1.Connect the training panel to the entire vehicle with dedicated harness. After disconnecting the special harness, the vehicle is fully functional and maintains all functions and harness integrity of the original vehicle.
2.The vehicle structure is complete and does not damage the original vehicle wiring harness structure. The control systems, sensors and actuators are complete and can operate normally.
3.The vehicle dynamic and static signal parameters (such as energy monitor screen, speed, gear position display and various working condition indicators, etc.) can be displayed through the original vehicle meter.
4.The vehicle controller VCU control unit is led out to the training panel, which can detect signals including accelerator pedal, brake pedal, vacuum pressure sensor, brake vacuum booster pump, high-pressure coolant pump, stepless fan, etc.
5.The power battery management BMS control unit is led out to the training panel. The detectable signal includes AC charging port, DC charging port, and low-voltage harness of power battery pack.
6.The drive system three-in-one motor controller control unit is led to the training panel, and the detectable signals include IG3 working power supply and ground wire, airbag collision signal, power network CAN-H, power network CAN-L, etc.
7.The high-voltage three-in-one charging and distribution control unit is led to the training panel, and the detectable signal includes the AC charging port charging connection confirmation CC, the AC charging port charging control and guiding CP, the AC charging port temperature detection, the power network CAN-H, the power network CAN-L, high voltage interlock output, high voltage interlock input, DC charging positive contactor control signal, DC charging negative control signal, DC charging contactor sintering detection signal, etc.
8.The automatic air-conditioner control unit is led out to the training panel. The detectable signal includes air-conditioner controller G21(A) / G21(B) / G21(C), heating and cooling cycle motor, internal and external cycle motor, air outlet mode cycle motor, pressure sensor, driver-side foot channel sensor, driver-side face channel sensor, electronic expansion valve (air-conditioner), pressure temperature sensor, sunlight intensity sensor, evaporator temperature sensor, outdoor temperature sensor, indoor temperature sensor, electronic expansion valve (battery thermal management), coolant temperature sensor, four-way coolant valve.
9.The training platform panel for testing uses a 4mm thick high-grade aluminum-plastic board with corrosion resistance, scratch resistance, pollution resistance, fire resistance and moisture resistance. The surface is treated with a special process primer. The panel is printed with a color control unit and actuator that never fades, a sensor terminal diagram, and a gold-plated detection terminal. Students can visually compare the circuit diagram with the original vehicle, measure and analyze the working principle and signal transmission process of each control system.
10.The frame of the training platform panel for testing adopts 2mm thick mold-formed aluminum alloy frame structure; the bottom frame is made of aluminum alloy profile, the main material is 80*40 aluminum alloy profile, and the top is covered with insulated wooden board; the bottom is installed with 4 3-inch wear-resistant nylon casters, which is flexible to move. Meanwhile, 2 casters are equipped with self-locking device that can be fixed at any time.
11.It is equipped with an intelligent fault setting and assessment system, and WIFI wireless fault settings, for fault settings by the teachers as well as fault point analysis and locating by the students. The intelligent fault setting system is equipped with a dedicated 12V switching power supply. The search under the power-off state does not affect the fault settings. Fault settings include open circuit, chance failure, etc. Compare the parts drawing and the connector pins on the training panel diagram, measure directly at the fault location, and master the fault analysis and troubleshooting methods of the real vehicle.
12.A electronic type training panel is equipped, it can be zoom in and out in real time. It draws a schematic diagram of the vehicle control system to guide fault setting and troubleshooting.
It’s designed based on the model 2019 BYD e5 pure electric car.
1.Power battery:
Nickel cobalt lithium manganate ternary power battery, with a total capacity of 394.2V 130AH (About 51kWh). A total of 108 single cells are divided into 11 power battery modules. Each of the 11 power battery modules has 8 or 10 battery cells in different numbers, and a total of 108 cells are connected in series, using distributed battery management system. It consists of battery management controller (BMC), multiple battery information collectors (BIC) and a set of power battery sampling lines. The power battery adopts water cooling and PTC heating system to adjust the temperature.
2.High-voltage three-in-one charging and distribution control unit (including DC/DC converter, on-board charger (OBC) and high-voltage distribution box PDU):
Cooling method: water cooling
Control Module: IGBT
Maximum output capacity: 180KW
Maximum output current: 270A
Protection class: IP67
OBC charging power: 6.6KW
OBC Type: Unidirectional, Isolated
DC rated output voltage: 13.8V
DC rated output current: 145A
3.Drive system three-in-one (including drive motor, motor controller, reducer):
Motor Type: Permanent Magnet Synchronous Drive Motor
Continuous power: not less than 35KW
Peak power: not less than 100KW
Continuous torque: 70N.m
Peak torque: 180N.m
Maximum speed: 12100rpm
Cooling method: water cooling
Gearbox Ratio: 10.7
4.HVAC system:
Electric air conditioner, with an operating voltage of 394.2V
Electric PTC heating water circulation
Car body: length: 4680mm; width: 1765mm; height: 1500mm; wheelbase: 2660mm
Front track: 1525mm; rear track: 1520mm
Maximum speed: 130Km/h
Pure electric cruising range: 405Km under comprehensive working condition
Fast charge: DC boost, 1.5h
Slow charge: 220V/7KW AC slow charge, greater than 8h
Number of doors: 4
Number of seats: 5
Body structure: sedan
Steering power: electric power
Front brake type: Ventilated disc Rear brake type: Disc
Hand brake type: EPB
Drive mode: front-wheel drive
Front suspension type: MacPherson independent suspension
Rear suspension type: Multi-link independent suspension
Achievable Training Programs
1.Understand the technical parameters of pure electric vehicles
2.Familiar with the names and functions of each assembly component
3.Understand the advanced technology and control principle of BYD's high-voltage three-in-one charging and distribution control unit
4.Understand the advanced technology and control principle of BYD's drive system three-in-one
5.Understand the control relationship between the assemblies of pure electric vehicles
6.Familiar with the composition of the control module
7.Understand the structure and working principle of the motor controller module
8.Master the testing method of the motor controller module
9.Understand the structure and working principle of the DC-DC converter module
10.Master the testing method of the DC-DC converter module
11.Understand the structure and working principle of the power distribution box module
12.Master the testing method of the power distribution box module
13.Understand the structure and working principle of the battery management unit
14.Master the testing method of the battery management unit
15.Familiar with the structure, working principle and working process of the motor assembly
16.Master the testing method of the motor assembly
17.Understand the structure and working principle of 220V/7KW AC vehicle slow charging
18.Master the testing method of 220V/7KW AC vehicle slow charging
19.Understand the structure and working principle of DC fast charge
20.Master the testing method of DC fast charge
21.Understand the structure and working principle of the gear controller
22.Master the testing method of the gear position controller
23.Understand the structure and working principle of the Vehicle controller VCU
24.Master the testing method of the Vehicle controller VCU
25.Understand the structure and working principle of the accelerator pedal
26.Master the testing method of the accelerator pedal