Cover
Half Title
Title
Copyright
Contents
Preface
About the authors
Acknowledgements
1 Introduction to electric vehicles
1.1 Types of electric vehicle
1.1.1 Introduction
1.1.2 Pure electric vehicles
1.1.3 Hybrid electric vehicles
1.1.4 Plug-in hybrid electric vehicles
1.1.5 How to recognise an EV
1.2 Safety
1.2.1 High-voltage
1.2.2 Quiet operation
1.2.3 Engines
1.2.4 Personal protective equipment
1.2.5 Work on electric vehicles
1.2.6 Emergencies
1.2.7 EVs are perfectly safe!
1.3 Driving
1.3.1 Driving an EV
1.3.2 Range
1.3.3 Range anxiety
1.3.4 Other advantages
1.4 Charging
1.4.1 Location of charging ports
1.4.2 Charging methods
1.4.3 Time to recharge
1.5 Test cycle and emissions
1.5.1 Carbon dioxide
1.5.2 Worldwide harmonised light vehicles test procedure
1.5.3 Life cycle assessment
1.5.4 Intelligent programming
1.6 Fear, uncertainty and doubt
1.6.1 Introduction
1.6.2 EV myths
1.6.3 EV speed
2 Safe working, tools and hazard management
2.1 General safety precautions
2.1.1 Introduction
2.1.2 Safety
2.1.3 IMI TechSafeโข
2.1.4 General safety guidance
2.1.5 General risks and their reduction
2.2 High-voltage safety precautions
2.2.1 Introduction
2.2.2 Low and high-voltage
2.2.3 Defining high-voltage
2.2.4 Personal protective equipment (PPE)
2.2.5 High-energy cables and components
2.2.6 AC electric shock
2.2.7 DC electric shock
2.2.8 Protection devices
2.3 Safe work process
2.3.1 Risks of working with EVs
2.3.2 Work categories
2.3.3 Valeting, sales and other lower risk activities
2.3.4 Incident response, including emergency services and vehicle recovery
2.3.5 Maintenance and repair, excluding high-voltage electrical systems
2.3.6 Working on high-voltage electrical systems
2.3.7 Work processes
2.3.8 Lifting techniques
2.3.9 Annual inspections
2.4 Hazard management
2.4.1 Initial assessment
2.4.2 Fire
2.5 Tools and equipment
2.5.1 Introduction
2.5.2 Hand tools
2.5.3 Test equipment
2.5.4 Workshop equipment
2.5.5 High-voltage tools
2.5.6 Scanner
2.6 Equality, diversity and inclusion (EDI)
2.6.1 Authorsโ comment
2.6.2 Institute of the Motor Industry (IMI)
2.6.3 What is equality?
2.6.4 What is diversity?
2.6.5 What is inclusion?
2.6.6 What are the protected characteristics?
3 Electrical and electronic principles
3.1 Basic electrical principles
3.1.1 Introduction
3.1.2 Electron and conventional flow
3.1.3 Effects of current flow
3.1.4 Fundamental quantities
3.1.5 Describing electrical circuits
3.1.6 Conductors, insulators and semiconductors
3.1.7 Factors affecting the resistance of a conductor
3.1.8 Resistors and circuit networks
3.1.9 Magnetism and electromagnetism
3.1.10 Electromagnetic induction
3.1.11 Mutual induction
3.1.12 Basic motor principle
3.2 Definitions and laws
3.2.1 Ohmโs law
3.2.2 Lenzโs law
3.2.3 Kirchhoffโs laws
3.2.4 Faradayโs law
3.2.5 Flemingโs rules
3.2.6 Ampereโs law
3.2.7 Summary
3.3 Electronic components
3.3.1 Introduction
3.3.2 Components
3.3.3 Integrated circuits
4 Electric vehicle technology
4.1 Electric vehicle layouts
4.1.1 Identifying electric vehicles
4.1.2 Single motor
4.1.3 Wheel motors
4.2 Hybrid electric vehicle layouts
4.2.1 Introduction
4.2.2 Classifications
4.2.3 Operation
4.2.4 Configurations
4.2.5 48 V hybrid system
4.2.6 Porsche 800 V performance battery system
4.2.7 Hybrid control systems
4.2.8 Hybrid case study
4.2.9 Efficiency
4.3 Cables and components
4.3.1 High-voltage cables
4.3.2 Components
4.3.3 Inverter developments
4.3.4 ECE-R100
4.4 Other systems
4.4.1 Heating and air conditioning
4.4.2 Thermal challenges
4.4.3 Liquid cooling
4.4.4 Heat pumps
4.4.5 Brakes
4.4.6 Power-assisted steering
4.4.7 DC-to-DC converter
4.4.8 Thermal management case study
4.4.9 Radiant heating
4.5 High-voltage safety system
4.5.1 Introduction
4.5.2 Pilot line
4.5.3 Crash safety
4.5.4 Insulation resistance
4.6 Heavy vehicles
4.6.1 Overview
4.6.2 Heavy vehicle options
4.6.3 Bus and coaches
5 Batteries
5.1 Overview
5.1.1 Describing a battery
5.1.2 What is a kilowatt-hour?
5.1.3 Battery life and recycling
5.1.4 State of charge
5.1.5 State of health
5.2 Types of battery
5.2.1 Introduction
5.2.2 Lead-acid batteries (PbโPbO2)
5.2.3 Alkaline (Ni-Cad, Ni-Fe and NiโMH)
5.2.4 Sodiumโnickel chloride (NaโNiCl2)
5.2.5 Sodium-sulphur (Na-S)
5.2.6 Lithium-ion (Li-ion)
5.2.7 Lithium-ion blade-battery case studies
5.2.8 Tesla battery case study
5.2.9 Fuel cells
