Hybrid Learner Guide

DEPARTMENT OF AUTOMOTIVE ENGINEERING
HYBRID ELECTRIC VEHICLE SYSTEMS & SAFETY
LEARNER’S GUIDE
Version 1.0
Issue Date: 12/06/2017
©Technical Training Division

National Training & Productivity Centre
2/8 Queen Elizabeth Drive, Nasese
P. O. Box 15676, Nasinu
Republic of Fiji
http://www.fnu.ac.fj
All rights reserved. This material may not be duplicated or reproduced in print without written permission
from NTPC, FNU.
HYBRID ELECTRIC VEHICLE SYSTEMS
& SAFETY
Foreword
I am delighted to present these training materials developed by the National Training and
Productivity Centre (NTPC) to enhance your theoretical and practical knowledge which will
enrich your experiences.
These resource materials are to be used under face-to-face mode of learning and it is our
hope that the structure and content of this manual along with the training provided will help
to achieve the learning outcomes of this program and ensure that candidates acquire and
develop the necessary skills and competencies.
It is also our desire to continuously improve the quality of our training programs as we move
forward. As such, we look forward to receiving your feedback on the materials, program
delivery and its effectiveness in realizing the program objectives and in knowledge transfer.
I welcome and thank you for choosing the Fiji National University to enhance your learning
and professional development.
Mr Peni Taoi
Acting Director
National Training and Productivity Centre
Fiji National University
Lot 2/8 Queen Elizabeth Drive
P.O. Box 15676, Suva
Fiji
Purpose of the Course
The Hybrid Electric Vehicle Systems & Safety is designed to provide basic knowledge and
techniques to automotive mechanics and electricians who are working Hybrid Electric
Vehicles (HEVs). HEVs are powered by both engine and High Voltage (HV) battery. The
high voltage supplied by HV battery is for system operation and needs to be taken care of.
This program includes the safe practices for HEV users
The program has been reviewed and structured to ensure relevant competencies are
achieved at the end of the course.
Contents
About the Learner‘s Guide.................................................................................................... 1
Advice to Learner ............................................................................................................... 2
Module Objectives.............................................................................................................. 5
Assessment ....................................................................................................................... 6
Terms used in this book ..................................................................................................... 7
Special Notes ..................................................................................................................... 8
1 Introduction to Hybrid Electric Vehicles........................................................................ 10
Section Introduction ......................................................................................................... 10
Unit Standard ................................................................................................................... 11
1.1 Introduction to Hybrid Electric Vehicle (HEV) ................................................................ 12
1.2 Driving and Owning a Hybrid Electric Vehicle ............................................................... 16
1.3 Types of Hybrid Systems .............................................................................................. 18
1.4 Common Features of All Hybrids .................................................................................. 22
1.5 Characteristics when driving a hybrid vehicle ................................................................ 23
1.6 Levels of Hybrid Vehicles.............................................................................................. 24
1.7 Hybrid Motor Systems .................................................................................................. 27
Section Summary .................................................................................................................... 27
Progress Check 1 .................................................................................................................... 28
2 Basic Hybrid Electric Vehicle Systems......................................................................... 30
Unit Standard ................................................................................................................... 31
2.1 Hybrid Electric Vehicle System Layout.......................................................................... 32
2.2 Auxiliary Battery ............................................................................................................ 34
2.3 High Voltage (HV) Battery Pack .................................................................................... 35
2.4 Power Cables Voltage .................................................................................................. 37
2.5 Inverter/Converter ......................................................................................................... 38
2.6 Gasoline Engine ........................................................................................................... 39
2.7 Electric Motor................................................................................................................ 40
2.8 Electric Generator ......................................................................................................... 41
2.9 A/C Compressor ........................................................................................................... 41
2.10 Fuel Tank and Fuel Line ............................................................................................... 41
2.11 Toyota Hybrid System .................................................................................................. 42
2.12 Toyota Electrical System Voltage ................................................................................. 47
2.13 Honda Hybrid System ................................................................................................... 47
2.14 Honda High Voltage Battery ......................................................................................... 50
Section Summary .................................................................................................................... 52
Progress Check 2 .................................................................................................................... 52
3 Tools & Equipment for Hybrid ...................................................................................... 56
Unit Standard ................................................................................................................... 57
3.1 Tools & Equipment for Hybrid ....................................................................................... 58
Section Summary .................................................................................................................... 68
Progress Check 3 .................................................................................................................... 69
4 Hybrid Electric Vehicle Safety ......................................................................................... 72
Unit Standard ................................................................................................................... 73
4.1 First Responder Procedures ......................................................................................... 74
4.2 Hybrid Electric Vehicle Safety in Case of Accident........................................................ 79
4.3 Electrocution when the vehicle is submerged in water .................................................. 81
4.4 Depowering the High-Voltage System for Honda .......................................................... 82
4.5 Depowering the High-Voltage System for Toyota ......................................................... 83
4.6 Preventing the HV Battery from becoming discharged .................................................. 85
4.7 Preventing the auxiliary battery from becoming discharged .......................................... 86
4.8 Jump starting Hybrid vehicles – when 12V battery is dead ........................................... 87
4.9 Safety precaution in relation to the towing of vehicle ..................................................... 89
4.10 Emergency towing procedure ....................................................................................... 91
4.11 High Voltage Safety ...................................................................................................... 91
Section Summary .................................................................................................................... 92
Progress Check 4 .................................................................................................................... 92
References ......................................................................................................................... 95
Acknowledgment ................................................................................................................ 95
Appendix 1: Practical Tasks .................................................. Error! Bookmark not defined.
Appendix 2: Assessment Reports ......................................... Error! Bookmark not defined.
Hybrid Electric Vehicle Systems & Safety Learner’s Guide
About the Learner’s Guide

Introduction to Learner’s Guide
The information in the module will provide you with the fundamental knowledge and skills in
hybrid vehicle system.
Your learner‘s guide is structured to take you logically through each section. Read the
section ‗Advice to Learner‘ to plan and direct your studies.
If you need more information on the topics covered in the learner‘s guide, refer to the book
list under ‗References‘ and ask your instructor for advice.
Nominal Duration
21 hours
Prerequisites
Nil
Target Audience
This course is intended for participants from industry who require formal training or skills
upgrade in the trade which may include practicing mechanics, labourers and enthusiasts
(e.g. Managers, Supervisors, Fleet Officers, Technical Officers, Sales & Operations
Representatives; Hybrid Vehicle Owners) or anyone interested in developing themselves to
up-skill knowledge in Hybrid System.
Required Resources
Access to:
1. Safety boot
2. Overall or dust coat
3. Fundamentals of Hybrid System - Learner‘s Guide.
4. Hybrid Vehicle
5. Service Kit (Insulated rubber hand gloves, Alkaline resistant rubber gloves, Red
Litmus Paper, Boric Acid, caution sign)
6. Automotive Multimeter
7. Magnetic Fender Cover
A Course by DAI, NTPC Page 1 of 110

Advice to Learner
What is a Learner’s Guide?
The focus of the learner‘s guide is to provide you with all the information and activities
required to achieve the competencies stated in the learning outcomes of the module.
The learner‘s guide is comprehensive and is the main learning resource of the modularized
package. However, you may at times need to refer to other resources and get assistance
from your instructor.
How to Use the Learner’s Guide
We suggest that you follow these steps in studying the learner‘s guide.
Step 1
Study the learning outcomes and assessment criteria. This will help you identify what
competencies are required and assess your current level of competence in each learning
outcome.
Step 2
Commencing from the first section, study the learner‘s guide and complete each activity at
the appropriate time. Feedback on the activities is given at the end of the learner‘s guide.
Step 3
Complete the ―Progress Check‖ at the end of each section and check your answers against
the feedback given at the end of the learner‘s guide. This will enable you to assess if you
have attained the competence stated for the learning outcome(s) of that section. If you do
not do well in the progress check, study the section again.
General
Make sure you complete each of the activities at the appropriate time, as they will help you
achieve the required competence. If required, you should obtain assistance from your
instructor during the study period and while carrying out activities.
Learner’s with Advance Knowledge
If you think that you already possess some or all of the competencies of the module, you
can assess this in the following manner.
 Read the learning outcomes and assessment criteria in each section.
 Identify the learning outcomes and assessment criteria that reflect the
competencies you may already have.
 Identify the sections that consist of these learning outcomes and assessment
criteria.
 Complete the ‗Progress Check‘ in these relevant sections and check your answers
against those provided at the end of the learner‘s guide.
 If you are successful, you have the competencies required for that section. You
can then go on to the next section.

Remember, this learner‘s guide has been developed in a logical sequence. Therefore, you
may have difficulty in completing the later sections, if you do not have the competencies of
the previous sections.

