Unique Hybrid Technology

Transcription

Unique Hybrid Technology
This class will help you understand the more
advanced concepts used in EMVs today. Based on
our own research and tech support calls over the last
15 years, this short class will have long benefits.
ACDC Craig Van Batenburg© 2015
Craig Van Batenburg, CEO
ASE Master L1 L3
508 852 5857
www.FIXHYBRID.com
E
[email protected]
Automotive Career
Development Center
ACDC
40 Boyd Street Suite 200
Worcester, MA 01606
How did ACDC evolve 1999 - 2015
The Legal and Disclaimer Note
HIGH VOLTAGE systems in HYBRID and
Electric vehicles can be lethal. ACDC
offers hands-on HYBRID training. Use
protective equipment.
Be safe, follow the shut down
procedure per OEM recommendations
before removing or handling any orange
colored HV parts and ALWAYS test for
HV before you go further.
What do we call a Hybrid,
Plug-in or Electric car?
ACDC FLEET
Give your Students a Good
Overview as to WHY HEV?
Real Cost of Oil
Climate Change
Energy
Independence
More Stable World
EVs / FCs are the
end game
ACDC Craig van Batenburg© 2015
Two Important Movies
My Training with Honda in 1972
The Civic was just
coming to
America
I was a Honda
Motorcycle Tech
The First 4 hours
1975 Honda Civic CVCC
Climate Change is the Effect
of Global Warming
Average temp. is 59º F
(15c)
78% Nitrogen 21% O2
400 ppm CO2 or 0.04%
Ozone (O3) is a protective
layer of gas
Radiation enters from the
Sun and warms the earth
Some Radiation must
leave or we will overheat
So What is a “Greenhouse
Effect” ?
All of Earth’s Energy comes
from the Sun as
Electromagnetic Radiation
µm = micrometer or 0.000001 of a meter
Gamma Rays 10 trillionths of a meter (deadly) 100 billionth
Radio Waves many miles long
Visible light is 0.4µm to 0.7µm
“Infrared Window” is where
Earth’s heat escapes
The Moon
Same distance as the Earth from the Sun
Temp at night -238ºF (-150c)
Temp Day 212ºF (100c)
Why?
No Atmosphere
What if the “Window” is
polluted?
Other Green House Gases: Methane, Nitrous Oxide, CFC’s
(man made). They all absorb radiation between 7 and 13 um
wave length, the “Escape Window”
What has been the norm?
What have we done in the last
150 years or so?
The Balance of CO2
When
Technicians
fix CO and
HC, what did
we turn it
into?
Future Numbers
We have burned about 1 trillion barrels
of oil
We have about 10 trillion left of all
sources
800 ppm CO2 killed the dinosaurs
We are at 400pm CO2 and climbing
100 years ago we were at 250ppm CO2
The Stone Age didn’t
end because we ran
out of stones
Using Gasoline for 100 Years.
How are we doing?
This Car Started a Revolution
2003.. Codes for stuck valve
P1436
Cold Start Emissions must be controlled
Collects HC and then treated
after the Cat heats up
Rust Belt … Ugly
2005 … This car had an
intermittent P3009 Code
This was before TechStream
Vetronics
Mastertech
scanner
Many
controllers
effected
C1259 .. Regen Code
P3009 … HV Battery HV Leak
Code
P3000 … HV ECU Code
C1521 and C1522 … EPS Code
Battery Block Voltages
Spec. is
0.02 volt
difference
Freeze Frame
Simple Test for a HV Leak
Component HV Leak Test (CHVLT)
Watch for Triangle Light while you do this
First, clear all codes and make sure the Triangle light is off.
Hook up a good scan tool. Each time you do the action below
watch for the triangle light. When it lights up you have
narrowed your list.
1.
Turn key (do not start ICE) wait 1 -20 minute
2.
Get “Ready” on and get into N as fast as you can (wait 1
-20 minutes)
3.
Shift into P (wait 1 -20 minute…ICE should Start)
4.
Turn on A/C (if electric) wait 1 -20 minutes
5.
Drive car forward and reverse (road test time )
6.
If Electric AWD use lots of power. Go slow first and then
add power.
Note: Put a 12 volt meter hooked to the 12 volt battery where you can see it
Nothing Found that Day
But wait … what are we missing?
Can this be an intermittent
source of a HV Leak
This is the
problem
areas
How can a HV leak be
intermittent?
Contaminated
ATF Fluid
Metal
Moisture
Something Else
Let’s drain some out
Voltmeter
Isolation tester
Do Something
Changing the CVT Fluid fixed
all the codes except the ESP
Do it 2x
C1521 and C1522 … EPS Code
ACDC © 2015 Craig Van Batenburg
Start with the Basics
Use this Every Time. Pin 16 and 4
12 Volt battery in Prius
Black box in front of 12 Volt
battery is a back up 12 volt
battery for the braking system.
This system has a stud under
the hood for a jump start
Same 12 battery precautions
as the early Prius
12.8 v AGM
11.5 Minimum
Nature Does Not Test 12 volt
Batteries in Most EMVs
Tape and Insulated Tools
FAAT CATS
560,000 kids in foster care
125,000 can never go home
29,000 will age out this year
www.faatcats.org
Foster Kids and FAAT CATS
This Class in PPT
Metric to English Converter
More reference materials
Videos and Mpegs
Much More
$20 ($15 goes to
www.FAATCATS.org)
$20 can get you to “Up Your
Voltage” in April 2016 or later
All Expenses to “Up Your Voltage”*
Retail in 2017 will be $4,700.00
Drawing is January 2016
* Up to $350 in
airfare if needed
Prius is a SULEV .. Great EVAP
Prius uses a similar
quick disconnect at fuel
lines, similar to Ford.
A steel gas tank has an
expandable rubber
bladder to help control
EVAP HC’s. Gas refills
will vary based on
outside temperature.
The gas gauge is not
accurate
Used only on Prius… 2001 – 2009
Discontinued in 2010
Jeff cut this open at UYV! VII
Resolver Connections
Stabilant 22a
Resolver (Encoder)
HONDA CIVIC II
Rotor
Interfering
Ring
BAS Very Small Resolver
Rotor is 1” (2.5 cm) height
Resolver Feedback Control
1 Excitation Coil
2 Detection Coils
Rotating egg
shaped iron piece
attached to rotor
Feedback on



