E-MOBILITY

THE MOBILITY OF TOMORROW IS ELECTRIC

AUTOMOTIVE

BASIC PRINCIPLES OF HIGH-VOLTAGE TECHNOLOGY

HIGH-VOLTAGE BATTERIES & ELECTRIC MOTORS
DIDACTIC HIGH-VOLTAGE & ORIGINAL SYSTEM TRAINER
 GENERATION E - FOR “ELECTRIC”
eVolution of eMobility

New registrations of purely electric cars are gradually

increasing throughout the world. It is true that even in LEARNING GOALS
2030, 3 out of 4 new vehicles will still be driven by a
conventional drive, but these will at least be supported Learning field 11S:
by electric motors, power electronics and batteries, e.g. Diagnose and repair networked drive,
convenience and safety systems
in the 48 V on-board electrical system.
Learning field 12S:
Even today, professional automotive training is facing Prepare vehicles for safety inspections
these new challenges and is benefiting from the and approvals
LEYBOLD® training material for electromobility.
Learning field 13S:
From the basic principles of vehicle electrics based Check and repair components of hybrid
on the proven STE plug-in system and numerous and electric vehicles
topics in the training panel system right up to com-
pact training guides, LD DIDACTIC offers solutions
for demonstration and practical use during training.
Conventional or also digital. The objective of our training systems is formed by the
Naturally, safety is paramount with all of the concepts real vehicle on which the knowledge gained can be im-
presented here. Non-hazardous low voltage and special plemented in everyday workshop practice.
high-voltage systems in the low voltage range guaran- Electric vehicles with didactic conversions, such as e.g.
tee safe use of our high-voltage training systems. the VW e-up, can be offered on request.

A1.1.1.1
Fundamentals of
electrics
A2.7.2.1
Electrical machines
A1.1.1.5 in hybrid &
A2.7.2.3
Fundamentals of electrical cars
Workstation vehicle
electrics & high
hybrid drive
voltage technology

E-MOBILITY

A2.7.2.7 A2.7.2.5
High voltage Vehicle high voltage
vehicle engineering A2.7.2.6 technology
High voltage &
battery technology

2
A1.1.1.1
FUNDAMENTALS OF ELECTRICS

Our STE plug-in actuators system equipment is used The following topics are covered with the A1.1.1.1
to convey the basic principles of electrical and elec- equipment:
tronic engineering as well as digital technology, espe- the electric circuit
cially with respect to applications that are typical in
the automotive industry. The equipment is collated in the ohmic resistance
a practical manner and are suitable for all brands e.g. current and voltage sources
Volkswagen, BMW, Tesla, Toyota etc.
the capacitor
Motor vehicles
the coil
The STE plug-in actuators system represents an ideal
the transformer
introduction to the subject areas. Furthermore, it is
distinguished by: the relay
conventional electronic components in transparent special resistances such as NTC, PTC or LDR
housings, the diodes
typical automotive components in transparent the Z diodes
housings,
LEDs
particularly robust design,
the transistor and
and plug-in board with circuit diagram layout
the thyristor.
ISO conformant component symbol representation.
Then the circuits of the automotive electronics that are
Here, electronic components and automotive sensors used in the vehicle’ equipment are built up and tested,
and actuators are investigated together with their such as e.g.:
application in a complete circuit.
an electronic tachometer,
Hybrid and electric vehicles an electronic voltage regulator for three-phase
In addition, the basic principles of the system and high- generators or
voltage technology in the area of electromobility can a transistor control unit.
also be imparted. The DC/DC converter or the high-vol-
tage battery management (HV-BMS) as well as other
protective measures of the IT network of an inherently
safe electric vehicle can be thoroughly investigated.