Description of Icons
The icons shown below are located in the left margin of the learner‘s guide. They advise
you on actions that are required and notices that you need to heed, during various stages of
your study.
Check your Progress icon Check Text icon
Caution/Beware icon Tips icon
Activity icon Key Point icon

Module Objectives
Module Purpose
To provide the learner with knowledge and skills on the safety requirements of the hybrid
electric vehicles in accordance with industry needs.
Learning Outcomes
On completion of this module the learner will be able to:
 Understand the fundamentals of the hybrid vehicle system

 Describe and identify basic Hybrid components, constructions and explain HEVs‘
differences from conventional vehicle.
 Demonstrate the hybrid vehicle safety while working on vehicles
 Demonstrate how to operate a Hybrid vehicle and the meaning of the READY indicator
light.
 Understand the need of taking precaution in case of emergency.
 Describe the procedure of jump starting hybrid vehicles
 Understand the precaution to be observed when towing a hybrid vehicle

Assessment
Assessment Criteria and Conditions
Assessment criteria and conditions for each of the learning outcomes are given in the
relevant sections of this learner‘s guide.
A range of methods is applied for measuring progress towards and achievement of

competencies in this module.
Assessment Methods
To successfully pass this module, you must complete all events so you can be assessed:
Competent / not yet competent.
The learning outcomes may be assessed through a combination of:
 Knowledge-based criteria will be satisfied through written or oral questioning relating to

practical training sessions.
 Skill-based criteria will be satisfied through practical exercises throughout the learning
period.
 Assessment will be undertaken off-the-job; however, where possible the environment will
simulate a real work place situation.

Terms used in this book

Assessment: This is the test stage. You should now be well practiced and able to
complete the task without assistance
Assessor: The person who will watch and check you during the assessment, this will
be a qualified person who is authorized to assess the unit you are
completing.
Prerequisite: The other units that must be passed before you start this current unit.
Resources: The things you will need to complete the tasks for this unit.
Progress Check: This test is for you to check if you are making the grade and are ready to
be assessed.
Skill development: This is the practice section to give you the skills to be competent and
successfully pass the unit
Theory knowledge: This is what you need to know to be able to complete the unit. Note:
Some units are assessed by theory test and some are theory combined
with practical tasks.
Unit: A self-contained specific learning package, part of a series that makes up
a larger complete qualification.
The Unit
A unit is broken down from its title into learning outcomes and then into assessment criteria.
To complete the unit all assessment criteria must be achieved. some learning outcomes &
assessment criteria have a range statement, this details variations that will need to be
considered to pass all aspects of the unit.
Study the learning outcomes & assessment criteria, as these are your goals to complete the
unit.
A pass in a unit means you are competent and have achieved the assessment criteria in
each learning outcome, so all learning outcomes must be completed.

Special Notes
1. Hand tools and workshop equipment vary between businesses and between occupations.
This standard is not intended to encompass all variants available on the market, but to
indicate basic tools and equipment required to complete the various welding jobs in a
welding workshop. The National Trade Testing Department can be referred to for a
recommended list of tools and equipment for particular levels.
2. Terminology can vary between manufacturers and between countries.

3. Legislation relevant to this unit standard includes but is not limited to - Health and Safety in
Employment Act 1996.
4. For the purpose of assessment, company guidelines may include training provider‘s
guidelines. These guidelines include workplace standards, practices, and procedures,
which must comply with current legislative requirements. It is assumed the policy also
meets product manufacturer‘s specifications, recommendations, and standards.
Safety Note:
You are required to practice safe work habits at all times. Any personal injury and or
damage to vehicles or equipment will jeopardize the successful completion of this unit.
Please note:
This book is the property of the student.
The assessment sheets will remain the property of the Training Provider.


1 Introduction to Hybrid Electric Vehicles

Section Introduction
A hybrid electric vehicle (HEV) is a type of hybrid vehicle and electric vehicle that combines
a conventional internal combustion engine (ICE) system with an electric propulsion system
(hybrid vehicle drivetrain). The presence of the electric powertrain is intended to achieve
either better fuel economy than a conventional vehicle or better performance. There are a
variety of HEV types, and the degree to which each functions as an electric vehicle (EV)
varies as well. The most common form of HEV is the hybrid electric car, although hybrid
electric trucks (pickups and tractors) and buses also exist.
Modern HEVs make use of efficiency-improving technologies such as regenerative brakes,

which converts the vehicle's kinetic energy into electric energy to charge the battery, rather
than wasting it as heat energy as conventional brakes do. Some varieties of HEVs use their
internal combustion engine to generate electricity by spinning an electrical generator (this
combination is known as a motor–generator), to either recharge their batteries or to directly
power the electric drive motors. Many HEVs reduce idle emissions by shutting down the
ICE at idle and restarting it when needed; this is known as a start-stop system. A hybrid-
electric produces less emissions from its ICE than a comparably sized gasoline car, since
an HEV's gasoline engine is usually smaller than a comparably sized pure gasoline-burning
vehicle (natural gas and propane fuels produce lower emissions) and if not used to directly
drive the car, can be geared to run at maximum efficiency, further improving fuel economy.

Unit Standard
AEHEV001-A: Understand the fundamentals of the hybrid electric vehicles
Learning Outcomes & Assessment Criteria

Learning Outcome 1
Understand the features, operation and types of hybrid vehicle
Assessment criteria
1.1 Describe the different types of hybrid electric
1.2 Explain how a hybrid vehicle is able to achieve an improvement in fuel economy
compared to a conventional vehicle design.
1.3 Discuss the advantages and disadvantages of the various hybrid designs.
1.4 Describe HEV components, including motors, energy sources, and motor
controllers.
1.5 Discuss the operation of a typical hybrid electric vehicle.
1.6 Identify basic components of hybrid vehicle
1.7 Identify features, operation and types of hybrid vehicle

1.1 Introduction to Hybrid Electric Vehicle (HEV)
A Hybrid Electric Vehicle is one that uses two different methods to propel the vehicle. A
hybrid electric vehicle, abbreviated HEV, uses both an internal combustion engine and an
electric motor to propel the vehicle. Most hybrid vehicles use a high-voltage battery pack
and a combination electric motor and generator to help or assist a gasoline engine. The
internal combustion engine (ICE) used in a hybrid vehicle can be either gasoline or diesel,
although only gasoline- powered engines are currently used in hybrid vehicles. An electric
motor is used to help propel the vehicle, and in some designs, it is capable of propelling the
vehicle alone without having to start the internal combustion engine.
1.1.1 History of Hybrid
Hybrids have been in development since 1899 and it lost momentum. Engineers took
another look in the 1970s due to the oil crisis and rising gas prices. However, no real
production models were ever produced until the 1990s. The first models were the Honda
Insight and Toyota Prius.

<History of Toyota’s Hybrid Models>
Fig 1.1 First Generation Toyota Prius

Fig 1.2 Second Generation Toyota Prius
Fig 1.3 Third Generation Toyota Prius
• Third generation Toyota Prius Hybrid

• Introduced in 2009
• The Car of the Year Japan Award for the second time

Fig 1.4 First Generation Honda Insight
• First generation Honda Insight Hybrid

• Model ZE1 / Engine 1.0L / Transmission 5 speed manual and CVT
• Introduced in November 1999
• The Insight featured optimized aerodynamics and a lightweight aluminum structure to
maximize fuel efficiency and minimize emissions.
Fig 1.5 Second Generation Honda Insight
• Second generation Honda Insight Hybrid

• Model ZE2 / Engine 1.3L / Transmission CVT
• Introduced in 2009
• Honda chose a 5-door hatchback configuration for the latest Insight.
• The wedge-shaped body assists aerodynamics and reduces drag for improved fuel
Economy

1.1.2 Hybrid Today
Hybrid electric vehicles (HEVs) include both a combustion engine as well as an electric
motor. Energy for the electric motor is gained mostly through the use of “regenerative
braking.” When a car slows down with traditional brakes a tremendous amount of energy
is lost as heat due to friction.
Regenerative brakes are essentially a motor acting as a generator. The energy used to
produce the electricity is naturally removed from the motion of the vehicle (conservation of
energy.)The cars with the largest mileage improvements (Prius and Honda Insight) also use
other technologies to improve performance. These include aerodynamics, smaller size and
more efficient tires.
1.1.3 Why is the hybrid vehicle necessary?
 Currently, the automobile market is expanding

 Energy consumption is increasing every year
 The reduction of CO2 emissions to prevent global warming has become an international
issue
 Considering the factors listed above, an ―Eco-car‖ which has good fuel economy and
low CO emissions is necessary.
2
1.2 Driving and Owning a Hybrid Electric Vehicle

1.2.1 Driving a Hybrid Vehicle
Driving a hybrid electric vehicle is the same as driving any other conventional vehicle. In
fact, many drivers and passengers are often not aware they are driving or riding in a hybrid
electric vehicle. Some unique characteristics that the driver may or may not notice include
the following:
 After the internal combustion engine has achieved normal operating temperature and
other conditions are met, the engine will stop when the vehicle slows down and
stops. This condition may cause a concern to some drivers who may think that the
engine has stalled and then may try to restart it.
 The brake pedal may feel different, especially at slow speeds of about 5 mph and 15
mph when slowing to a stop. It is at about these speeds that the brake system
switches from regenerative braking to actually applying brake force to the
mechanical brakes. A slight surge or pulsation may be felt at this time. This may or
may not be felt and is often not a concern to drivers.
 The power steering works even when the engine stops because all hybrid electric
vehicles use an electric power steering system.
 Some hybrid electric vehicles are able to propel the vehicle using the electric motor
alone, resulting in quiet, almost eerie operation.

