General Sir John Kotelawala Defence University, Ratmalana

Department of Mechanical Engineering

Automobile Laboratory

Introduction to Advanced Vehicular

Powertrain Configurations

Instructor : Chief Thelasinghe Group: MC 01

Group Members:
Name : LLD Perera OBH Thanthreege
Index : D/ENG/21/0025/MC DV Lokuranamuka
Intake : 38 IRG Wijeratne
Stream : Mechatronics WLS Wickramaarachchi
Lab 01 – Identifying the advanced Powertrain configuration using the EV
trainer
1. Explain the all-vehicle powertrain configurations with neat sketches.

a) Internal Combustion Engine (ICE) – Front engine front wheel drive, front engine rear
wheel drive, mid-engine rear wheel drive, rear engine rear wheel drive. They convert
chemical energy stored in fuel into mechanical energy, which propels the vehicle.
Components of an ICE powertrain – Engine, transmission, drivetrain, exhaust

b) Series Hybrid – It combines an internal combustion engine (ICE) and an electric motor,
but the two components do not directly drive the wheels. Instead, the ICE is used to
generate electricity, which is then stored in a battery and used to power an electric motor
that drives the wheels.

c) Parallel Hybrid – It combines an internal combustion engine (ICE) and an electric motor,
with both components directly driving the wheels. This configuration allows for a more
flexible and powerful driving experience compared to series hybrid powertrains.
d) Series/Parallel Hybrid – It combines the features of both series and parallel hybrid
powertrains, offering a more flexible and efficient solution. It allows the ICE, electric
motor, and battery to work together in various configurations to optimize performance
and fuel economy.

e) Electrical Vehicle – It powered by one or more electric motors, which are powered by
rechargeable batteries.

f) Fuel Cell Vehicle – It uses a fuel cell to generate electricity to power its electric motor.
Fuel cells convert the chemical energy stored in hydrogen gas into electrical energy
through a chemical reaction.
 2. Compare the pros and cons of each power flow configuration.

a) Internal Combustion Engine (ICE)

Pros Cons
High efficiency (90%+ motor efficiency) Long charging times
Quiet and smooth operation Dependent on charging infrastructure
Low maintenance due to fewer moving High initial cost due to batteries
parts

b) Series Hybrid

Pros Cons
Can optimize ICE operation for efficiency Heavier and more complex than ICE
Smooth power delivery High initial cost
Suitable for city driving Requires battery and generator

c) Parallel Hybrid

Pros Cons
Better fuel efficiency than ICE Increased mechanical complexity
Regenerative braking adds efficiency Limited pure electric driving range
Effective for highway and city driving Battery and motor add weight

d) Series/Parallel Hybrid

Pros Cons
Can operate as a series or parallel hybrid High manufacturing and repair cost
Excellent fuel economy Heavy due to multiple components
Smooth transition between modes High development costs

e) Electric Vehicle (EV)

Pros Cons
High efficiency (90%+ motor efficiency) Long charging times
Quiet and smooth operation Dependent on charging infrastructure
Low maintenance due to fewer moving High initial cost due to batteries
parts

f) Fuel Cell Vehicle (FCV)

Pros Cons
Zero emissions Limited hydrogen refueling infrastructure
Longer range compared to EVs High initial cost and complexity
Efficient energy conversion Hydrogen production can be energy-
intensive if not renewable
 3. Highlight the special components of each configuration and briefly explain their
functions.
a) Internal Combustion Engine (ICE)
Special Components:
Internal Combustion Engine: Converts chemical energy from fuel into mechanical energy
to drive the wheels.
Transmission: Transfers engine power to the wheels, adapting torque and speed.
Fuel System: Delivers fuel to the engine for combustion.
Exhaust System: Manages emissions from combustion.

b) Series Hybrid
Special Components:
Generator: Converts mechanical energy from the ICE into electrical energy.
Function: Supplies electricity to the battery or electric motor.
Electric Motor: Drives the wheels using electricity from the generator or battery.
Battery Pack: Stores electricity for the motor when the generator isn’t running.
Power Control Unit (PCU): Manages power flow between the generator, motor, and battery.

c) Parallel Hybrid
Special Components:
Electric Motor/Generator (MGU): Functions as both a motor and generator.
Clutch System: Connects or disconnects the electric motor from the drivetrain.
Battery Pack: Stores energy for the electric motor.
Transmission: Combines power from the ICE and motor to drive the wheels.