3
 A1.1.1.5
FUNDAMENTALS OF ELECTRICS &
HIGH VOLTAGE TECHNOLOGY

Protective measures in the intrinsically safe HV

PRODUCT HIGHLIGHTS
vehicle
A vehicle that has a complete contact and arc protec-  Operation with non-hazardous low voltage
tion by means of technical measures in comparison to
the high-voltage system is known as “inherently safe”.  Genuine insulation monitoring unit

In an IT system (IT: French Isolé Terre), the conductive  Visualisation of flow through body
housing of the equipment is earthed but the energy  Metal objects with potential equalisation
source is not. The high-voltage drive system of electric
and hybrid vehicles is designed so that e.g. the housing 582 73 Lamp, 24 V/10 W, with housing, STE 2/50
of the inverter and the electric motor are connected
together via the chassis. This connection represents 582 85 Human model
the potential equalisation. 758 202 Isulation monitoring device, STE 6/100
The important features of such a system include the 758 203 Automatic circuit breaker Z 1 A, STE 4/1
permanent monitoring of the insulation resistance and
a low-ohm potential equalisation resistance.
For hazard-free testing of such systems, LEYBOLD ®
offers all necessary components as plug-in elements
that are operated with a extra low voltage of 24 V.
Voltages and the potential equalisation resistance can
be directly measured with Sensor-CASSY 2, the insu-
lation resistance is determined and evaluated with a
specially designed measuring device.

4
A2.7.2.1
ELECTRICAL MACHINES IN HYBRID
& ELECTRICAL CARS

The inspection of the basic characteristics of hybrid And in this way, fundamental knowledge and termin-
and electric vehicles requires a fundamental knowledge ology are imparted such as e.g.
of the design and functionality of electric motors and electromagnetism,
the associated power electronics.
induction & voltage generation,
This includes:
DC/DC & DC/AC converters,
DC motors,
use of an electric motor as a motor & generator and
AC and induction motors,
power and energy flow.
servomotors and
The electric motors are designed to be transparent
power electronics (inverters). and fully functional. As standard, the inverter which
For basic motor training, LEYBOLD ® uses the com- converts the DC voltage of the high-voltage batte-
ponents of the modular electrical machine teaching ry into three-phase AC voltage to supply the electric
models “ELM”. When conveying the basic principles of motor works on a voltage level of less under 24 V and
power electronics, a modern inverter is used to power thus provides absolute safety for students and trainees.
the different motor types. In this way, the trainee can
put together entire systems that not only teach trac-
tion but also recuperation in an experiment.

PRODUCT HIGHLIGHTS

 Modular design
 Operation with rotor position sensors
 Rotors with internal or external magnets
 Traction operation as motor
 Recuperation operation as a generator

725 721G Three-phase generator in case

727 812 Rotor position pick-up
727 815 ELM set: Multipole stator and rotor
727 816 ELM PM magnet rotor with inner magnets

5
 A2.7.2.3
WORKSTATION VEHICLE
HYBRID DRIVE

LEYBOLD® has developed a student workplace in which The student can independently investigate the com-
all important aspects of hybrid drives can be investi- plex theme of hybrid technology. Different systems can
gated using the smallest amount of space. The unit is be selected using overlay masks. The workplace can be
equipped with: connected to the PC to show e.g. the energy flow display.
a PMSM as electric motor,
PRODUCT HIGHLIGHTS
an inverter and
a dual-voltage on-board electrical system.  Self-supporting learning environment
The control devices are networked via the motor CAN  COM4LAB course software support
bus.
 Operation with non-hazardous low voltage
All common operating modes can be reconstructed:
 Can be used without other devices
starting
electric driving 739 9401 Workstation Vehicle Hybride Drive

boosting
regenerative braking

6
A2.7.2.5
VEHICLE HIGH VOLTAGE TECHNOLOGY

Since vehicle electrics have been generally regarded

PRODUCT HIGHLIGHTS
as non-hazardous up to now, awareness of hazardous
contact voltage must be raised and new safety mea-
sures and procedures must be conveyed in a targeted  Operation with low voltage
manner.  Additional personal protection
In this way, the automotive mechatronics engineer and  No maintenance-intensive batteries
also the trainer are faced with new challenges in the
 Metal objects with potential equalisation
field of electromobility. It is difficult having to work
with voltage under real conditions but still guarantee
maximum safety for trainees during the lesson.
To this end, LEYBOLD® has developed a trainer in which
electric vehicles can be activated in a realistic manner.
The device is suitable both for demonstration by the
trainer/teacher and also for practical training by the
trainee/student. Even technical service companies, in-
spection bodies, emergency services (fire brigade, tech-
nical relief organisations) or recyclers can benefit from
this training concept to prepare their technical staff
for this innovative segment of automotive technology.
As a supplement, a private charging station is also
offered. With this, the charging process can be repro-
duced in states A to F since a genuine charge controller
is used.
The high-voltage trainer is designed that the charging
process can be started and stopped at any time wit-
hout affecting the functionality of the trainer.