 If a hybrid electric vehicle is being driven aggressively and at a high rate of

acceleration, there is often a feeling that the vehicle is not going to slow down when
the accelerator pedal is first released. This is caused by two factors:
I. The inertia of the rotor of the electric motor attached to the crankshaft of the ICE
results in the engine continuing to rotate after the throttle has been closed.
II. The slight delay that occurs when the system switches the electric motor from
powering the vehicle to generating (regenerative braking). While this delay would
rarely be experienced, and is not at all dangerous, for a fraction of a second it gives
a feeling that the accelerator pedal did not react to a closed throttle.
1.2.2 Owning a Hybrid Vehicle
 The fuel economy will be higher compared to a similar- type vehicle, especially if
driven in city-type driving conditions where engine stop and regenerative braking
really add to the efficiency of a hybrid electric vehicle. However, the range of the
hybrid version may be about the same as the conventional version of the same
vehicle because the hybrid version usually has a smaller fuel tank capacity.
 A hybrid electric vehicle will cost and weigh more than a conventional vehicle. The
increased cost is due to the batteries, electric motor(s), and controllers used plus the
additional components needed to allow operation of the heating and air-conditioning
systems during idle stop periods. The cost is offset in part by returning improved fuel
economy as well as government energy credits awarded at the time of purchase for
some new-technology vehicles: It may take many years of operation before the extra
cost is offset by cost savings from the improved fuel economy. However, many
owners purchase a hybrid electric vehicle for other reasons besides fuel savings,
including a feeling that they are helping the environment and love of the high
technology involved,

1.3 Types of Hybrid Systems
The types of hybrid electric vehicles include series, parallel, and series-parallel designs.
1.3.1 Series Hybrid Vehicles

In a series-hybrid design, sole propulsion is by a battery-powered electric motor, but the
electric energy for the batteries comes from another on- board energy source, such as an
internal combustion engine. In this design, the engine turns a generator and the generator
can either charge the batteries or power an electric motor that drives the transmission. The
internal combustion engine never powers the vehicle directly.
The engine is operated only to keep the batteries charged. Therefore, the vehicle could be
moving with or without the internal combustion engine running. Series-hybrid vehicles also
use regeneration braking to help keep the batteries charged. The Chevrolet Volt is an
example of a series-hybrid design.
The engine is designed to just keep the batteries charged, and, therefore, is designed to
operate at its most efficient speed and load. An advantage of a series-hybrid design is that
no transmission, clutch, or torque converter is needed.
Fig 1.6 A drawing of the power flow in a typical series-hybrid vehicle.

A disadvantage of a series-hybrid design is the added weight of the internal combustion

engine to what is basically an electric vehicle. The engine is actually a heavy on-board
battery charger. Also, the electric motor and battery capacity have to be large enough to
power the vehicle under all operating conditions, including climbing hills.
All power needed for heating and cooling must also come from the batteries so using the air
conditioning in hot weather and the heater in cold weather reduces the range that the
vehicle can travel on battery power alone.
Fig 1.7 This diagram shows the components included in a typical series-hybrid
design.The solid-line arrow indicates the transmission of torque to the drive
wheels.The dotted-line arrows indicate the flow of electrical current.
1.3.2 Parallel Hybrid Vehicles

In a parallel-hybrid design, multiple propulsion sources can be combined, or one of the
energy sources alone can drive the vehicle, in this design, the battery and engine are both
connected to the transmission.
The vehicle using a parallel-hybrid design can be powered by the internal combustion
engine alone, by the electric motor alone (full hybrids only), or by a combination of engine
and electric motor propulsion. In most cases, the electric motor is used to assist the internal
combustion engine. One of the advantages of using a parallel-hybrid design is that by using
an electric motor or motors to assist the internal combustion engine, the engine itself can be
smaller than would normally be needed.
One disadvantage of a parallel-hybrid design is that complex software is needed to
seamlessly blend electric and ICE power. Another concern about the parallel-hybrid design

is that it had to be engineered to provide proper heating and air- conditioning system
operation when the ICE stops at idle.
A parallel-hybrid design could include additional batteries to allow for plug-in
capability, which could extend the distance the vehicle can travel using battery
power alone.
Fig 1.8 The power flow in a typical parallel-hybrid vehicle.

Fig 1.9 Diagram showing the components involved in a typical parallel-hybrid vehicle. The solid-
line arrows indicate the transmission of torque to the drive wheels, and the dotted-line arrows
indicate the flow of electrical current.
1.3.3 Series-Parallel Hybrid

The Toyota and Ford hybrids are classified as series-parallel hybrids because they can
operate using electric motor power alone or with the assist of the ICE. Series-parallel
hybrids combine the functions of both a series and a parallel design.
The internal combustion engine may be operating even though the vehicle is stopped if the
electronic controller has detected that the batteries need to be charged.

Fig 1.10 A series-parallel hybrid design allows the vehicle to operate in electric motor modeonly or in
combination with the internal combustion engine.
1.4 Common Features of All Hybrids

There are four most common features of hybrids that improve fuel economy:
1.4.1 Idle Stop
The idle stop mode turns off the engine when the vehicle is stopped. When the brake is
released, the engine immediately starts. This ensures that the vehicle is not using fuel, nor
creating CO2 emissions, when the engine is not required to propel the vehicle.
1.4.2 Regenerative braking
.When decelerating, the braking system captures the energy from the vehicle‘s inertia and
converts it to electrical energy which is stored in the battery or other device for later use.
Regenerative braking helps keep the batteries charged.

1.4.3 . Power Assist.
The electric motor provides extra power using electrical current drawn from the battery to
assist the internal combustion engine during acceleration. This power-assist mode enables
the vehicle to use a smaller, more fuel-efficient engine without giving up vehicle
performance..
1.4.4 . Engine-off Drive-Electric Vehicle Mode.
The electric motor propels the vehicle at lower speeds. This mode is often called the
motoring mode. Because the internal combustion engine is not being used during
acceleration, no fuel is being used and no emissions are being released. When the hybrid is
in this mode, it is essentially an electric vehicle.
Hybrid Synergy Drive is smart technology, telling the car when to switch between
petrol and electric power and when to combine both for maximum efficiency,
which guarantees a high level of on-road performance while minimising fuel
consumption and pollution from exhaust gases.
1.5 Characteristics when driving a hybrid vehicle

 The vehicle can be driven while the READY indicator light is on.
 The engine will stop while the vehicle is stopped in order to improve fuel economy.
 The engine starts up automatically after the vehicle starts off.
Fig 1.10 Series Hybrid System

1.6 Levels of Hybrid Vehicles

The term hybrid refers to a type of vehicle. However, there are different levels of
―hybridization‖ among hybrids on the market. Different vehicle manufacturers use various
hybrid technologies
1.6.1 Mild Hybrid
A mild hybrid will incorporate idle stop and regenerative braking but is not capable of using
the electric motor to propel the vehicle on its own without help from the internal combustion
engine. A mild hybrid system has the advantage of costing less, but saves less fuel
compared to a full hybrid vehicle and usually uses a 42-volt electrical motor and battery
package (36-volt bail eries, 42-volt charging). An example of this type of hybrid is the
General Motors Silverado pickup truck and the Saturn VUE. The fuel savings for a mild type
of hybrid design is about 8% to 15%.
• Uses relatively low voltage – three 12- volt batteries connected in series to equal 36
volts; 42-volt charging voltage (GM PHT).
• Electric power steering
• Torque smoothing
• Regenerative Braking
• Not able to propel the vehicle using the electric motor alone.

Fig 1.11 Mild Hybrid Vehicle
1.6.2 Medium Hybrid
A medium hybrid uses 144- to 158-volt batteries that provide for engine stop/start,
regenerative braking, and power assist. Like a mild hybrid, a typical medium hybrid is not
capable of propelling the vehicle from a stop using battery power alone. Examples of a
medium hybrid vehicle include the Honda Insight, Civic, and Accord. The fuel economy
savings are about 20% to 25% for medium hybrid systems.
• High voltage batteries rated at 144-158 volts
• Uses electric power steering
• Regenerative braking
• Newer models are capable of powering the vehicle (but not from a stop) using electric
motor power only

1.6.3 Full Hybrid
A full hybrid, also called a strong hybrid, uses idle stop regenerative braking and is able to
propel the vehicle using the electric motor(s) alone.
Each vehicle manufacturer has made its decision on which hybrid type to implement based
on its assessment of the market niche for a particular model. Examples of a full or strong
hybrid include the Ford Escape SUV. Toyota Highlander, Lexus RX400h, Lexus GS45Oh,
Toyota Prius, and Toyota Camry. The fuel economy savings are about 30% to 50% for full
hybrid systems.
Fig 1.12 Full Hybrid Vehicle

1.7 Hybrid Motor Systems

There are three different motor sytems adapted by different hybrid electric vehicle
manufactures.
1.7.1 One-Motor Hybrids
Hybrid electric vehicles that use one electric motor include VW, Nissan, Honda, and
General Motors. In these units, an electric motor is attached to the ICE (engine) crankshaft
and is used to perform two functions:
1. Start the ICE engine
2. Act as a generator to charge the high-voltage batteries.
General Motors also uses a belt alternator starter (BAS) system, which uses a belt-driven
motor/generator attached to the front of the engine. Hybrids that use one motor are often
called mild hybrids and usually are not able to power the vehicle using electric power alone.
1.7.2 . TWO-MOTOR HYBRIDS
Hybrid electric vehicles that use two motors are the most commonly used hybrids by
Toyota, Ford, and General Motors in their full-size two-mode trucks. Each electric motor
serves two purposes:
 The motor/generator attached to the engine, usually labeled M/G1, is used to start
the gasoline engine and to charge the high-voltage batteries.
 The motor/generator that is connected to the drive wheels, usually labeled M/G2, is
used to propel the vehicle and to recharge the high-voltage battery during
deceleration (regenerative braking).
Two-motor hybrid electric vehicles are full (strong) hybrids and are capable of propelling the
vehicle using electric motor power alone for short distances.
1.7.3 . Three-Motor Hybrids
Three-motor hybrid electric vehicles are usually two-motor hybrids that use an additional
electric motor to propel the rear wheels for all-wheel-drive Capability. Hybrid electric
vehicles that use three electric motors include the Toyota Highlander and Lexus
RX400hJ45Oh SUVs.
Section Summary
In this chapter you have learnt about the basics of computers.
After completion of this section you should be able to:
 Describe the different types of hybrid electric vehicles
 Explain how a hybrid vehicle is able to achieve an improvement in fuel economy
compared to a conventional vehicle design.
 Discuss the advantages and disadvantages of the various hybrid designs.
 Describe HEV components, including motors, energy sources, and motor controllers.
 Discuss the operation of a typical hybrid electric vehicle.

