Lithium Ion Battery Family Systems

InstructorDr .Mark Quarto

Course Length: 5 modules (each containing approximately 1 hour of instruction)

Course Handbooks Included: 1 digital copy per module

Learning Assessments: Post-module assessments with certificate of completion

 

The Lithium Ion family of technologies are the primary technology for plug-in and electric vehicles but, it is also being found in hybrid products.  The many different Lithium technologies will force technicians to become familiar with it so they will understand how it impacts diagnostics and repair.  Each family can have a different discharging voltage characteristic which effects vehicle and Scan Tool diagnostics.  This series will provide the technician with the necessary information on all of the Lithium technologies, cell balancing systems, failure modes, diagnostics, and how these battery packs can be repaired instead of replaced. 


Course Objectives

By participating in this On Demand Course, you will be able to:

  • List the advantages and disadvantages of lithium technologies and the automotive lithium battery formats
  • Describe the discharging and charging process of a lithium battery cell
  • Describe the operation of a battery module/cell temperature sensing circuit
  • Describe the purpose and operation of battery pack contactors, the battery pack Pre-Charge circuit, and the battery pack Current Sensor
  • Identify the components in air and liquid cooling system for lithium battery packs
  • Identify and describe the components of a battery management system cell balancing system
  • Explain the difference between how vehicle instrumentation displays battery pack SOC% vs. actual battery pack SOC%
  • Relate in how SEI Layer growth effects battery cell operation
  • Describe how failure modes on the positive and negative electrode evolve
  • Compare the difference between battery power vs. capacity
  • Explain the battery pack Stress Test process and how the results can help determine what actions are needed

Course Outline

Part 1:  Lithium Ion Battery Families: Cell Construction and Operation

  • All Battery Electric Vehicles (BEV)
  • All Plug-In Hybrid Electric Vehicles (PHEV)
  • Hybrid Electric Vehicles (HEV) - Examples
    • Buick LaCrosse
    • Chevrolet Malibu (e-Assist)
    • Ford Fusion (2013) & C-Max
    • Honda Civic (2013)
    • Hyundai Sonata/Kia Optima
    • Mercedes-Benz S400
    • VW Jetta

 

Part 2:  Lithium Product Systems

  • Battery Pack Hardware
    • Temp Sensors
    • HV Contactors and Pre-Charge System
    • Current Sensor
  • Battery Pack Cooling Systems
  • Battery Heating Systems
  • Hardware Diagnostics

 

Part 3:  Vehicle Performance Changes Due to Lithium Aging and Cell Balancing

  • Ensure/limits cell overcharging
  • Differences in cell aging/degradation
  • Differences in balancing load currents
  • Differences in cell temperatures
  • Ensure cells are not undercharged
  • Permits battery cells to be “Top Balanced”
  • Provides superior battery pack performance
  • Lengthens life of battery pack

 

Part 4:  Failure Modes and What Causes Cell Aging or Loss of Capacity

  • SEI Layer Growth = Capacity & Power Reduction
  • Effects of Lithium Aging on Vehicle Performance
  • DTC Criteria
  • Effects of Lithium Cells on Vehicle Performance
  • Battery Cell Cycling: Performance & SOH Testing

 

Part 5:  How to Test/Diagnose Plug-In and EV Battery Packs Using the Scan Tool

  • Stress Test Data PIDs
  • Battery Cell Voltages and Stress Testing
  • Stress Test Voltages During Stress Test
  • Stress Test Process

 


At the conclusion of this course, the technician will be able to identify the various Lithium formats, aspects cell aging, rebuilding concepts, and understand how to use Scan Tool PIDs to help analyze, diagnose and repair the battery pack.  

 

Is this online training course for you? 

Technicians with limited or some knowledge or experience with high voltage Lithium battery pack education will find this course of immense benefit.  There are also areas within the course that could benefit more seasoned battery pack professionals.  Whether a Technician is involved with HEV, PHEV, BEV, EREV or FCEV products, this course will provide information on Lithium cell operation, Battery Management System operation, battery pack hardware systems, battery cell failure modes, cell/module testing methods, battery stress testing, and how this differs from NiMH Systems.

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