727 293 Digital insulation tester

739 947 PEV High Voltage Trainer
739 948 Electric vehicle charging station
739 949 HV PC measurement adapter for E-Mobility

Electric vehicle charging station

7
 A2.7.2.6
HIGH VOLTAGE &
BATTERY TECHNOLOGY

SAFELY LEARN ABOUT HIGH-VOLTAGE BATTERIES The system contains:

There are many further developments with respect to individually exchangeable battery blocks
the high-voltage battery, which is still often the weak
exchangeable battery management units
point of an electric vehicle. Inadequate ranges due
to insufficient capacities and excessive charging times main contactor with switching logic
due to cells being less than perfect are the main causes monitoring via a safety line
of this.
selective service disconnect between the
To understand this, the lesson plan of the trainee auto- battery blocks or in the main contactor
motive high-voltage technician deals with the high
voltage component “high-voltage battery”. However, battery data collection
depending on the system, the hazard potential is espe- battery temperature simulation
cially high due to the high voltages of up to 800 V.
fault switch e.g. to simulate defective cells
Hence, LEYBOLD offers the high-voltage battery
®
on-board electrical system charging infrastructure
trainer as a supplement to the high-voltage trainer.
Modelled and transformed to uncritical voltages of optional insulation monitoring
24 V, the trainee can acquire all skills in this area. The As a supplement, an inverter unit is available that
highlight: Due to the separate battery blocks, these can allows the assembly of a complete traction drive in
be exchanged and hence different battery chemistry combination with the electrical machine teaching
can be investigated such as e.g. lithium-ion cells or models (ELM) system. The detection of the engine
lithium iron phosphate cells. system with traction and recuperation operation inclu-
ding the signals of the rotor position sensor are easily
possible with the sensor-CASSY 2.
PRODUCT HIGHLIGHTS
In addition, the activation of an electric vehicle can
 Intrinsic safety on 24-volt basis be implemented in the complete system. All necessary
components are already integrated and can thus be
 Supplement to the system of electrical machine used for practical work.
teaching models and high-voltage trainers
 Operation with different cell chemistry structures
 Use of LiIo or LiFe cells and future new cells in
LEARNING GOALS
the same system Diagnosis and repair networked drive,
 Integrated fault switch box convenience and safety systems
Prepare vehicles for safety inspections
739 952 Model HV Battery „Cells“ and approvals
739 954 STE BMS LiIo Check and repair components of hybrid
739 958 Model HV Battery „Monitor“ and electric vehicles
739 959 Model HV Battery „Inverter“

8
A2.7.2.7
HIGH VOLTAGE
VEHICLE ENGINEERING

With the high-voltage system, it is possible to simulate Equipment:

insulation faults in the HV cables and components. In HV on-board electrical system
this way, systematic troubleshooting can be trained
and improved in a targeted manner. Unlike in the Two consumers (PTC heater and air conditioning
vehicle, all installed HV components are easily accessi- compressor) for fault simulation
ble. In the event of a fault, a detectable HV voltage is Electric motor connection with measuring options
present but it has a very low current carrying capacity. on open cable ends
The system provides an overview of all installed HV Charging socket
components that come from genuine vehicles. The
Various 4 mm safety test sockets
necessary steps for activation can be performed under
more simple conditions, identical to the vehicle. Further components:
With the system trainer, the dissuasive complexity is Power electronics
removed from the HV vehicle technology due to the
clear and easily comprehensible layout. Application Charger
and haptics correspond to the real vehicle. HV battery housing
The system can be activated with an ignition key,
deactivation of the system is effected via the service
PRODUCT HIGHLIGHTS disconnect.