d) Series/Parallel Hybrid
Special Components:
Power Split Device (e.g., planetary gear system): Allows power to flow from the ICE,
electric motor, or both simultaneously to the wheels.
Electric Motor: Drives the wheels or assists the ICE.
Generator: Produces electricity from the ICE for the motor or battery.
Battery Pack: Stores energy for electric drive.
PCU: Coordinates power distribution between the ICE, motor, and generator.

e) Electric Vehicle (EV)

Special Components:
Electric Motor: Provides all the propulsion power directly to the wheels.
Battery Pack: Stores electricity to power the motor.
Inverter: Converts DC electricity from the battery into AC for the motor.
Onboard Charger: Converts AC electricity from the grid into DC to charge the battery.
Regenerative Braking System: Recaptures energy during braking and stores it in the battery.

f) Fuel Cell Vehicle (FCV)

Special Components:
Fuel Cell Stack: Converts hydrogen and oxygen into electricity via an electrochemical
reaction.
Hydrogen Storage Tank: Stores compressed hydrogen fuel.
Electric Motor: Drives the wheels using electricity from the fuel cell.
Battery Pack (optional): Stores surplus electricity for peak power demands.
Power Control Unit (PCU): Manages energy from the fuel cell and battery to the motor.

4. Discuss the applications of each powertrain configuration with examples.

a) Internal Combustion Engine

Application – Used in traditional vehicles due to simplicity and established infrastructure.
Examples – Toyota Corolla, Ford F-150, Harley Davidson

b) Series Hybrid
Application – Used for urban driving with frequent stops and starts due to high efficiency
at low speeds.
Examples – Chevrolet Volt, Hyundai Ioniq Plug-In Hybrd

c) Parallel Hybrid
Application – Suitable for both city and highway driving
Examples – Toyota Prius, Honda Accord Hybrid, Lexus RX 450h

d) Series/Parallel Hybrid
Application – Ideal for vehicles requiring high efficiency in diverse driving conditions.
Examples – Toyota Prius, Ford Escape Hybrid, Hyundai Sonata Hybrid
e) Electric Vehicle
Application – Well-suited for urban and suburban commutes, delivery services, and eco-
conscious users.
Examples – Tesla Model S, Nissan Leaf, Rivian R1T

f) Fuel Cell Vehicle

Application – Ideal for long-range applications and regions with established hydrogen
infrastructure.
Examples – Toyota Mirai, Hyundai Nexo

Conclusion
Internal Combustion Engine powertrains remain dominant due to their reliability and
established infrastructure. However, the push for sustainability and lower emissions has
accelerated the adoption of electric and hybrid powertrains. Electric Vehicles (EVs) offer
environmental benefits, energy efficiency, and quiet operation, supported by advances in
battery technology and charging infrastructure.
Hybrid powertrains provide a balanced solution, improving fuel efficiency and reducing
emissions, with configurations like series, parallel, and series-parallel tailored to various needs.
Fuel Cell Vehicles (FCVs) show promise for long-range zero-emission transport but require
further development in hydrogen infrastructure.
As the industry shifts towards electrification, the focus on sustainability and efficiency will
drive future powertrain advancements, shaped by performance demands and consumer
preferences.

Lab 02 – High Voltage handling using Electric Vehicle Trainer

• Prepare a report mentioning the HV components and describe their functions. Then
explain the benefits of utilizing safety precautions and implementing do-test-do tests.
Finally, write down the HV disabling procedure for the actual vehicle (Toyota Prius).
HV Components and their functions
1. HV Battery Pack
Function: Stores electrical energy at high voltage and supplies power to the electric
motor and other vehicle systems. The Toyota Prius typically uses a nickel-metal
hydride (NiMH) or lithium-ion battery pack.

2. Inverter/Converter
Function: Converts the high-voltage DC from the HV battery into AC for the electric
motor and manages energy flow during regenerative braking.

3. Electric Motor/Generator
Function: Drives the vehicle using electricity and acts as a generator to recover energy
during braking.
 4. DC-DC Converter
Function: Steps down high voltage from the HV battery to 12V to power auxiliary
systems like lights, infotainment, and other accessories.