Location
Direction
Speed
Resolver
Most motor-generators have a dedicated
resolver. Some have 3 Hall Sensors.
The resolver is a speed sensor.
This allows the MG ECU to determine the
position, direction, and rotational speed of
the MG rotor.
The resolver consists of a stationary stator
and an oval-shaped rotor that turns with the
motor-generator.
The stator contains excitation and detection
coils.
Resolver
The MG (or HV) ECU sends a fixed
frequency signal to the excitation coil.
This signal generates a magnetic field
around the excitation coil, which
expands and contracts with the signal.
As the rotor revolves, signal strength
varies in the S (sine) and C (cosine)
detection coils.
Resolver
Based on the fixed frequency signal and
the signal strength of the detection
coils, the MG (or HV) ECU determines:



Rotor position
Rotor direction
Rotor speed
The position can be determined
without rotating the shaft
Resolver Alignment
Pico Scope Resolver ..
Normal Pattern
Interlocks
Put all
covers
back
before
starting
car
Inverter
Simple Layout
Blinking Gas gauge (all bars)
indicates no communication from
PCM to DLC
Dim or Blinking “P” indicates low voltage at 12
volt battery
What about scopes?
$400 to $800
for each
Differential
Probe
ACDC 2015 Craig Van Batenburg
Scope Safety
Differential Probes used for Safety
Work Benches
Plastic
Steel
Wood
Body Shop Concerns
Do not exceed 150 deg.
F (63 c.) if baking paint
in an oven. Check the
manual.
30 minutes max.
HV batteries can be
damaged.
2011 Volt Has Problems
2011 Chevy Volt will not Charge
Scanning the Volt
Code POCD2 … Charge Door
Maxidas Scan Tool P1FFF
2011 Volt Fail to Charge HV
Battery
Recently at dealer for update
How Does it Cool
Volt
So what
was
wrong?
Proper Bleeding Required
We broke the VOLT
ACDC Craig Van Batenburg © 2015
Disconnect High Voltage Fuse
Tape up Power Button First
Or
Disconnect 12 Volt Battery
If you Push the Power Button
with the Service Disconnect Out
Remove Keyless Transmitter from
Range … Extra Key in car?
Remove Inverter Cover
Inverter Cover Interlock
Make Sure Interlock Plug Stays with
Cover
Disconnect Cables from High Voltage
Battery by Loosening Connecter
Verifying No Voltage at Battery
Connector
Verifying No Voltage at Inverter
Perform repair system now
safe
ACDC Craig Van
Batenburg © 2015
Page 71
Service Mode
This is included with the ACDC HEV
book.
You must disable “Idle Stop” to do
maintenance and diagnose ICE issues
2011 Nissan LEAF
Pure Electric
LEAF A/C system
LEAF Heater Diagram
All 2011-2012 and Base model S (2013-2015)
2015 Kia Soul EV and Leaf 20132015 have a New HVAC
Valves Reverse Flow
Not Used in Base Leaf S Model (2013-2015)
2013 Nissan Leaf (top two trim
levels) has a Heat Pump of sorts

The Evaporator and Condenser
trade jobs
Why use this system
EVs try to get more range without
adding more batteries
What must an HVAC do?
-30 C = -22 F
Next slides are courtesy of Kia
Power Electronics = P.E.
High Voltage will help Heat Cabin
When Needed
Waste Heat is Used for
Heating
What Components Produce Heat?
Moving Flaps…Cooling
Heating …. Normal Mode
Heating with Iced Outside
Cond.
Heating with Defogger On
Concept for more Heat on EV
Cooling Cycle is Normal
This is How it Cools
TXV = Thermal Expan
More to go
wrong and
more to fix
when it
does
Heating the Cabin with the
A/C
The Front Condenser is now an
Evaporator
Valves redirect refrigerant
(R134a)
HVAC is getting more complex
BSHS…How do we introduce
HEV and EV at that level?
What Else Does ACDC Offer
Additional Study
We have a NEW Hybrid 101 series that
was recorded in the Fall of 2014
8 Parts (over 8 hours with PDFs)
Retail is $425 $50 off if ordered before
September 30, 2015.
Up Your Voltage! 42
6 Days of Hybrid / EV
Seekonk, Massachusetts
16 students
9 HEV / PHEV / EV at Class
Scanners, scopes, lots more
Hands-on
October 20-26, 2015
$4,400.00 … Books, Hotel, Meals
Price Increase in 2016
ACDC has two books out
Every Hybrid / EV
350 pages
Tips per model
Glossary / Charts A/C
Color $250
At Class $200
Introduction to HEV, PHEV and EV
90 Pages
New 2015
This Class was
based on this book
Retail $100
At Class $80
Also in Spanish
We are a Partner with
Electude on-line Training
My Experience with Dutch
Automotive Schools
The van Batenburg’s former home
Last Chance for Questions
The Automotive World is Changing

Unique Hybrid Technology

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