 Identify basic components of hybrid vehicle
 Identify features, operation and types of hybrid vehicle
If you have answered ―no‖ to the above question, you should read through this section
again and work through the activities or approach your instructor. The following ―Check
Your Progress‖ exercises will help you in self-assessment.
Progress Check 1
Check your progress by trying the following:
1. What are the sources of power for Hybrid Electric Vehicles?

___________________________________________________________________
___________________________________________________________________
__________________________________________________________________
2. List down five components of hybrid electric vehicles?

___________________________________________________________________
___________________________________________________________________
________________________________________________________________
3. Explain the basic operation of engine and motor in the series hybrid system?
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
4. Explain the basic operation of engine and motor in the parallel hybrid system?
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
5. Explain the basic operation of engine and motor in the series - parallel hybrid
system?
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
6. List three levels of hybrid electric vehicles
___________________________________________________________________
___________________________________________________________________
________________________________________________________________

7. What are the advantages of owning a HEV?

___________________________________________________________________
___________________________________________________________________
________________________________________________________________
8. List the drive modes for HEVs
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
9. State the voltage for the following
Mild Hybrid___________________________________
Medium Hybrid________________________________
Full Hybrid___________________________________
10. List the three different motor systems adapted by different hybrid electric vehicle
manufactures.
___________________________________________________________________
___________________________________________________________________
________________________________________________________________

2 Basic Hybrid Electric Vehicle Systems

The hybrid electric vehicles are made of different systems which work together to run the
vehicle in most economical way to fulfill the needs of the users. The internal combustion
engine and the high voltage system are working in conjunction components.
The high voltage system drive the car and auxiliary battery powers the normal lighting and
accessories system. The basic introduction of the system and the operation is covered in
this section.

Unit Standard
AEHEV001-A: Demonstrate basic knowledge of the hybrid electric vehicle systems.
Learning Outcome 2
Understand the basic function and operation of the hybrid electric vehicle systems.
Assessment criteria
2.1 Describe the two types of batteries used on hybrid electric vehicles
2.2 Explain construction of HV battery use on HEVs.
2.3 Discuss the advantages and disadvantages of the HV battery used on HEVs.
2.4 Describe HEV system components, including motors, generators, and
inverter/converters.
2.5 Discuss the operation of power split unit.
2.6 Identify high voltage components HEVs.
2.7 Identify high voltage cables on a HEV.

2.1 Hybrid Electric Vehicle System Layout
Fig 2.1 1-12 Volt Auxiliary Battery, 2- High Voltage (HV) Battery Pack, 3-Power Cables, 4-
Inverter/Converter, 5-Gasoline Engine
Fig 2.2 6-Electric Motor, 7-Electric Generator, 8-A/C Compressor

Fig 2.3 9-Fuel Tank and Fuel Line
Fig 2.4 Layout of Hybrid Main Components

2.2 Auxiliary Battery
The12 volt auxiliary battery is located in the cargo area. Every electrical component in a
vehicle is supplied current from this battery. A lead-acid battery is used as an auxiliary
battery and it‘s the primary purpose battery is to provide a source of electrical power for all
of the vehicle electrical needs. In a hybrid electric vehicle (HEV), the 12-volt auxiliary
battery is used to
 Power all of the 12-volt accessories

 Power the electronic controller for the high-voltage system
Fig 2.5 A comparison showing the relationship between battery voltage and state of charge.
The location of the 12-volt auxiliary battery varies according to the make, model, and year
of hybrid electric vehicles. As a general rule, the type of battery used is determined by the
location such as
 An ACM battery is used when the battery is located in the trunk or near the
passenger compartment area.
A flooded-type battery is used if the battery is located under the hood.
Fig 2.6 12-volt auxiliary battery

2.3 High Voltage (HV) Battery Pack
Most current production HEVs use nickel-metal hydride (NiMH) battery technology for the
high-voltage battery. NiMH batteries are being used for these applications because of their
performance characteristics such as specific energy, cycle life, and safety. From a
manufacturing perspective, the NiMH battery is attractive because the materials used in its
construction are plentiful and recyclable.
Nickel-metal hydride (NIMH) uses a positive electrode made of nickel hydroxide and
potassium hydroxide electrolyte. The nominal voltage of a NiMH battery cell is 7.2 volts.
The negative electrode is unique, however, in that it is a hydrogen-absorbing alloy, also
known as a metal hydride. The 201.6 Volts Nickel Metal Hydride (NiMH) battery pack
consisting of 28 low voltage (7.2 Volts) modules connected in series.
Fig 2.7 NiMH battery cell
NiMH batteries are known as alkaline batteries due to the alkaline (pH greater than 7)
nature of the electrolyte. The electrolyte is aqueous potassium hydroxide. Potassium
hydroxide works very well for this application because it does not corrode the other parts
of the battery and can be housed in a sealed steel container. Also, potassium hydroxide
does not take part in the chemical reaction of the battery, so the electrolyte concentration
stays constant at any given state of charge. These factors help the NiMH battery achieve
high power performance and excellent cycle life.

Fig 2.8 A NiMH cell. The unique element in a nickel- metal hydride cell is the negative electrode
which is a hydrogen- absorbing alloy- The positive electrode is nickel hydroxide. The electrolyte
does not enter into the chemical reaction and is able to maintain a constant conductivity regardless
of the state of charge of the cell
Advantages of Nickel-based alkaline batteries have a number of advantages over other

battery designs. These include the following:
• High specific energy.

• The nickel electrode can be manufactured with large surface areas, which increase
the overall battery capacity.
• The electrolyte does not react with steel, so NiMH batteries can be housed in sealed
steel containers that transfer heat reasonably well.
• The materials used in NiMH batteries are environmentally friendly and can be
recycled.
• Excellent cycle life.
• Durable and sale.
Disadvantages of the NiMH battery include the following:

• High rate of self-discharge, especially at elevated temperatures.
• Moderate levels of memory effect, although this seems to be less prominent in newer
designs.

• Moderate to high cost.
Fig 2.9 High Voltage (HV) Battery Pack
2.4 Power Cables Voltage
Power cables carry high voltage Direct Current (DC) between the HV battery pack,
inverter/converter, and A/C compressor. These cables also carry 3-phase Alternating
Current (AC) between the inverter/converter, electric motor, and generator.
Fig 2.10 Yellow conduit or Blue- Usually represents a 42 volt circuit. This level could cause an
arc to be maintained if a live circuit is broken.

Fig 2.11 Orange conduit- High and dangerous voltage levels of 144 to 650 volts
Black conduit-12 to 42 volts. This voltage level usually does not represent a
shock hazard
2.5 Inverter/Converter
The inverter/ converter unit is located in the engine compartment. It boosts and inverts the
high voltage electricity from the HV battery pack to 3-phase AC electricity that drives the
electric motor. The inverter/converter also converts AC electricity from the electric generator
and electric motor (regenerative braking) to DC that recharges the HV battery pack.
Fig 2.12 Prius inverter and voltage converter unit

Fig 2.13 Prius inverter and voltage converter unit without cover
2.6 Gasoline Engine
Provides two functions:
1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the vehicle computer

Fig 2.14 Prius Engine
2.7 Electric Motor

A 3-phase high voltage AC permanent magnet electric motor contained in the front
transaxle. It is used to power the front wheels.
Fig 2.15 Prius Electric Motor

2.8 Electric Generator

A 3-phase high voltage AC generator that is contained in the transaxle and recharges the
HV battery pack.
2.9 A/C Compressor

A 3-phase high voltage AC electrically driven motor compressor.
Fig 2.16 Prius A/C Compressor
2.10 Fuel Tank and Fuel Line

The fuel tank provides gasoline via a fuel line to the engine. The fuel line is routed under
the center of vehicle.
Fig 2.17 Fuel tank

2.11 Toyota Hybrid System

The Toyota Hybrid System (THS) uses two electric motor/generators (MGI and M02) and
an ICE all connected together by a power-split device which is a simple planetary gear set.
• This system is series and parallel in operation.
• Each motor/generator performs two functions:
• MG1-starts the ICE and charges the HV batteries.
• MG2-propels the vehicle and charges the HV batteries during braking and
deceleration
Fig 2.18 Prius Engine with Transmission

