Hybrid Electric & Alternative Automotive Propulsion: Low Carbon Technologies

Preface

Welcome to hybrid electric and alternative automotive propulsion.

This book has been written because, as fuel demand and environmental pollution increases, it is important that substitutes are found for traditional methods of vehicle drive. An alternative propulsion vehicle is one that operates using something other than the established petrol or Diesel.

Low carbon technologies are a key component of all automotive qualifications in the UK from Level 1 to Level 4 and finding information to cover the subjects in one title has been difficult until now.

Whether you are a vehicle technician, automotive trainer, student or part of the emergency services, an awareness of current and emerging propulsion sources is vital in order to work on or around these vehicles safely.

Warning, you should not attempt to work on high voltage vehicle systems unless you have had appropriate training. Failure to do so may result in injury or death.

This book embraces new technologies, but also helps cover what can be achieved with traditional propulsion methods. The chapters will introduce health and safety, electrical diagnosis and tooling, followed by technical chapters on the operation of low carbon technologies for alternative propulsion.

It also lays out key terms, points of interest, safety and knowledge checks in order to support the information provided within the text.

Chapters:

Chapter 1 Introduction to Electrical Principles and Safety

Chapter 2 Hybrid and Electric Vehicles

Chapter 3 Alternative Fuel Vehicles

Common Acronyms

This book offers:

Ideal support for learners and tutors undertaking automotive qualifications.

Information to help cover the requirements for knowledge of low carbon technologies.

Information to help cover the requirements for the knowledge and understanding of hybrid and electric vehicles.

A large number of illustrations to support knowledge and understanding.

Information that would be useful for emergency services, including police, fire, ambulance and coastguard.

Text © Graham Stoakes 2014

Original illustrations © Graham Stoakes 2014

The rights of Graham Stoakes to be identified as author of this work have been asserted by them in accordance with the Copyright, Designs and Patents Act 1988.

Copyright notice ©

All rights reserved. No part of this publication may be reproduced in any form or by any means (including photocopying or storing it in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright owner, except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency, Saffron House, 6 - 10 Kirby Street, London EC1N 8TS (www.cla.co.uk). Applications for the copyright owners written permission should be addressed to the author.

Acknowledgements

Graham Stoakes would like to thank Anita and Holly Stoakes for their support during this project.

Thank you to alerrandre for the cover design.

Author

Graham Stoakes AAE MIMI QTLS is a lecturer and author of college textbooks in automotive engineering for light vehicles and motorcycles.

With his background as a qualified Master Technician, senior automotive manager and specialist diagnostic trainer, he brings 30 years of technical industry experience to this title.

Cover design - fiver.com/alerrandre

Published by Graham Stoakes

First published June 2014

First edition

ISBN 978-0-9929492-1-1

Chapter 1 Introduction to Electrical Principles and Safety

This chapter provides an overview of the health and safety awareness that is required when working on vehicle systems. (Specific health and safety information and control measures relating to high voltage and alternative propulsion systems will be described as appropriate throughout this book). It also introduces the fundamental operating principles of electricity and electrical systems that will aid you when undertaking maintenance and repairs.

Introduction

All work undertaken on vehicles will require general Personal Protective Equipment. The following list can be used to help you decide the type of PPE that you may need, however specific protection will be described at the appropriate points within this book.

Personal Protective Equipment (PPE)

Safety helmet protects the head from bump injuries when working under cars.

Safety goggles reduce the risk of small objects, chemicals or electrical burns to the eyes.

Overalls provide protection from coming into contact with oils and chemicals. Overalls should have non-electrically conductive fasteners.

Safety gloves insulating safety gloves provide protection from high voltage electrical systems used in electric and hybrid drive.

Safety boots protect the feet from a crush injury and often have oil and chemical resistant soles. Safety boots should have a non-metallic protective toe-cap and rubberised soles.

Vehicle Protective Equipment (VPE)

To reduce the possibility of damage to the car, always use the appropriate vehicle protection equipment (VPE):

Legal requirements

In order to conduct road tests on customer’s cars, you must ensure:

• You hold the correct type of driving license for the vehicle being tested

• The vehicle has a valid MOT and tax disc

• You are insured to drive this vehicle on the road

• The vehicle is not clearly in an unroadworthy condition

Health and safety legislation

Health and safety policies are there to help protect you, and will have been developed to make sure that government legislation is observed. It is important that you are aware of the legislation and your rights and responsibilities, as well as those of your employer. It is your right to expect your employer to fulfil their responsibilities and it is your employer’s right to expect you to fulfil yours. Legislation is the law and, if you do not observe it, you are committing an offence.

