EV and Hybrid Training - Shop Tour
Hello, I'm Professor John Kelly, and this is the WeberAuto YouTube channel. Today I want to take you on a tour of our new building our new facility here. About a year ago, we started to move in. And I feel like I'm finally moved in and ready to show you the amazing things that we have here for teaching hybrid and electric vehicle technologies. And not just for Weaver state automotive students, but for anyone in the world that wants
to sign up and learn about hybrid and electric vehicle high voltage safety and how these vehicles work and how to diagnose them. This is the place to come. So let me take you on a tour of our new 6800 square foot facility that I'm quite proud of. Okay, this is our new building, we share a portion of it with computer science, the computer science department. This whole wing right here is the shop that I teach in for our hybrid and electric vehicles are as you come into our building, we have a nice lobby area here, where we have a first-generation Toyota Prius that I've restored. And we have it on display as a vehicle that introduced a lot of what we see today in hybrid and electric vehicles. The same common components that you see in a newer hybrid are found in this first-generation Toyota Prius. And then coming on in, we have a little museum off to the side here with a bunch of historical automotive stuff in it.
First-generation Nissan LEAF transaxle at the bottom there first-generation Toyota. While we're here we've got a RAV4 EV battery section from the original 1998 through 2003. And a set of service manuals for the original Saturn EV one and then a bunch of other historical things, including the first automatic transmission, the mass-produced automatic transmission, the Hydra-Matic four-speed. All right, well, let's head on down to my shop. Shop 131 down here so we'll head on down the hallway. Okay, as we come into our shop, we have the Chevrolet Bolt EV drive unit, here on a stand, a Subaru hybrid engine on a stand the Toyota Prius engine on a stand, Honda hybrid engine on a stand. And as we turn left coming into the shop here, I have multiple electric vehicle batteries laid out here along with a bunch of Tesla powertrain components.
so I have on the wall right here, the complete high voltage system from a Tesla Model S late model Tesla Model S like the one that we have here in our shop, we have all of the high voltage components, all connected together showing our students what they connect to and we talk about what they do, and a little bit of diagnostics. Here on the workbench, we have the front electric motor from the Tesla Model S that I did a separate video on and the rear electric motor that I also did a separate video on and then we have the Tesla Model three front inductive motor and the rear permanent magnet motor. Here, I'm still working on building a wall of the high voltage components. For the Tesla Model three, I have the Tesla Model three and model y common components. gear set up here that I shot a separate video on the carbon components that are used in the Model 3, in the Model Y for the front and the rear motors. Right here I have the Nissan LEAF power train, the high voltage components, and the stack-up, the gear reducer, inverter converter, onboard charging module, all the high voltage parts of a Nissan LEAF as we turn around here in the shop, I have powertrain mock up here for a Toyota Prius and then turning back around we have first-generation Chevrolet Volt plug-in hybrid battery second-generation Chevrolet Volt plug-in hybrid battery, a BMW i3 EV battery, a Nissan LEAF, EV battery. And then straight ahead, we have a high voltage safety wall information informational wall for our high voltage safety discussion as students come into our program. And then this door here with the label that says high voltage that is the entrance to our battery room. And
so we have if we come around the corner here, I've got the doors, the big garage doors open to the battery room. Here in our battery room, we have shelves with multiple hybrid and electric vehicle batteries. And along with other hybrid and electric vehicle parts that we needed a place to store several of the Toyota different generations of hybrid batteries. over here on this side, I have a battery section from a Tesla Model three, right here and a battery section or module from the Tesla Model S. And this room is climate-controlled humidity-controlled. We have these big garage doors that come down and we lock it all up for safety to keep untrained people out. It's an OSHA regulation to make
sure that anything that has any high voltage that is exposed that anyone can come up and make contact with is either blocked off or locked away. And I'd actually block off the entire shop when I leave at night to keep people from coming in and warn them that there are high voltage components in here. Over here on this wall, let me back up a little bit. We've got a level two charger we talked about plugging charging systems in this in our training that's a level 230 amp. One we have several level ones and several level two chargers in this in this shop. Right here we have a 2017 Toyota Prius and right next to it 2010 Toyota Prius, so this is the 2010 is the third generation Prius, the grey one there and then this white one is the fourth generation Prius. There's a fifth-generation one in the works apparently. Also, as we come down the aisle here, we have computer workstations with laptops and the official factory scan tools for these vehicles. We've got Chevrolet Bolt EV, this wood actually belongs to my wife, it's in here waiting
for the recall to be completed. And then we've got the second-generation Chevrolet Volt right here. And coming on down farther, we've got a Subaru Crosstrek hybrid right here. And then just to the right here on the hoist, we have our 2018 Tesla Model S P100D, and then our 2020 Ford Explorer hybrid right here. I've got a scissor hoist underneath it right now getting ready to remove the high voltage battery that is up underneath that. Our Tesla Model S is actually a driving vehicle. The rest of these are trading vehicles. And although we do the training on the Tesla also, we use this vehicle for recruiting events and it's the start of a new school year. So some of our guys are going out to visit different schools.
