Electric Vehicle Operation and Diagnosis Course

Lesson 1 • High-Voltage System Architecture

Explains high-voltage bus layout, component interconnections, and power flow paths. Builds the system-level mental model required for safe diagnosis.

Lesson 2 • Electric Motor and Inverter Basics

Introduces AC induction, permanent magnet, and switched reluctance motor types alongside inverter control principles. Links motor selection to vehicle performance targets.

Lesson 3 • Electrical Safety Principles

Defines shock hazards, arc flash risks, and lockout/tagout procedures specific to high-voltage EVs. Mandatory safety baseline before any hands-on work.

Lesson 4 • Energy Storage System Fundamentals

Covers battery cell chemistry, pack construction, and state-of-charge estimation methods. Establishes battery knowledge needed for later diagnostic chapters.

Lesson 1 • Cell Balancing Strategies

Compares passive dissipation and active energy-transfer balancing approaches and their trade-offs. Directly impacts pack longevity and capacity utilization.

Lesson 2 • BMS Hardware Architecture

Examines cell monitoring ICs, balancing circuits, and isolation monitoring devices. Connects hardware design to the fault detection capabilities explored later.

Lesson 3 • State Estimation Algorithms

Covers SOC, SOH, and state-of-power estimation methods including Coulomb counting and Kalman filtering. Explains how estimation errors propagate to range prediction.

Lesson 4 • Thermal Management and BMS Interaction

Explains how the BMS commands cooling and heating to maintain cell temperature within safe limits. Connects thermal control to battery longevity and performance.

Lesson 1 • AC Charging Levels and Standards

Distinguishes Level 1, Level 2, and three-phase AC charging in terms of power delivery and connector types. Establishes the charging vocabulary used throughout the chapter.

Lesson 2 • Charging System Fault Diagnosis

Applies systematic fault isolation to common charging failures including pilot faults, insulation loss, and thermal shutdowns. Reinforces diagnostic logic introduced in earlier chapters.

Lesson 3 • DC Fast Charging Architecture

Covers off-board DC charger topology, combined charging system protocols, and high-power thermal challenges. Prepares students for diagnosing fast-charge faults.

Lesson 4 • Onboard Charger Operation

Examines power factor correction, AC-DC conversion stages, and thermal management within the onboard charger. Links charger efficiency to battery charge acceptance.

Lesson 1 • Power Electronics Components

Examines IGBT and SiC MOSFET characteristics, gate driver circuits, and thermal management of power modules. Provides component-level knowledge for inverter fault diagnosis.

Lesson 2 • Drive System Performance Analysis

Uses efficiency maps, torque-speed curves, and thermal derating data to evaluate drive system health. Prepares students for advanced diagnostic interpretation in later chapters.

Lesson 3 • DC-DC Converter and 12V System

Covers the high-voltage to 12V DC-DC converter operation and its role in powering auxiliary loads. Connects 12V system health to overall vehicle operability.

Lesson 4 • Regenerative Braking Integration

Explains blended braking control, brake-by-wire coordination, and energy recovery optimisation. Links regenerative braking to range extension and brake system interaction.

Lesson 1 • Network Fault Isolation Techniques

Applies termination resistance checks, node dropout analysis, and wiring continuity tests to network faults. Reinforces systematic diagnosis using skills from all prior chapters.

Lesson 2 • OBD and UDS Diagnostic Protocols

Covers OBD-II service modes, UDS request/response structure, and session management for EV-specific ECUs. Directly enables scan tool use and DTC interpretation.

Lesson 3 • CAN Bus Signal Analysis

Teaches oscilloscope-based CAN signal measurement, bit timing verification, and error frame identification. Builds hardware-level diagnostic skills beyond scan tool capability.

Lesson 4 • EV Network Architecture Overview

Maps CAN, Ethernet, and FlexRay network segments used in modern EVs and their gateway relationships. Establishes the network topology knowledge required for all diagnostic tasks.

Lesson 1 • Battery Pack Service and Handling

Covers safe lifting, transport, and storage of HV battery packs including damaged or thermally compromised units. Connects handling procedures to fire and chemical hazard prevention.

Lesson 2 • High-Voltage Disable Procedures

Details manual service disconnect removal, capacitor discharge verification, and voltage absence confirmation. Mandatory prerequisite for any physical HV component work.

Lesson 3 • Insulation Resistance Testing

Covers megohmmeter use, test voltage selection, and pass/fail criteria for HV wiring and components. Directly detects insulation degradation before it causes faults.

Lesson 4 • Service Documentation and Compliance

Covers repair order documentation, safety certification records, and regulatory reporting for HV incidents. Connects documentation practices to liability and quality assurance.

Lesson 1 • Drive System Fault Cases

Diagnoses inverter overcurrent, motor winding faults, and resolver errors using oscilloscope and scan tool data. Connects drive system theory to hands-on fault resolution.

Lesson 2 • Charging System Fault Cases

Works through onboard charger failures, EVSE communication errors, and DC fast-charge interruptions systematically. Applies charging system knowledge to real customer complaints.

Lesson 3 • Battery and BMS Fault Cases

Analyses cell imbalance, isolation faults, and SOH degradation cases using BMS data and physical testing. Reinforces BMS knowledge from earlier chapters in a diagnostic context.

Lesson 4 • Diagnostic Process Framework

Introduces the six-step diagnostic process: verify, define, research, test, repair, and confirm. Provides the repeatable workflow applied to every case in this chapter.

Lesson 1 • Predictive Maintenance and Telematics

Uses telematics data streams and machine-learning health indicators to anticipate EV component failures. Advances students from reactive repair to proactive service strategies.

Lesson 2 • Solid-State and Next-Gen Batteries

Introduces solid-state electrolyte technology, lithium-sulfur chemistry, and their service implications. Equips students to service future battery platforms as they enter the market.

Lesson 3 • Vehicle-to-Grid and V2H Systems

Explains bidirectional charging hardware, grid interconnection requirements, and energy management control. Connects V2G capability to new service and commissioning tasks.

Lesson 4 • Advanced Driver Assistance Integration

Covers ADAS sensor calibration requirements triggered by EV-specific repairs such as motor or suspension work. Links ADAS recalibration to complete repair quality.