Fig 2.19 Prius Power Flow
Fig 2.20 MG 1

Fig 2.21 ICE
Fig 2.22 MG 2

Fig 2.23 Prius Drive

Fig 2.24 Prius Chain Drive
Fig 2.24 Prius Gear Drive

2.12 Toyota Electrical System Voltage
The Prius utilizes the following electrical systems:
•Maximum 650 Volts AC-A boost converter in the inverter/converter that boosts the
available voltage to the electric motor to 650 Volts.
•Nominal 201.6 Volts DC-A high voltage Hybrid Vehicle (HV) battery pack rated at 201.6
Volts.
•Maximum 27 Volts DC-An optional solar ventilation system rated at 27 Volts.
•Nominal 12 Volts DC-A body electrical system rated at 12 Volts, negative chassis ground.
2.13 Honda Hybrid System
The Honda hybrid starting with the 2014 model year uses a two-motor hybrid drive system
that is totally different from that used by Toyota and Ford. It does not use a transmission.
Instead, the two motor/ generators are separated by a clutch and each performs two
functions:
• Primary motor/generator. It propels the vehicle and recharges the high-voltage

battery during deceleration.
• Secondary motor/generator. It is used to start the gasoline engine and supply

electrical energy to the primary motor/generator or charge the high-voltage battery.
The 2.0-liter i-VTEC four-cylinder engine incorporates an Atkinson cycle operation and
produces 141 horsepower and 122 pounds-feet of torque. Other features include:
• An electric-only air-conditioning compressor
• Electric water pump
• Electric power steering
• Uses 1 .3-kW-hr lithium-ion battery located in the trunk and can provide electric-only
driving for about two miles (3 km)

Fig 2.25 A cutaway view of the two motor/generators used in the two-motor Honda hybrid electric
vehicle.
Honda‘s hybrid system is known as IMA (Integrated Motor Assist). IMA is a parallel-hybrid
configuration that uses a motor-generator located between the ICE and the transmission.
The IMA motor is an AC synchronous electric machine that can provide torque assist for
moving the vehicle or generate electricity for recharging the HV battery module. All of the
electronics for this system are located at the rear of the vehicle, with three power cables
running between the IMA motor and the intelligent power unit (IPU).
Under most conditions, Honda hybrid engines are started by the IMA motor, which instantly
spins the engine to1000 RPM.
Honda hybrids also use a conventional 12-volt auxiliary starter motor that is used in the
following situations:
• The state of charge of the battery module is too low.
• The ambient temperature is too high or too low, usually below 0°F or over 115°F.
• There is a failure of the IMA system and the IMA light is commanded on.
• A technician has turned off the master switch in the hatch area.
When any of these conditions exist, the vehicle will not enter idle stop mode. In the last two
examples, any further restarts will continue to use the 12-volt starter. In the case of the first
two examples, if the HV battery SOC is raised or ambient air heats up or cools down, the
IMA motor will once again be the default for startup.

Fig 2.26 Under most conditions, the IMA motor is used to start the ICE.
Fig 2.27 During acceleration, the battery module provides electrical energy to the IMA motor to help
accelerate the vehicle.
Fig 2.28 During deceleration, the IMA converts kinetic energy into electrical energy for recharging the
HV battery pack.

2.14 Honda High Voltage Battery
The battery pack uses nickel metal hydride (NiMH) technology for high-energy density and
long service life.
The battery pack is manufactured by Panasonic EV Energy and weighs only 48 lbs (22 kg).
Its operating temperature range is —22°F to ±140°F (—30°C to +60°C).
The battery pack, sometimes called the battery module, is constructed in a modular form.
The individual NiMH cells are the same size as standard 0-cell flashlight batteries.
Constructing the module from standard- sized cells helped to ensure cost-effectiveness.
Fig 2.29 The view of the battery pack and the electronic assemblies after removing the rear seat and
the steel panel.
The battery module is only available as a complete assembly.
The cells each have a voltage of 1.2 volts, and are connected in series for a battery module
terminal voltage of 144 volts. The rated capacity of the battery module is 6.5 ampere- hours
(Ah), resulting in a storage capacity of 0.036 kW.
The 2006 Honda Civic battery module operates at 156 volts. This is achieved
by using 132 1.2-volt ―0‖ NiMH batteries instead of just 120 cells and 144 volts,
as used in most other Honda hybrid electric vehicles.
If battery module service is required, refer to the service information because

serious injury or even death can occur it high-voltage safety precautions are not
observed. High-voltage wires and cables are covered with orange plastic
shielding or tape. Never casually handle any orange wiring or the component
connected to it!

The battery module is used to supply the high voltage to the IMA motor during the assist
mode and on start up in most conditions. The battery module is also used to store the
regenerated power in the cruising, deceleration, and braking modes. Battery module energy
is also used to charge the conventional 12-volt battery, using the DC—DC converter. The
12-volt battery is a conventional flooded-cell design and is located in the engine
compartment.
The battery module cell groups are connected in series to the terminal plate, located on the
side of the battery module.
The battery module contains 10 voltage sensors and 4 temperature sensors that send data
to the battery condition monitor (BCM).
The battery module uses ―cabin air‖ to dissipate the heat produced by the NiMH cells. A
two-speed cooling fan is located in front of the battery module and draws air past the NiMH
cells to aid in cooling of the high-voltage batteries. An inlet behind the passenger seats is
the inlet for cool air.
Fig 2.30 Vent on a Honda Civic hybrid
The battery as well as the electronics are cooled through this vent on a Honda Civic hybrid.
Blocking the airflow through this vent could cause serious damage to the hybrid system and
would likely cause the setting of a diagnostic trouble code.

Fig 2.31 Cooling airflow through the intelligent power unit (IPU) of a Honda Civic hybrid.
Section Summary
 Describe the two types of batteries used on hybrid electric vehicles
 Explain construction of HV battery use on HEVs.
 Discuss the advantages and disadvantages of the HV battery used on HEVs.
 Describe HEV system components, including motors, generators, and
inverter/converters.
 Discuss the operation of power split unit.
 Identify high voltage components HEVs.
 Identify high voltage cables on a HEV.
Progress Check 2
1. What is the voltage and purpose of auxiliary battery on Hybrid Electric Vehicles?
___________________________________________________________________
___________________________________________________________________
__________________________________________________________________

2. What is the voltage and purpose of high voltage battery pack on Hybrid Electric
Vehicles?
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
3. What is the cell voltage for Toyota Prius HV battery?
___________________________________________________________________
___________________________________________________________________
4. How many cell make up a HV battery pack for Toyota Prius?
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
5. Name the materials used for positive and negative plates of HV battery on a HEV.
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
6. List three levels advantages of Nickel-based alkaline batteries used on hybrid
electric vehicles
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
_________________________________________________________________
7. List two disadvantages of Nickel-based alkaline batteries used on hybrid electric

vehicles
___________________________________________________________________
___________________________________________________________________
________________________________________________________________
8. What is the purpose of inverter/converter unit used on HEVs?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
_________________________________________________________________
9. State the cable voltage for the following
Black Cable___________________________________
Yellow Cable_________________________________
Blue Cable___________________________________
Orange Cable_________________________________
10. State how many phase winding is used the electric motor of a HEV.
___________________________________________________________________
_________________________________________________________________
11. How many volts is supplied to air-conditioning compressor?
___________________________________________________________________
___________________________________________________________________
12. Name the components of power split unit
___________________________________________________________________
___________________________________________________________________
_________________________________________________________________
13. List the purpose of the following
MG1_____________________________________________________________
MG 2_____________________________________________________________
14. What are two types of drives used on Toyota Prius transmission?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
15. What is the maximum operating voltage of Toyota HEVs?
16. What hybrid system does Honda use?
___________________________________________________________________
___________________________________________________________________

17. To start ICE for Honda Hybrid Vehicle at what RPM does motor spins the engine?
___________________________________________________________________
___________________________________________________________________
18. In Honda hybrid system under which condition will12-volt auxiliary starter motor will
operate?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
19. What is the cell voltage for Honda Civic HV battery?

___________________________________________________________________
___________________________________________________________________
20. How many cell make up a HV battery pack for Honda Civic?
___________________________________________________________________
___________________________________________________________________
________________________________________________________________

3 Tools & Equipment for Hybrid

It is very important for technicians to be well equipped with hybrid service kit while carrying
out any work on hybrid vehicles. Due to the high voltage circuit‘s one must have proper
hand gloves, safety shoes, goggles, insulated tools and testing materials such as digital
multimeter, litmus paper and boric acid to avoid electrocution.

Unit Standard
AEHEV001-A: Prepare tools & equipment used for hybrid vehicle.

Learning Outcome 3
Understand the importance of hybrid service kit and battery charger
Assessment criteria
3.1 Identify tools and equipment used in hybrid vehicle
3.2 The use of insulated tools when working on high-voltage circuits
3.3 Explain the use of battery charger charging high voltage battery and auxiliary battery

3.1 Tools & Equipment for Hybrid

 Workshop should have hybrid service kit available before technician starts to carryout
work on hybrid vehicle.
 Insulated tools are a requirement during working on high voltage circuit.
Service kit: Insulated rubber hand gloves, Alkaline resistant rubber gloves, Red
Litmus Paper, Boric Acid, caution sign (cones)
3.1.1 Hybrid Safety Gloves

Two separate types of gloves are necessary; firstly, insulated gloves made from rubber
materials are needed for working on any of the high voltage components or wiring circuits.
These are commonly known as electrical linesman‘s gloves and are designed to meet Fiji
and Australian standard for working voltages up to 650 volts.
Secondly, alkaline resistant synthetic rubber gloves are also needed when working with any
electrolyte spillage as the potassium hydroxide electrolyte is extremely hazardous to all
human tissue.
Fig 3.1 Insulated Rubber Gloves Fig 3.2 Alkaline Resistant Gloves
 Remove jewellery and watches to avoid any damage to the insulated gloves & set aside
all metal objects.
3. 1.2 Rubber Gloves
Before working on the high-voltage system of a hybrid electric vehicle, be sure that high-
voltage lineman‘s gloves are available. Be sure that the gloves are rated at least 1,000 volts
and class ―0‖ by ANSI/ASTM. The American National Standards Institute (ANSI) is a
private, nonprofit organization that administers and coordinates the U.S. voluntary
standardization and conformity assessment system. ASTM International, originally known
as the American Society for Testing and Materials (ASTM), was formed over a century ago,
to address the need for component testing in industry. The Occupational Safety and Health
Administration (OSHA) requirements specify that the HV gloves get inspected every six
months by a qualified glove inspection laboratory. Use an outer leather glove to protect the
HV rubber gloves. Inspect the gloves carefully before each use. High voltage and current
(amperes) in combination is fatal.
The high-voltage insulated safety gloves must be recertified every six months to
remain within Occupational Safety and Health Administration (OSHA) guidelines.
Fig 3.3 Rubber lineman’s gloves protect the wearer from a shock hazard.
Fig 3.4 Wearing leather gloves over the lineman’s gloves helps protect the rubber gloves from
damage.