 Mobile compact trainer

 Switch box for the simulation of faults
 High-voltage battery housing with mains adaptor
 Equipotential bonding cable
 Mechanical work according to repair guide

739 965 Monitor holder

739 966 Tools set e mobility
739 967 Safety torque wrench

9
 LAB DOCS &
LAB DOCS EDITOR

Interactive boards, PCs, tablets and smartphones have With the Lab Docs Editor you can:
found their way into schools. Edit & delete tasks
In order to include all of these end devices in classes, Add text & answer fields
LD DIDACTIC has developed new equipment literature
in the HTML format, under the name of Lab Docs, which Integrate & adapt interactive diagrams & tables
can hence be used in any browser. Insert pictures, vector images, hyperlinks, etc.
What exactly are Lab Docs? Create & generate material lists
Lab Docs are not only digital experiment instructions, Create formulas
they are also multiply interactive.
The students and trainees can enter their responses,
LeyLab - Central management of experiment
record measured values, evaluate these and represent instructions & devices & literature
them graphically directly in the Lab Doc. LeyLab is an online portal for the central administ-
For institutions that are not yet able to provide com- ration of experiment instructions, experiments and
plete digital learning, all Lab Docs are also available as devices. With LeyLab, all devices of a school (depart-
PDF files with adapted layout for printing. ment) can be inventoried. A great advantage is that
LeyLab can be accessed from anywhere – even from
The Lab Docs Editor home.
To give teachers the possibility of editing purchased Lab Docs can be uploaded quickly and easily to
Lab Docs or creating their own Lab Docs, LD DIDACTIC LeyLab for each experiment. You can also store
has developed the Lab Docs Editor. A user-friendly Lab Docs from LD literature packages with the respec-
tool was developed in collaboration with competent tive experiments. The experiment instructions can be
authors and allows the editing or creation of inter- easily distributed to students or trainees via the share
active experiment instructions. function in LeyLab with a QR code or a link.
With the easy-to-understand tool, the creation of Once the devices have been inventoried, all the
experiment instructions is quick and easy. It is also necessary equipment for an experiment is listed with
easy to share the instructions with colleagues. details of the devices and their storage location.
The highlight: The experiments with all the associa-
ted equipment can be easily borrowed or returned to
the teacher/lecturer, which means that all colleagues
always have an up-to-date overview.

10
DIGITAL MEASURING DEVICES

For experiments, the LEYBOLD CASSY system offers Intuitive measuring devices for the highest measu-
a complete data-logging and measuring system. The ring demands
ultimate measuring devices work with all CASSY S sen-
Sensor-CASSY 2 Starter, Automotive
sors and the popular CASSY Lab 2 software. It offers
Two Sensor-CASSYs can be connected to represent
simple operation and handling of both hardware and
three-phase voltages for the field of “electromobility”.
software.
In addition, a high-voltage warning is present in
Furthermore, CASSY opens the door to digital teaching DMM mode that appears in the display as soon as the
by means of a WiFi adapter for Sensor-CASSY 2. This displayed voltage exceeds 25 V AC or 60 V DC. With the
makes it possible for you to easily incorporate inter- help of the integrated Sensor-CASSY voltage source,
active whiteboards. Also the software CASSY Lab 2 measurement of the potential equalisation resistance
let teachers/lecturers share measurement data with can be performed in accordance with the four-wire
students/trainees online and in real-time. Students/ method (“Kelvin” measurement).
trainees can observe the measurements on their tab-
Software: Vehicle diagnosis
let/smartphone and can follow the measurement from
The Sensor-CASSY 2 automotive edition contains its
their workstation. The measured values can then be
own diagnostic software that is specially developed
evaluated by them as well.
for the automotive sector and that is recreated from
a genuine diagnostic tester. A digital multimeter
(DMM) and digital storage oscilloscope (DSO) are im-
plemented with an adaptation for the measurement of
voltage and current as well as resistance, temperature,
pressure, injection duration or ignition angle via corre-
sponding sensor boxes. In addition, other functions for
data protocol analysis of CAN, LIN, SENT Fast Channel,
SENT Slow Channel and KMI data are available incl. a
trigger function on an ID (CAN and LIN bus).

524 013SKFZ Sensor-CASSY 2 Starter, Automotive

524 013W Sensor-CASSY 2 WiFi
739 589 Software: Vehicle diagnosis

Sensor-CASSY 2 with WiFi adapter

11
 Technical details subject to change without notice.
134 0101EN 12.2022 LD
GERMANY:
LD DIDACTIC GmbH
Leyboldstrasse 1
50354 Huerth
Tel.: +49 2233 604 0
Fax: +49 2233 604 222
E‐Mail: info@ld‐didactic.de

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