And this is a great vehicle to help drum up interest in the hybrid and electric vehicle programs that we have here. While I'm out here we have a whole other side of our shop where we teach a traditional automotive program. We have a General Motors training center here and so let's go back in and finish looking at the shop for the hybrid, any V's all right as we come down here towards the end of the shop. We have a lot of special service tools, storage cabinets, That
we're very pleased to have, obviously, there's a lot of specialty tools involved, and tools involved in any type of automotive work. But for hybrid and electric vehicle work, there's also an additional number of those. Now I have the shop divided up into several different areas. This particular area is for what I refer to as parallel hybrids. And in the, in our classes, we learned about parallel hybrids. This transmission that's right here is actually the exact same transmission that is in our 2020 Ford Explorer here on the hoist, this transmission has a regular 10 speed Ford 10 r at transmission in the back portion of it. But then sandwiched in between the input shaft of the transmission which is right here. And the input shaft of the overall unit, we have this electric motor assembly here. So we have a torque converter with a rotor with permanent magnets inside of it that is connected directly to the input shaft of the transmission. And then we have the state or assembly with a hydraulic engine disconnect clutch right here. So
when the engine is on and running, it rotates this clutch pack, but that clutch pack, unless it's engaged, it does not connect to our torque converter and electric motor rotor right here. And so this is called a parallel hybrid. Ford calls this the M HT transmission, a modular hybrid transmission. Because this can be a hybrid version in which the state or thickness is or width is this width right here. Or it can be even wider if it's a plug-in hybrid version, like in the Lincoln Navy, Lincoln Navigator and the Explorer in other parts of the world. And so that is a parallel hybrid. But that's just one of many types of parallel hybrids here that you'll learn about in our training
programs. If we come around the corner here we have a 2017 Chevrolet Bolt EV that is not a parallel hybrid, that's an electric vehicle. But I have a whole other row of parallel hybrids here. So right here I have a Hyundai set up for a parallel hybrid, a Kia parallel hybrid, Honda parallel hybrid, and Acura parallel hybrid systems. Then we have a separate workstation just for cooling systems, cooling system service, the right types of coolant, the specialty tools, the vacuum refill tools to remove the air from the cooling systems on these vehicles and then have a vacuum in there that actually pulls in the proper coolant with deionized water in it. While we are back here, in this
corner of the shop. I mentioned our 2017 Chevrolet Bolt on hoist here. Okay, so over here on this side of the shop, I have removed our battery from the Chevrolet Bolt EV and are doing some discussions and we'll be showing my students what's involved in doing the recall where we replace all five of these battery sections. This is one of the battery sections right here. This machine right over here is the machine that's used to balance the battery module voltages in this and any
other General Motors high voltage battery system. That Green Machine there is one that's used to do the smoke test, the leak checking of the cover to make sure that it is sealed and keeps out moisture as you drive down the road. And then we have more toolboxes full of specialty tools and high voltage tools. On the top of this toolbox, I have on the right the Ford 10 speed transmission, and on the left the General Motors 10 speed transmission and they share some common internal pieces. And we learn about 10 speed transmissions in the automatic transmission classes that I teach here in this same shop Right here in this toolbox, I've got a drawer full of insulated tools. These, this
particular brand is Wiha, we got a really good deal on some of these. It's a very good company and very pleased with their, with their tools. We have a Lexus 10 speed transmission right here. And over on another bench, we have a Honda front-wheel drive 10-speed transmission. So, in this shop we do, besides the hybrid and electric vehicle, stuff,
we also do automatic and manual drive train, work as well. Okay, let's continue on. up this other side of the shop. I've already showed you our parallel hybrid section of the shop. And now I've got a bunch of tables right here in the middle of the shop with several different variations of automatic transmissions for my automatic transmission class. Here's our Subaru Crosstrek hybrid again, right here on this bench, I have a battery, that would actually go in that 2020 Ford Explorer over there. And I'm in the middle of exploring it and getting ready to shoot a video on how it works and all of the high voltage components in that high voltage battery for the Ford hybrids, then we have a separate table over here because I couldn't get them all into one location. This
is a parallel hybrid that is in this Subaru right here. So this Subaru Crosstrek hybrid uses a special CVT transmission, you can see the chain-style CVT transmission belt right there. But then we have an electric motor right up there, that helps propel the vehicle down the road on the output shaft, and then this whole aisle is series hybrids.