Before using the rubber gloves, they should be tested for leaks using the following
procedure:
1. RoIl the glove up from the open end until the lower portion of the glove begins to balloon
from the resulting air pressure. Be sure to ―lean‖ into the sealed glove to raise the internal
air pressure. If the glove leaks any air, discard the gloves.
2. The gloves should not be used if they show any signs of wear and tear.
Fig 3.5 Checking rubber lineman’s gloves for pinhole leaks.
3.1.3 Safety Cones
Ford requires that cones be placed at the four corners of any hybrid electric vehicle when
service work on the high-voltage system is being performed. They are used to establish a
safety zone around the vehicles so that other technicians will know that a possible shock
hazard may be present.
Fig 3.6 Safety Cones

3.1.4 Red Litmus Paper
When you are confronted with a possible electrolyte spill, wear the Alkaline Resistant
Gloves and apply a strip of red litmus paper to the spill. If the litmus paper turns blue, then
the spill needs to be neutralised with the saturated boric acid mixture.
Fig 3.7 Red Litmus Paper Fig 3.8 Checking Acid Spill
On completion, re-check the spill with red litmus paper and ensure that it does not change
colour. Once neutralised, always clean up the residue with waste cotton rags.
3.1.5 Boric Acid Solution
A boric acid solution needs to be used to neutralise any electrolyte spills. This solution is
made by dissolving 800 grams of powdered boric acid into a clean vessel containing 20
litres of tap water. Pour the solution onto the electrolyte spillage to neutralise. If Boric Acid
isn‘t available, household vinegar is a good alternative.
Fig 3.9 Boric Acid Solution
Waste rags are recommended to wipe up neutralized electrolyte spills from HV

battery
3.1.6 Eye Protection
Eye protection should be worn when testing for high voltage, which is considered by many
experts to be over 60 volts. Eye protection should include the following features:
1. Plastic frames (avoid metal frames as these are conductive and could cause a shock
hazard)
2. Side shields
3. Meet the standard ANSI Z87.l
Most hybrid electric systems use voltages higher than this threshold. If the system has not
been powered down or has not had the high-voltage system disabled, a shock hazard is
always possible. Even when the high-voltage system has been disconnected, there is still
high voltage in the HV battery box.
NOTE: Some vehicle manufacturers specify that full face shields be worn instead of
safety glasses when working with high-voltage circuits or components.
3.1.7 Alkaline Resistant Safety Goggles
Alkaline Resistant Safety Goggles are made to resist liquid splashes to the eyes. Normal
glasses or other kinds of safety glasses are more comfortable but not as good at stopping
liquid from getting in the eyes.
Fig 3.10 Alkaline Resistant Safety Goggles

3.1.8 Steel Capped Safety Shoes
Some safety shoes are designed to discharge static electricity built up in the human body
through the soles of the shoes to ground (ground function). If this type of safety shoes is
used, electricity may be conducted through the shoes when insulation resistance is
decreased, resulting in electrocution.
Fig 3.11 Safety Shoes
 Use of safety shoes that do not have a ground function is recommended when
servicing hybrid vehicles.
3.1.9 Insulated Tools
Insulated tools, such as this socket set, would provide an additional margin of safety to the
service technician when working around high-voltage components and systems.
Fig 3.12 Insulated tools

 We recommend to use an insulated tool set when loosening or tightening the bolts
and nuts of high-voltage circuits in a hybrid vehicle
Fig 3.13 Insulated Hand Tools
3.1.10 CAT Ill Rated Digital Multimeter
Hybrid electric vehicles are equipped with electrical systems whose voltages can exceed
600 volts DC. A CAT Ill-certified digital multimeter (DMM) is required for making
measurements on these high- voltage systems.
Fig 3.14 Be sure to only use a meter that is CAT Ill- rated when taking electrical voltage measurements
on a hybrid electric or electric vehicle.

Fig 3.15 The meter leads should also be CAT Ill-rated when checking voltages on a hybrid electric
vehicle.
A high quality, digital multimeter is required to check various points of the high voltage
circuit to ensure that all electrical charge/potential has depleted prior to commencing any
service work. Also it is used to carry out basic diagnosis of electrical systems.
Fig 3.16 Digital Multimeter

3.1.11 Insulation Tape

Electrical tape (or insulating tape) is a type of pressure-sensitive tape used to insulate
damage or naked electrical wires and other conductors on the motor vehicles. It is made of
Polyvinyl chloride(PVC) as it stretches well and gives an effective and long lasting
insulation.
Fig 3.17 Insulation Tape
Whenever a high voltage cable or terminal is uncovered it is necessary to insulate

the exposed conductor with electrical insulation tape. Also, after removing the
service plug, cover the gap with tape to insulate the port.

3.1.12 Hybrid Battery Charger
Battery charger plays an important role in the battery and electric vehicle technology. Due
to on-board type of charger it should be light in weight and should occupy less space as it
should be on the vehicle all the time.
Wear insulated gloves when working on the high voltage system. Hybrid battery
charger is recommended to be used when HV battery is flat.
Fig 3.11 Hybrid Battery Charger
3.1.13. Auxiliary Battery Charger
An auxiliary battery charger is used to charge a 12volts auxiliary battery for HEVs. To avoid
damage to the battery it is recommended to use a low amperage charger to charge the 12
volts auxiliary battery.
The Auxiliary Battery Charger is required in all phases of vehicle storage &
delivery.
Fig 3.12 Auxiliary Battery Charger

3.1.14. Jumper Wire
A HEV car with a "dead" (discharged) auxiliary battery can be made to start by supplying it
with power from an external source, such as the battery of another car. The cables used to
make the necessary temporary connection are recommended to be equipped with a very
good alligator clips at the ends to prevent voltage spikes while connected..
Fig 3,13 Jumper cables with Alligator clips
Section Summary
In this chapter you have learnt about the gas welding.
 Identify tools and equipment used in hybrid vehicle
 The use of insulated tools when working on high-voltage circuits
 Explain the use of battery charger charging high voltage battery and auxiliary battery

Progress Check 3

1. List down 4 items is required in hybrid service kit?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
2. What type of tools is required for use during working on high voltage circuit?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
3. What should be the minimum voltage rating on the rubber glove and insulated tools
used on HEVs?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
4. How do you test rubber glove before using on HV system?

_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
5. Why do you need safety cones while working on HEVs?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
6. List the PPEs used by a technician while working on HEVs
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________

7. What rating of digital multimeter is recommended for HEV system testing and why?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
8. What rating of multimeter leads should be used and why?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
9. Why it is necessary to use a jumper cable with good alligator clip?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
10. Why it is necessary to charge a battery with low current?
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________


4 Hybrid Electric Vehicle Safety

The hybrid electric vehicles are new to our roads in Fiji. The owners and drivers need to
take extra precautionary measures when using hybrid electric vehicles since it has high
voltage system.
Also proper guidelines and instructions need to be followed in the event of accidents. The
owners and drivers need to be well versed with emergency response guide. It is important
to use follow the correct procedures in the case of emergency.

Unit Standard
AEHEV001-A: Demonstrate the hybrid vehicle safety while working on vehicles.
Learning Outcome 2
Understand the safety precaution after vehicle is involved in an accident and submerged in
water.
Assessment criteria
2.1 Understand safety precaution is followed immediately after an accident

2.2 Understand safety precaution is followed when submerged in water

4.1 First Responder Procedures

Whenever first responders approach an incident, they do not know for sure what they will
find or how to handle the situation. The best approach for first responders is to follow
standard operating procedures (SOP) also called standard operating guidelines (SOG).
SOP/SOC procedures and guidelines are used to ensure that everyone in the department
perform common tasks in a specific manner.
All standard operating procedures specify that human life should be considered the highest
priority over any property damage. In other words, save the occupants first and/or do not
put the lives of first responders in danger to save a vehicle or other property from harm.
Standard operating procedures also include the use of the proper personal protection
equipment (PPE) including:
• Protective clothing including helmet with face shield
• Self-contained breathing apparatus (SCBA)
• High-voltage gloves, including leather protective gloves over the rubber insulated
gloves
• Have insulated tools available, if possible, in the event that tools are needed.
4.1.1 Visual Analysis
When approaching the scene of an incident, the first consideration is always the safety of
people including:
• Occupants of the vehicle
• First responders
• Others in the area
If the initial visual evaluation of the scene indicates that a hybrid electric vehicle may be
involved, then check the vehicle to confirm that it is a hybrid.
4.1.2 Identifying a Hybrid Vehicle
To confirm whether a vehicle is a hybrid, look for the word ―HYBRID‖ (Emblems) on the
rear, front, or side of the vehicle. Most hybrid electric vehicles (HEVs) can be identified by
emblems on the front, side, or rear of the vehicle. Except for the Honda Insight and the
Toyota Prius, there is very little difference in the exterior or interior appearance of hybrids,
compared to those of their gasoline-only counterparts.