5.2.10 Super-capacitors
5.2.11 Comparing energy storage methods
5.3 Battery technologies
5.3.1 Ambient temperature
5.3.2 Battery temperature
5.3.3 Thermal runaway
5.3.4 Solid-state batteries
5.3.5 Swarm intelligence
5.4 Research and development
5.4.1 Battery research
5.4.2 Toyota 1500 km battery
5.4.3 Fire detection
5.4.4 Leading edge (lithium-air)
5.4.5 Obituary
6 Motors and control systems
6.1 Introduction
6.1.1 Types of motor
6.1.2 Trends
6.2 Construction and function of electric motors
6.2.1 AC motors: basic principle
6.2.2 Asynchronous motor
6.2.3 Synchronous motor: permanent excitation
6.2.4 DC motor: series wound
6.2.5 DC motor: separately excited shunt wound
6.2.6 Electronically commutated motor
6.2.7 Switched reluctance motor
6.2.8 Motor efficiency
6.2.9 Motor torque and power characteristics
6.2.10 Winding shapes and insulation
6.2.11 Axial and radial windings
6.2.12 Drive motor developments and case studies
6.3 Control system
6.3.1 Introduction
6.3.2 Basic operation
6.3.3 Start up and shut down
6.3.4 High-voltage DC relays
6.3.5 Power control
6.3.6 Pulse-width modulation
6.3.7 Sensors
6.3.8 Battery
6.3.9 Battery management systems
6.3.10 Cell balancing
6.3.11 Component cooling
7 Charging
7.1 Charging, standards and infrastructure
7.1.1 Infrastructure
7.1.2 Standardisation
7.1.3 Charging time and cost
7.1.4 Charging methods, modes and plugs
7.1.5 Communication
7.1.6 Fast charging
7.1.7 Vehicle-to-grid
7.1.8 Charging case study
7.2 Wireless power transfer
7.2.1 Introduction
7.2.2 Stationary WPT
7.2.3 Dynamic WPT
8 Maintenance, repairs and replacement
8.1 Before work commences
8.1.1 Introduction
8.1.2 Technical information
8.1.3 De-energising
8.2 During work
8.2.1 Maintenance intervals
8.2.2 Repairs affecting other vehicle systems
8.2.3 Inspect high-voltage components
8.2.4 Cables
8.2.5 Battery
8.2.6 Other components
8.3 Remove and replace
8.3.1 High-voltage components
8.3.2 Battery pack
8.3.3 Low-voltage components
8.4 Completion of work
8.4.1 Re-energising
8.4.2 Results, records and recommendations
8.5 Recovery and roadside assistance
8.5.1 Introduction
8.5.2 Emergency start
8.5.3 Roadside repairs
8.5.4 Recovery
8.5.5 Towing
8.5.6 Emergency response
8.5.7 Fire
8.5.8 Damaged vehicle delivery
8.5.9 Accident and incident reporting
8.6 Transportation and storage
8.6.1 Electric vehicles
8.6.2 High magnetic strength components (motors)
8.6.3 High-voltage batteries
8.6.4 Storage of cells and battery packs
8.7 Recycling industry guidance
9 Diagnostics
9.1 Diagnostic operations
9.1.1 Introduction
9.1.2 Live data
9.1.3 Insulation testing
9.1.4 Equipotential bonding
9.2 Diagnostic tools and equipment
9.2.1 Introduction
9.2.2 De-energisation procedures
9.2.3 Two-pole tester
9.2.4 Multimeter and insulation tester
9.2.5 Amp clamp
9.2.6 Oscilloscope
9.2.7 Differential probe
9.2.8 Scanner
9.2.9 Summary
9.3 Non-invasive measurements
9.3.1 Introduction
9.3.2 Known good waveforms and measurements
9.3.3 COP and signal probe
9.3.4 Current flow: HVAC
9.3.5 Current flow: motor
9.3.6 Summary
9.4 Charging testing
9.4.1 Protocol
9.4.2 Communication
9.4.3 Breakout box
9.4.4 Charging waveforms
9.5 Three-phase testing
9.5.1 Operation
9.5.2 Motor drive waveforms
9.6 Batteries
9.6.1 Battery repairs
9.6.2 Balancing
9.7 Summary
10 High-voltage pathway for the in dependent workshop
10.1 Introduction
10.2 Analysing the EV/hybrid market
10.2.1 Demographics of EV/hybrid owners
10.2.2 Common issues that require garage services
10.2.3 Projected growth of the EV/hybrid market
10.3 Adapting your business model
10.3.1 Adjusting service prices
10.3.2 Offering EV-specific services
10.3.3 Building relationships with EV/hybrid owners
10.4 Setting up the workspace for EV/hybrid maintenance
10.4.1 High-voltage safety considerations
10.4.2 EV-specific equipment placement
10.4.3 Adequate ventilation for battery work
10.5 Building relationships with suppliers, industry associations and technology providers
10.5.1 Benefits of relationships
10.5.2 How to establish these relationships
10.6 Opportunities and challenges
10.6.1 The growing market for EV repair and maintenance
10.6.2 Potential challenges and how to overcome them
10.7 Suggested checklist for transitioning to EV/hybrid maintenance
10.8 Summary
10.9 Case studies
10.9.1 Lindleys autocentres (Nottingham)
10.9.2 Cleevely EV (Cheltenham)
Index