Hybrid Electric Panel Training Equipment

(HYD104)

1. Blowing fan status LED 2. High Voltage Battery Status LED 3. Electric Motor Status LED 4. Inverter Status LED 5. AC Compressor Status LED 6. Trainer ON/OFF Switch 7. H.V Batt Temperature Indicator 8 H.V Batt. Manual Disconnector 9. H.V Batt. SOC Indicator 10. 12V Batt. GND Disconnector 11. L.V Batt. SOC Indicator 12. DC/DC Converter Status LED 13. Pre-chargContactor Status LED 14.Negative Contactor Status LED 15. Positive Contactor Status LED 16. Overload Status LED 17. Low Voltage Battery Status LED

Pre-charge state during car start
Start-up assist
Engine-powered operation
Motor-powered operation
Acceleration assist
Regenerative braking
Response under DC-DC converter failure
Response under three-phase inverter failure
Response under high thermal dissipation from traction battery
Response under 12V battery failure

Power supply:
- 220V AC 50/60 Hz
• Operating switch power capability: 10A AC • Touch screen size: 10-inch.
• High Voltage battery Type :
- Nickel hydride.
Low Voltage battery type :
- Sealed Lead Acid.
High Voltage battery rating :
- 172 VDC 116Ah.
Pre-charge Resistor Rating :
- 5 Ohm 50W
DC/DC converter rating :
- 200VDC To 14.2 VDC 2.8kW
DC/AC converter rating :
- 315VAC 19kW
Electric motor:
- continuous power rating (for 40 min) : 8kW @ 1400-6000 RPM
- Maximum power rating (for 5 sec) : 15kW @ 1500-4000 RPM.
- Maximum Torque rating : 94 Nm @ 126A.
- Maximum Speed rating : 6300 RPM.

Hybrid Electric Panel Training Equipment (HYD104).
Hard copy user manual

Digital content (B-01)

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Description
Technical Details

This trainer is a simulation for a “Mild Hybrid” car. The simulation (HYD104) depicts the electrical system and powertrain system found inside a Mild Hybrid Car. The trainer aims at demonstrating the principles of “Integrated Motor Assist” technology used in mild hybrid cars. Trainees will be introduced to the concept of hybridization and its influence on improving car performance, as well as its role in lowering carbon dioxide emissions in the atmosphere. The trainee will be able to control the car lever position, acceleration pedal and brake pedal through an interactive software, hence, giving the user the same driving experience as in real life.

The educational unit features a setup placed on a wooden bench. The setup comprises the power electronic components embedded within a mild hybrid car. Students will be able to visualize how the wire harnessing is implemented between the various electrical components. The electrical system is composed of the following components:
- High Voltage Nickel-Metal Hydride Traction Battery
- Battery Management Unit
- Pre-charge Contactor Unit
- Power Control Unit which encloses the Three-phase Inverter and DC-DC buck Converter
- 14kW permanent magnet three-phase synchronous electric motor.
Printed on the front panel of the trainer is a schematic diagram of the interconnection between components of the electrical system in a mild hybrid car. The diagram shows how the DC link input of converters and inverters are wired to the pre-charge contactor, as well as shows how the high voltage system is connected to the 12V system through the DC-DC converter.
The front panel includes a 10-inch Touch screen where all the interaction takes place.
The 10-inch Touch screen is programmed with a special software created within BEDO. There are three pages which the user can navigate through them. The pages are as follows:
- Dashboard / Start-Stop page
- Configuration page
- Internal Fault Activation page
In the Dashboard page, the user can ignite the car and start driving. There are three modes for the lever position which are Park, Neutral, Drive, Park. The car speed is increased through a virtual accelerating pedal. Similarly, car speed is decreased through a virtual brake pedal. The dashboard also shows the current engine RPM, as well as the linear speed of the car. In addition, the percentage of hybridization is displayed on the screen to alert the driver how much fuel is being burnt with respect to electrical to produce the accelerating power. The amount of carbon emissions released for various trips can also be displayed.
In the configuration page, the user can adjust control parameters (such as engine compartment temperature, battery SOC level and driver compartment temperature). The main purpose of this page is putting the car under different operating conditions to observe how the virtual Energy Management Unit will try to manage the high voltage battery and fuel resources such that car performance is at its optimum and driver comfort is of highest priority. The student monitors the distance driven throughout the journey and the total fuel consumption to calculate the miles per gallon under different operating conditions.
In the Internal Fault Activation page, the user can de-activate an electrical component such that it appears as a defective element in the system. The student then observers how the virtual ECUs interact together to solve such a malfunction.
The front panel contains nine signal pilot LED indicators and three two-state LED indicators. The pilot indicators are used to specify whether an element is operating normally or defective (if activated from faults page), whereas the two-state LED indicators are used to specify the status of the following components:
- High voltage battery is being charged or discharging
- Electric machine is assisting the engine or used as a generator to charge DC link
- 12V battery is being charged or discharging
The front panel contains small LED indicators. There are mono-color indicators which are used to show whether the electric motor is in the prime mover state or in the energy recuperation state. There are also multi-color LED indicators which represent a heat indicator to tell whether object temperature is high or low.
The trainer is supported on four wheels with a brake.

Digital content (BI-01)

BI-01

Hybrid Electric Panel Training Equipment

(HYD104)