Fig 4.1 Hybrid emblems on vehicles
Fig 4.2 Honda Insight
Fig 4.3 Toyota Prius

4.1.3 High Voltage Cables
A hybrid electric vehicle can often be identified by high voltage cables under the hood, as
well as other markings on the engine cover.
4.1.3.1 What Do the Colors of Cables Mean?
brid electric vehicles are equipped with plastic conduit to cover and protect the electrical
cables. This plastic conduit is color coded to help identify the potential flak. The colors and
their meaning include;
• Black—12-volt cable. Not a shock hazard but can power airbags and pretensioners.
• Red—12 volts
• BIue—42 volts. Not a shock hazard but could maintain an arc if the circuit is
opened. Is used for some electric power steering systems and mild hybrid vehicles
such as the GM Belt-Alternator Starter (BAS) system.
Fig 4.4 Blue Cables - 42 Volts

•
• YeIIow—42 volts. Not a shock hazard but could maintain an arc if the circuit is
opened (cut). Usually used for electric power steering.
Fig 4.5 Yellow Cables – 42 Volts

• Orange— 144 to 600 volts or higher. Shock hazard and could cause severe burns
or death.
Fig 4.6 Blue Cables – 144-600 Volts
Fig 4.7 Signage on the engine cover

4.1.4 Electric Shock & the Human Body
Electric shock is the physical act of electric current passing through the human body. The
effects of electric shock can range from a slight tingling sensation, to immediate death. This
handy chart is a good reference for how different types of current (AC and DC having
different safety thresholds):
Fig 4.8 Effects of electric current entering the human body for men and women
HEV is 50-250 kHz
Offhand it would seem that a shock of 10,000 volts would be more deadly than 100 volts.
But this is not so! Individuals have been electrocuted by appliances using ordinary house
currents of 110 volts and by electrical apparatus in industry using as little as 42 volts direct
current. The real measure of shock's intensity lies in the amount of current (amperes)
forced though the body, and not the voltage. Any electrical device used on a house wiring
circuit can, under certain conditions, transmit a fatal current.
While any amount of current over 10 milliamps (0.01 amp) is capable of producing painful to
severe shock, currents between 100 and 200 mA (0.1 to 0.2 amp) are lethal. Currents
above 200 milliamps (0.2 amp), while producing severe burns and unconsciousness, do not
usually cause death if the victim is given immediate attention. Resuscitation, consisting of
artificial respiration, will usually revive the victim.

Fig 4.9 Human body resistance and current flow
4.2 Hybrid Electric Vehicle Safety in Case of Accident

Hybrid vehicles use a high-voltage system and an HV battery that utilizes a highly alkaline
electrolyte of potassium hydroxide. Take extra caution as mishandling could lead to a
serious accident.
Advice to drivers immediately after an Accident;
1. If possible, move the collision damaged vehicle to a safe place and shut down the hybrid
system
2. Give aid to any injured persons and contact the police and fire department
3. In the case that damage to high-voltage wiring, the drive battery, and high-voltage
devices is likely, evacuate to a safe place away from the vehicle and wait
4. If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire.
 Trying to extinguish a fire using only a small amount of water can be more dangerous
than effective. Use a substantial amount of water or wait for firefighters.

Fig 4.10 Vehicle involve in Fire
Fig 4.11 Firefighter putting Fire out
Fig 4.12 Co2 fire extinguisher

If a Hybrid Electric Vehicle catches fire, use a conventional ABC type fire
2
extinguisher designed for use on both oil and electrical fires. Use CO type
extinguisher on HV battery. DO NOT USE WATER, unless a large continuous
supply is available.
4.3 Electrocution when the vehicle is submerged in water

If the vehicle is submerged in water, the SMRs will turn off due to a malfunction in the low-
voltage system, or the high voltage will be cut off by the high-voltage fuse of the HV battery.
As a result, high voltage only remains in the HV battery and in the inverter with converter
assembly (high-voltage capacitor).
As the inverter with converter assembly is located in the engine room, even if a short circuit
occurs due to the engine room being flooded, the cabin is not affected. If the HV battery is
submerged in water, as the HV battery is only a collection of battery modules and the
terminals of the battery modules would be shorted.
However, touching the service plug grip or other high-voltage system parts may lead to
electrocution.
You will not be electrocuted

in the cabin
SMRs OFF
Short Circuit
Inverter with
Short Circuit
Converter HV Battery
Assembly
(High-
voltage
Capacitor)
Fig 4.13 Hybrid Component Layout
Do not touch the service plug grip or any high-voltage components and cables
because of the danger of electrocution. If you need to touch them, do so only
after pulling the vehicle completely out of the water and taking the necessary
precautions.

4.4 Depowering the High-Voltage System for Honda

There are four simple steps to ensuring that the system is safe to work on:
 STEP 1 Remove the ignition key.
 STEP 2 Remove the back seat cushions.
 STEP 3 Remove the two bolts holding the oval cover.
 STEP 4 Remove the red plastic retainer and turn the switch to off; replace the red
plastic retainer on the switch.
Even though these steps have been taken, do not assume that every vehicle will power
down properly. Always wear high- voltage linesman‘s gloves with leather protectors, as well
as approved eye protection, when working around high-voltage systems. Before
disconnecting a high-voltage part or connector, use a CAT Ill meter and test for zero volts.
As long as testing for high voltage is done prior to disassembly, a high level of safety can
be maintained.
Fig 4.14 After removing the back seat, remove the access panel to reach the shut-off switch for the
high-voltage system.

Fig 4.15 Remove the red retainer and flip the switch to the off position. Reinstall the red retainer to
prevent the switch from accidentally being moved to the on position.
4.5 Depowering the High-Voltage System for Toyota

The high-voltage system on a Toyota hybrid electric vehicle can produce upwards of 650
volts. Incorrect handling of high- voltage circuits can cause severe burns or electric shock
that could result in serious injury or death. Service on thehighvoltage system should always
start with steps to manually depower the system.
The following steps must be performed prior to servicing the high-voltage system on a
Toyota hybrid electric vehicle:
1. Turn the ignition system OFF and secure the key on your person or in a special lock
box. If the vehicle uses a smart key, secure it at least 15 feet from the vehicle to
prevent inadvertent starting.
2. Disconnect the negative battery cable from the auxiliary battery. This provides an
extra margin of safety when dealing with the HV system.
3. While wearing high-voltage linesman‘s gloves with leather outer gloves, remove the
orange service plug. As an extra precaution, place a strip of electrical tape acrossthe
service plug socket in the HV battery case to prevent objects from entering the
cavity. t SEE FIGURE 14—27.

4. Take steps to make sure that the service plug cannot be installed by another service
technician while you are servicing the vehicle. This can be done by securing the
service plug on your person or in a special lock box.
5. After removing the service plug, wait 5 minutes before touching any part of the high-
voltage system. Verify that the system is de-energized by measuring system voltage
with a digital multimeter (DMM).
Increase the wait time to 10 minutes when servicing a Camry Hybrid or

Lexus GS45Oh.
6. After disconnecting a high-voltage connector or terminal, be sure to wrap it with
electrical tape.
Fig 4.16 The high-voltage service plug being removed on a second-generation Prius. The handle must
be lifted straight up before rotating to the left for removal.

4.6 Preventing the HV Battery from becoming discharged
Charging Method;
1. Connect the negative terminal of the auxiliary battery.

2. Turn the power switch on (IG) without applying any electrical load. Keep the vehicle
in this state for 3 minutes.
This step is needed to allow the ECU to detect the correct SOC.
3. Enter the READY-ON state. After the engine starts, leave it idling with park (P)
selected until the engine stops (self-charge has completed).
Fig 4.17 Hybrid Battery Charging is needed every 2 to 3 months
When storing the vehicle for long periods of time, it is necessary to charge the
HV battery once every 2 to 3 months to prevent it from discharging completely.
 If the HV battery is discharged;]

4.6.1 Preparation for HV Battery Charging

After removing the service plug grip, do not turn the ignition switch ON (READY) as this
may cause a malfunction.
After removing the service plug grip, put it in your pocket to prevent other technicians from
accidentally reconnecting it while you are working on the high-voltage system.
After removing the service plug grip, wait 10 minutes before touching any of the high
voltage connectors or terminals.
Wear insulated gloves when working on the high voltage system
 Actions to be taken when the HV battery is discharged

 Charge the HV battery using the Hybrid charger
Fig 4.18Hybrid Battery Charging
4.7 Preventing the auxiliary battery from becoming discharged

 Nothing is displayed on the instrument panel when the power switch is turned on (IG).
 Park (P) cannot be disengaged.
 The vehicle is unable to enter the READY-ON state.
 The sound from the horn is weak.
Fig 4.19 Auxiliary Battery Disconnected