The Health and Safety Executive (HSE)

The Health and Safety Executive (HSE) is the national independent watchdog for work-related health, safety and illness. They are an independent regulator and act in the public interest to reduce work-related death and serious injury across all workplaces in the UK. HSE inspectors have powers to issue improvement notices and prohibition notices if they believe that there are any poor health and safety practices in a workplace they are inspecting.

Some of the laws that are relevant to the automotive industry are covered in the next section:

The Health and Safety at Work Act 1974 (HASAWA)

The health and safety of everyone in the workplace is protected by the Health and Safety at Work Act (HASAWA). This law protects you, your employer and all employees while at work. It also protects your customers and the general public when they are visiting your workplace.

Personal Protective Equipment (PPE) at Work Regulations 1992

This regulation requires that employers provide appropriate personal protective clothing and equipment for their employees. 

When selecting PPE, make sure that the equipment:

• is the right PPE for the job – ask for advice if you are not sure

• fits correctly – it needs to be adjustable so it fits you properly

• is properly looked after

• prevents or controls the risk for the job you are doing

• does not interfere with the job you are doing

• does not create a new risk, e.g. overheating

• is comfortable enough to wear for the length of time you need it

• does not impair your sight, communication or movement

• is compatible with other PPE worn

The CE mark found on PPE confirms that it has met the safety requirements of the Personal Protective Equipment at Work Regulations 1992. All PPE should have this mark.

Examples of specific PPE related to high voltage or alternative propulsion systems can be found throughout this book.

Provision and Use of Work Equipment Regulations 1998 (PUWER)

The equipment used in your workshop needs to be:

• safe to use

• maintained correctly

• inspected regularly

• only used by people who have received appropriate training

The Provision and Use of Work Equipment Regulations 1998 (PUWER) place the responsibility for the safety of workplace equipment on anyone who has control over the use of work equipment, including your employer, you and your colleagues.

Control of Substances Hazardous to Health Regulations 2002 (COSHH)

The legislation which you and your employer must observe when using hazardous substances in the workshop, is the Control of Substances Hazardous to Health Regulations 2002 (COSHH).

There are eight steps that employers must take to protect employees from hazardous substances. These are shown in the next section:

Step 1: Find out what hazardous substances are used in the workplace and the risks these substances pose to people’s health.

Step 2: Decide what precautions are needed before any work starts with hazardous substances.

Step 3: Prevent people being exposed to hazardous substances or, where this is not reasonably practicable, control the exposure.

Step 4: Make sure control measures are used and maintained properly and that safety procedures are followed.

Step 5: If required, monitor exposure of employees to hazardous substances.

Step 6: Carry out health surveillance where assessment has shown that this is necessary or where COSHH makes specific requirements.

Step 7: If required, prepare plans and procedures to deal with accidents, incidents and emergencies.

Step 8: Make sure employees are properly informed, trained and supervised.       

Electricity at Work Regulations 1989

The electricity at work regulations are mainly concerned with electrical appliances, equipment and supply systems, but as the amount of vehicles using high voltages increases, sections of this law may apply to vehicle maintenance and repair. For example, regulation 16 states: 'No person shall be engaged in any work activity where technical knowledge or experience is necessary to prevent danger or, where appropriate, injury, unless he possesses such knowledge or experience, or is under such degree of supervision as may be appropriate having regard to the nature of the work.'

Specific electrical regulations regarding the maintenance and repair of high voltage electrical systems on vehicles can be found in Chapter 2.

Other health and safety regulations

As well as the legislation listed previously, the following regulations apply across the full range of workplaces:

1 The Management of Health and Safety at Work Regulations 1999: require employers to carry out risk assessments, put in place measures to minimise risks, appoint competent people and arrange for appropriate information and training for their staff.

2 Workplace (Health, Safety and Welfare) Regulations 1992: cover a wide range of basic health, safety and welfare issues such as ventilation, heating, lighting, workstations, seating and welfare facilities.

3 Health and Safety (Display Screen Equipment) Regulations 1992: set out requirements for work with computers and visual display units (VDUs).

4 Manual Handling Operations Regulations 1992: cover the moving of objects by hand or bodily force.

5 Health and Safety (First Aid) Regulations 1981: cover the requirements for first aid, including the number of trained first aiders required in the workplace.

6 The Health and Safety Information for Employees Regulations 1989: require employers to display posters telling employees what they need to know about health and safety.

7 Employers’ Liability (Compulsory Insurance) Act 1969: require employers to take out insurance against work-related accidents and ill health involving employees and visitors to the premises.

9 Noise at Work Regulations 1989: require employers to take action to protect employees from hearing damage.

10 The Pressure Safety Systems Regulations 2000: users and owners of pressure systems are required to demonstrate that they know the safe operating limits, principally pressure and temperature, of their pressure systems, and that the systems are safe under those conditions. This will include compressed air systems, but does