5. HV Cabling
Function: Transfers high voltage safely between components, such as from the battery
to the inverter or motor.

6. HV Junction Box
Function: Acts as a distribution point for high-voltage circuits and contains relays to
manage HV power flow.

7. HV Cooling System
Function: Keeps HV components like the battery and inverter at optimal operating
temperatures to prevent overheating.

8. Service Plug/Relay
Function: Allows manual disconnection of the HV battery for service or safety
purposes.

Benefits of Utilizing Safety Precautions and Do-Test-Do Tests

• Safety precautions:
o Prevent accidents like electric shocks, burns, or short circuits.
o Protect technicians and vehicle occupants from HV-related hazards.
o Avoid component damage and costly repairs.

• Do-Test-Do Tests:
o A structured approach where a task is paused for testing to ensure safety or
performance before proceeding.
o Ensures that the system behaves as expected after every critical step.
o Reduces the likelihood of error or oversight, especially when working with
HV systems.
HV Disabling Procedure for a Toyota Prius
1. Preparation:
Ensure the vehicle is parked, and the parking brake is applied.

2. Power Off the Vehicle:

Turn off the ignition and remove the key. Confirm the Ready light is off.

3. Access the HV Battery Service Plug:

Locate the service plug cover (typically under the rear seat or in the cargo area).
Remove the cover to expose the service plug.

4. Disconnect the 12V Auxiliary Battery:

 Open the hood and locate the 12V battery. Disconnect the negative terminal to ensure
all systems are deactivated.

5. Remove the Service Plug Grip:

Pull the service plug grip outward and then rotate it to the unlock position. Remove it
completely.

6. Wait for Capacitor Discharge:

Allow at least 5-10 minutes for HV capacitors to discharge fully. Use a multimeter to
confirm no voltage remains in the HV circuit.

7. Verify Voltage:
Use an appropriate voltmeter to check HV circuits for residual voltage. Proceed only
if the reading is 0V.

Conclusion
Following proper procedures and safety measures ensures the safe handling of high-voltage
systems in hybrid vehicles. Understanding HV component functions, employing safety
precautions, and adhering to the do-test-do methodology significantly reduce risks and improve
work efficiency. The Toyota Prius HV system requires careful attention to detail and adherence
to these procedures to ensure technician safety and vehicle integrity.

Lab 03 - Fault Diagnostic and Troubleshooting

1. Include the steps of the procedure conducted for diagnosis and troubleshooting.
• Once the instructor generated the error, students were instructed to wear required personal
protective equipment.
• Once the instructor checked the personal protective equipment, students were given the
confirmation to proceed.
• The vehicle model was started and observed model and malfunctions.
• The vehicle model was not allowed to start, that was the first diagnosis we made.
• As the next step inbuilt scanner was used to identify the error.
• Error code and fault area were observed while investigating the problem area.
• Inbuilt oscilloscope was used to check the problem area, and lab multimeter was not used
as it was not designed check higher voltages.
• It was identified that the battery cover was not closed properly, and that led to the error.
• Error was explained to the instructor and solutions were provided.
• Troubleshooting was done, once the instructor approved the solution.

2. Include the observed parameters and values and give reasoning as to why you use
those parameters to check the problem area.
• Error Codes – It directly indicates the area of error, it made easy to access the starting
point of error recovery.
• Current readings – By observing current fluctuations and flow irregularities, circuit errors
can be identified such as short circuits.
• Voltage readings – By observing voltage across components it helps to determine whether
the components operate under correct operating voltages. Abnormal voltages can indicate
errors in wiring.
• Oscilloscope readings – BY observing shapes and patterns of waveforms can reveal
irregularities which might indicate component failures or signal interference.
These parameters were used because of comprehensive analysis that should be made, for
targeted troubleshooting, efficiency and accuracy.

Conclusion
The practical on fault diagnosis and troubleshooting provided hands-on experience in
identifying and resolving faults in vehicle electrical systems. Using structured procedures and
diagnostic tools, errors were efficiently traced to their root causes. Error codes from the inbuilt
scanner streamlined troubleshooting by pinpointing problem areas, while current and voltage
measurements assessed component health. The oscilloscope revealed waveform irregularities
that indicated potential failures. This experience emphasized the importance of systematic
troubleshooting and effective use of diagnostic tools in automotive diagnostics.