4.8 Jump starting Hybrid vehicles – when 12V battery is dead

Description of jump starting: ―Jump starting‖ is an emergency procedure to start the
engine by temporarily feeding it electricity using a booster cable connected from a 12V
battery of another vehicle to the discharged battery.
When using a sealed-type battery, do not perform a quick charge. If a quick charge is
performed, the amount of battery fluid that evaporates will increase due to the large current
and the amount of battery fluid may decrease.
Adding battery fluid to sealed-type batteries is not possible due to their construction.
 Some vehicles
Actions have
to be a positive
taken when thebooster terminal
auxiliary (used
battery for jump starting) located
is discharged
 on the engine room junction block assembly.
Recharge the auxiliary battery with a battery charger, or with the assistance of another
vehicle.
4.8.1 How to jump start the engine
First open the hood and check the condition of the 12V battery in your vehicle. If the
electrolyte is frozen, the engine cannot be jump started until the electrolyte has melted.
Turn off all the accessory units such as audio equipment and lights. Fasten the booster
cable to the battery firmly by its clips so that it does not move during engine vibrations.
Make sure that the cable is not tangled when connecting.
4.8.2 4.8.2 Connect the booster cable in the following sequence procedure:
1. Connect one end of the cable to the positive (+) terminal of the discharged battery in your
vehicle.
2. Connect the other end of the cable to the positive (+) terminal of the 12V battery in the
other vehicle. The other vehicle must have a 12V battery.
3. Connect one end of another booster cable to the negative (–) terminal of the 12V battery
in the other vehicle.
4. Connect the other end of the cable to the grounding terminal of the engine in your
vehicle.
5. Start the engine of the other vehicle. Rev up a little.

Fig 4.20 The under hood 12-volt jump-start terminal on this 2004 Toyota Prius has a red plastic cover
with a “÷“ sign. The positive booster cable clamp will attach directly to the vertical metal bracket.
Fig 4.21 Jump Starting Vehicle
7. Disconnect the booster cables in the reverse order of connection.
If the positive booster terminal was used to jump-start another vehicle:
 100 to 600 A of current would flow to the starter of the other vehicle.
 The DC/DC fuse (125 A) would blow and your vehicle would become undrivable.

4.9 Safety precaution in relation to the towing of vehicle

If a disabled vehicle needs to be moved a short distance (to the side of the road, for
example) and the vehicle can still roll on the ground, the easiest way is to shift the
transmission into neutral and manually push the vehicle. To transport a vehicle away from
an emergency location, a flatbed truck should be used if the vehicle might be repaired. If a
flatbed is not available, the vehicle should be towed by wheel-lift equipment with the front
wheels off the ground (FWD hybrid electric vehicles only). Do not use sling-type towing
equipment. In the case of 4WD HEVs such as the Toyota Highlander, only a flatbed vehicle
should be used.
Gear lever cannot be selected to Park (N) if the auxiliary battery is disconnected
 Use one of the following methods to tow the vehicle.

 If the vehicle has trouble with the chassis or drive train, use method 1
Conditions
Parking Brake Transaxle Shift
Position
Towing Method
1. Flatbed Truck
Applied Any Position
2. Wheel Lift Type Truck
Applied Any Position
Fig 4.22 Towing Vehicle

4.9.1 Precautions to be observed when towing
 Tow the damaged vehicle with its front and rear wheels lifted off the ground.
 Towing the damaged vehicle with its wheels on the ground will cause the motor to
generate electricity. This electricity could, depending on the nature of the damage,
leak and cause a fire.
4.9.2 Moving the Hybrid Vehicle in the Shop
After an HEV has been serviced, it may be necessary to push the vehicle to another part of
the shop or outside as parts are ordered. Make sure to tape any orange cable ends that
were disconnected during the repair procedure. Permanent magnets are used in all the
drive motors and generators and it is possible that a high-voltage arc could occur as the
wheels turn and produce voltage. Another way to prevent this is to use wheel dollies. A sign
that says ―HIGH VOLTAGE—DO NOT TOUCH‖ could also be added to the roof of the
vehicle. Remove the keys from the vehicle and keep in a safe location.
Fig 4.23 Using a warning cover over the steering wheel helps others realize that work is being
performed on the high-voltage system and that no one is to attempt to start or move the vehicle .

If your vehicle needs to be towed, do it with the rear wheels raised. If the rear
wheels are on the ground when towing, the electric motor may generate electricity.
This may damage the Hybrid System components and cause a fire.
 If a tow truck is not available, in an emergency vehicle may be temporarily towed

using a cable or chain secured to the emergency towing eyelet. This should only be
attempted on hard surfaced roads for short distances below 30 km/h (19 mph).
 A driver must be in the vehicle to steer and operate the brakes. The vehicle‘s wheels,
drive train, axles, steering and brakes must be in good condition.
4.10 Emergency towing procedure

1. Turn the power switch on (IG).
2. Depress the brake pedal and move the selector lever to N.
3. Release the parking brake.
4. Release the brake pedal slowly.
Never tow automatic transmission models with the rear wheels on the ground or
four wheels on the ground (forward or backward), as this may cause serious and
expensive damage to the transmission. If it is necessary to tow the vehicle with the
front wheels raised, always use towing dollies under the rear wheels.
 When towing rear wheel drive models with the front wheels on the ground or on towing
dollies: Push the ignition switch to the ACC or ON position, and secure the steering
wheel in a straight-ahead position.
4.11 High Voltage Safety

4.11.1 Need for Caution
There have been electrical systems on vehicles for over 100 years. Technicians have been
repairing vehicle electrical systems without fear of serious injury or electrocution. However,
when working with hybrid electric vehicles, this is no longer true. It is now possible to be
seriously injured or electrocuted (killed) if proper safety procedures are not followed.
Hybrid electric vehicles and all electric vehicles use high- voltage (HV) circuits that if
touched with an unprotected hand could cause serious burns or even death.
4.11.2 Identifying High-Voltage Circuits
High-voltage cables are identified by color of the plastic conduit and include:
• Blue or yellow. 42 volts (not a shock hazard but an arc will be maintained if a circuit is
opened)
• Orange. 144 to 600 volts or higher

Section Summary
 Understand safety precaution is followed immediately after an accident
 Understand safety precaution is followed when submerged in water
 Explain the basic preventive maintenance task for hybrid voltage battery.
 Explain the basic preventive maintenance task for auxiliary battery.
 Demonstrate jump starting of the auxiliary
 Explain jump starting of hybrid vehicle
Progress Check 4

1. What are some of the actions required immediately after an accident?
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2. Describe necessary action in the case that there is possible damage to high-voltage
parts or wiring?
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3. What action is required when the vehicle is submerged in water?
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4. What possible danger can be cause to the hybrid vehicle if towed with the rear wheels
are on the ground?
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5. List down the emergency towing procedure while towing hybrid vehicle?
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6. What type of hybrid vehicle should not be towed with the rear wheels on the ground or
four wheels on the ground?
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7. What 2 method are used to jump start vehicle when auxiliary battery is discharged?
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8. What PPEs are required to depower a HEV?
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9. List down the steps required to depower Toyota Prius
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10. List down the steps required to depower Honda Insight
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References
Hybrid Electric Vehicle Technology Aug 20, 2009 by Automotive Research and Design
Acknowledgment
Some illustrations have been reproduced from the text listed above.

Notes
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DEPARTMENT OF AUTOMOTIVE ENGINEERING

HYBRID ELECTRIC VEHICLE SYSTEMS & SAFETY

©Technical Training Division

About the Learner’s Guide

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Check your Progress icon Check Text icon

Caution/Beware icon Tips icon

Activity icon Key Point icon

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 Understand the fundamentals of the hybrid vehicle system

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A range of methods is applied for measuring progress towards and achievement of

The learning outcomes may be assessed through a combination of:

 Knowledge-based criteria will be satisfied through written or oral questioning relating to

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Terms used in this book

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2. Terminology can vary between manufacturers and between countries.

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1 Introduction to Hybrid Electric Vehicles

Modern HEVs make use of efficiency-improving technologies such as regenerative brakes,

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Learning Outcomes & Assessment Criteria

Understand the features, operation and types of hybrid vehicle

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1.1 Introduction to Hybrid Electric Vehicle (HEV)

1.1.1 History of Hybrid

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<History of Toyota’s Hybrid Models>

Fig 1.1 First Generation Toyota Prius

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Fig 1.2 Second Generation Toyota Prius

Fig 1.3 Third Generation Toyota Prius

• Third generation Toyota Prius Hybrid

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Fig 1.4 First Generation Honda Insight

• First generation Honda Insight Hybrid

Fig 1.5 Second Generation Honda Insight

• Second generation Honda Insight Hybrid

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1.1.2 Hybrid Today

1.1.3 Why is the hybrid vehicle necessary?

 Currently, the automobile market is expanding

1.2 Driving and Owning a Hybrid Electric Vehicle

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 If a hybrid electric vehicle is being driven aggressively and at a high rate of

1.2.2 Owning a Hybrid Vehicle

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1.3 Types of Hybrid Systems

1.3.1 Series Hybrid Vehicles

Fig 1.6 A drawing of the power flow in a typical series-hybrid vehicle.

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A disadvantage of a series-hybrid design is the added weight of the internal combustion

1.3.2 Parallel Hybrid Vehicles

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Fig 1.8 The power flow in a typical parallel-hybrid vehicle.

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1.3.3 Series-Parallel Hybrid

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1.4 Common Features of All Hybrids