Hybrid Assembly Overview

Using multiple text and video segments, this course describes the technology of Hybrid Drivetrains, including modification procedures to install additional 10kwh battery capacity into a Toyota Prius and produce a plug-in Hybrid EV (PHEV).  The original gasoline engine and its hybrid equipment are not altered or removed from the vehicle.  None of the vehicle’s OEM software or computer interfaces are changed. The vehicle will perform in the same hybrid modes as designed from the factory.  Modifications include adding capacity to the battery pack and integrating driver interfaces, battery management and charging components. When completed, the system will allow the Hybrid to be plugged in and charged on any 120VAC, 15 amp receptacle (basically any household outlet).  The car will operate either as a normal hybrid or 100% electric drive by engaging a switch on the dashboard.

Course Goals

To educate the student with the basic knowledge of hybrid/electric drive vehicle technology.  Students experience hands-on assembly of a working hybrid vehicle.

Advantages of the Plug-in Hybrid

-up to 100 mpg equivalent per charge
-drive in electric mode at any speed
-automatic switching between EV and ICE modes

Vehicle Models

Toyota Prius
Ford Escape Hybrid
Toyota Camry Hybrid
Toyota Highlander Hybrid

Components Included in the Course

Dashboard Data Display
Lithium Iron Phosphate Battery Cells
Battery Management System
Battery Containment Structure and Mounting Materials
Battery Charger & Bumper Charge Port
Electronic Controls
Cabling & Wires
Copper Bus Bars, Terminals, Screws & Connection Hardware
Suspension Upgrade

Course Objectives

Student will learn and master knowledge of:

  1. High Voltage safety related to hybrid vehicles
  2. Traction Battery and auxiliary power storage systems
  3. Electric motor components and interface
  4. Controller design and operation
  5. Wiring and Ethernet
  6. Battery containment
  7. Dash and instrumentation
  8. Summary of Hybrid technology

Module I: Introduction to Hybrid Electric Drive Vehicles

  1. History
  2. What is a Hybrid
  3. Hybrid components
  4. High voltage safety
  5. Workplace safety

Module II: Overview of Components and Systems

  1. Batteries
  2. Electric Motors
  3. Controllers/Inverters/Converters
  4. Manufacturers: the Ford, Honda and Toyota hybrid systems
  5. General Systems overview
  6. Summary

Module III: Plug-in System Assembly Instructions

  1. Plug-in Hybrid Assembly Sequence
  2. Interior modification (dash, seats, panels, cooling fans, electrical routing)
  3. Drivetrain integration (service plug, OEM and aux. battery, AC charge plug, suspension upgrade, wiring, charger, control computer)
  4. Battery integration
  5. Venting and air flow
  6. Drivetrain testing and service

See our other alternate fuel courses: