic sensors and the purpose of digital cameras in driver assist systems is also covered. The student will also learn the main types of actuators on the body of EVs and be able to describe the operation of solenoid valves and motor position sensors. In addition, the steps required for troubleshooting sensors and actuators is also discussed.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • List the four main quantities measured by sensors in EVs.
  • Describe the difference between and NTC and PTC thermistor.
  • Name three applications for pressure sensors in EVs.
  • Explain the operating principle of ultrasonic sensors.
  • List four applications of digital cameras in driver assist systems.
  • Name three types of actuators on the body of EVs.
  • Describe the operation of solenoid valves in EV applications.
  • List four applications of temperature sensors in EV powertrains.
  • Explain the difference between Hall-effect and shunt current sensors.
  • Name the two methods of motor position sensing.
  • Discuss how speed is measured in an EV.
  • Describe the danger of thermal runaway how it can be prevented.
  • List the three basic steps for troubleshooting sensors and actuators.

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Module 12 - COMMUNICATION & CONTROL
It is in this module that the student learns the principles of gateways and communication buses. The five main communication protocols in EVs are also described including the CAN protocol. Communication conductors are also discussed and the basic operating principles of MCUs, VCUs and ECUs are explained. In addition, an introduction to zonal architecture and domain architecture is presented.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Explain the purpose of a communications bus.
  • List the seven layers in the OSI topology.
  • Differentiate between ring, star and bus topology.
  • Describe the purpose of a gateway in a communication system.
  • Compare a CAN transceiver's recessive and dominant state.
  • List five types of communication protocols used in EVs.
  • Explain the main difference between CAN and CAN FD.
  • Name four benefits of automotive Ethernet.
  • Compare three of the most common communication conductors in EVs.
  • Describe the basic operating principles of MCUs.
  • Explain the difference between a VCU and ECU.
  • Differentiate between zonal architecture and domain architecture.

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Module 13 - SAFETY, MAINTENANCE & REPAIRS
This module describes the difference between active safety and passive safety and outlines the most important safety features found in EVs. It also covers safety risks associated with ADAS and hazardous conditions such as arc flashes. Safety equipment such as PSSs, battery protection units and battery management systems are also described. In addition, the module also includes a discussion of PPE requirements for troubleshooting EVs as well as safe troubleshooting practices.
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Differentiate between active safety and passive safety.
  • List seven safety features found in EVs.
  • Describe the two main safety risks associated with ADAS.
  • Distinguish between an arc flash and an arc blast.
  • Explain the operation of a pyrotechnic safety switch (PSS).
  • Differentiate between an active and passive discharge system.
  • Compare a battery protection unit and battery management system.
  • Distinguish the maintenance procedures for high voltage vehicles.
  • Name five types of sensors in an EV charging station.
  • Describe a typical EV maintenance schedule.
  • Differentiate between PIDs and DTCs.
  • List five types of essential PPE for troubleshooting HV systems.
  • Apply safe troubleshooting practices to HV systems.

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Module 14 - AUTONOMOUS VEHICLES
This module introduces the student to autonomous vehicles and the fundamental differences between AVs and EVs. The various levels of autonomy are discussed as well as the benefits of each respective level. A comparison of relative and global localization is presented, Various types of odometry sensors and AV steering controllers are described. In addition, the module also provides an introduction to artificial intelligence (AI).
Learning Outcomes:
Upon completion of this module the student will be able to:

  • Differentiate between an AV and EV.
  • Define phantom traffic jams.
  • List three benefits of AVs.
  • Describe the meaning of spatial perception.
  • Name the six levels of autonomy.
  • Differentiate between static and dynamic object detection.
  • Explain the basic principle of Kalman filters.
  • Describe the operation of flash LiDAR.
  • Compare relative and global localization.
  • Explain the purpose of sensor fusion.
  • Name two types of odometry sensors.
  • Discuss the three most popular AV steering controllers.
  • Define the term Artificial Intelligence (AI).
  • Differentiate between machine learning & deep learning.

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