So we looked at parallel hybrids, these now are series hybrids. So the Chevrolet Volt had a series hybrid mode, in its 4-mode, transmission, their newer 5-mode transmission got rid of the series of hybrid. And then there's another series hybrid, the Honda two electric motor series hybrid that I have a separate video on right here. This transmission and system also has a series mode for it. So we have a whole section of parallel hybrids a whole section of Series II birds. And then our largest section is what is referred to as power-split hybrids, or series parallel hybrid is another term for that. So anything that's Toyota, Ford, Chrysler, some of the General Motors stuff is
this power split design. So we've got first second, third fourth generation, Toyota is over here. We've got first second and third-generation Ford transmission transmissions. Over here. We've got the Lexus, rear-wheel drive, power split transmission, the Chrysler Pacifica transmission and hybrid system, the Toyota rav4, front and rear motors. All of these are part of the Toyota hybrid system, which here in the United States is a parallel split or a power split I'm sorry, a power split system, which is also referred to as a series-parallel transmission. Over here against the firewall, we have our rear axle and manual drive train sections with differential bearing shims, different types of differentials, I've shot a video on differences in differentials of all kinds of transfer cases transmissions, manual and automatic that we have over here. And then as we continue forward into the front corner
of our shop again, here in the hybrid and electric vehicle area, we have brake systems that we talked about hybrid electric and, and so on brake systems. We have a section here for high voltage cables, and testing those and checking for loss of isolation. Here's a Honda Accord high voltage Battery, Battery right there. Here is the Ford Fusion, high voltage battery we go into that the third generation battery for the Toyota Prius the matches the car that we have here in the shop, fourth-generation Prius that matches the car, here in the shop the battery for it. Here on the opposite side of these benches, we have electric air conditioning systems, cooling systems, heating systems chilling systems that we go through grid heaters, ceramic heaters, these are all the high voltage parts of a Tesla Model three, we talked about that. And the Honda, the latest Honda to electric motor systems that I've mentioned already. And then to get
finished up with the components here on our shop for our classes. We have right here on the end, the third generation Ford, the HF35 transmission, the hybrid transmission, and then we have the inverter and all the high voltage components for the third-generation Prius, and the fourth-generation Prius right here. And then we have additional tools, storage, high voltage, insulated tools, and just regular hand tools, as well. Okay, one last area I want to show you is our actual classroom area, all of these gray benches, and tables and our big screen TV. Here, this is our
classroom area, we have room for 22 students in this section. And this is where you will be if you come to our boot camp or sign up for any of our automotive training courses on hybrid and electric vehicles. As we come forward here, I have a wall with all of the high voltage components for the Chevrolet Bolt EV. And it's all of these components that are common from one vehicle manufacturer to another. All of them have them how they work is pretty much identical, their efficiencies are different. But we learn and concentrate on what is common between all of those
vehicles. Right here is the Chevrolet Bolt, drive unit, the electric motor, and gears. And then we also, I forgot to mention, besides these vehicles that I've shown you here in the shop, we have a first-generation Toyota Prius, a first generation Chevrolet Volt, and we ordered a new Mustang, Mach-E GT, that should be here in a few months. And we also have a Nissan LEAF that has been donated to us. Okay, I know that was a lot to see, we have a lot of fun things here to see and do and learn about and I believe, for the future of the electrified vehicles. Here in our, at least in our country and the world. Education is a major factor for acceptance of that, if we can take the mystery out of how these vehicles work, and how actually pretty safe they are to work around and very safe if you're following the proper service procedures using this, the proper specialty tools and personal protective equipment that these vehicles are actually pretty fun and not too hard to work on, compared to a regular internal combustion engine powered vehicle. So if you're interested in getting more training on high voltage, safety, different system operation of all
these different systems that we've looked at different components, how all of that stuff works, and then actually coming here on campus, and spending five days with me, we offer a five-day boot camp every year, several of them and if you'll check this website, here at the bottom of the screen, we post an update the dates of when those classes are available. The high voltage safety training and the component training is our those are online classes and you can take those today you can take those anytime. The boot camps the five-day ones, we only do those 5, 6, 7 times a year. And so I hope to see you in one of the boot camps and in some of the training and have a good day.